Quality inspection is a critical part of the manufacturing process. It helps identify and fix problems in production before they reach the customer, minimizing product recalls and supply chain disruptions.
There are five different types of inspections for products and materials. We’ll explore them here along with how they can be used in various industries.
Visual Inspection
Visual inspection is one of the oldest quality control methods. It involves looking for flaws in products and assets with the naked eye, and it can be used alone or alongside other inspection techniques. This type of inspection is a critical part of manufacturing and asset maintenance, and it can be used to identify and correct errors before the product or equipment leaves the facility. It’s also a key component in industries like aerospace, where safety issues can be deadly, and the medical industry, where inspectors check for stents, pacemakers, and other life-saving devices to make sure they are free of defects.
This inspection technique is often paired with other types of non-destructive testing (NDT) techniques to find more defects in a product or device. For example, magnetic particle inspection and liquid penetrant inspection use magnetic particles or liquids to scan for cracks and voids in the surface of a product, helping inspectors catch unforeseen problems that might not be immediately visible.
In addition to enhancing productivity and efficiency, visual inspection can help ensure compliance with standards and regulations. This includes ensuring that a product meets all safety requirements and that buildings comply with fire codes. It can also be used to identify safety hazards and mitigate them in a workplace or building, such as cracks in a foundation or electrical wiring that pose a risk of fire.
As digital tools become increasingly more integrated with traditional inspection practices, they’re transforming the way companies do business. Tablets allow for digital checklists and real-time recording during an inspection, reducing errors and improving workflow efficiency. Drones can also be used to inspect hard-to-reach or dangerous areas that may be too hazardous for human inspectors, allowing them to perform inspections more quickly and efficiently.
To optimize the visual inspection process, it’s important to develop a detailed inspection procedure that is easy for inspectors to follow. This should include guidelines for identifying the scope of an inspection and any specialized equipment that will be needed. It’s also important to train your team on the inspection process so they know what to look for and can spot even the most subtle problems.
X-Ray Inspection
X-ray inspection is a robust and accurate testing technique for detecting defects that are not visible to the naked eye. This type of inspection can help manufacturers ensure that their products meet industry standards and specifications. It can also help reduce manufacturing costs by catching defective components early in the production process. This can save money by preventing the need for expensive product rework or recalls.
Unlike visual inspection, which relies on human eyes to detect surface-level defects, X-ray inspection can detect defects inside the components and in hard-to-reach areas. It is capable of detecting a wide variety of defects, including cracks, voids, inclusions, and foreign materials. Moreover, X-ray inspection can also be used to measure and detect dimensions in complex products. For example, it can be used to determine the fill level of a container, verify that there is no leakage in a sealed package, and assess mass and weight to ensure that the correct amount of product is included in each package.
Many different industries can benefit from implementing X-ray inspection in their production processes. Electronics, food & beverages, construction, oil & gas, and automotive are some of the key sectors that can utilize this quality inspection technique to ensure compliance with industry regulations. The growth of the X-ray inspection market can be attributed to the high demand for products with stringent quality and safety standards, along with the increasing need for non-destructive testing.
For electronics, X-ray inspection is important for ensuring that the integrity of circuit boards is not compromised during assembly. For example, X-ray inspection can identify broken solder joints or other defects that may impact the performance of the PCB. It can also be used to inspect the shape of solder balls to ensure that they are properly placed and connected to other components.
In terms of reducing manufacturing costs, X-ray inspection can help manufacturers improve efficiency by reducing the time it takes to complete quality control checks. This can increase productivity and reduce the risk of costly mistakes, such as defective components or inaccurate measurements. Additionally, X-ray inspection can reduce manufacturing costs by enabling manufacturers to identify and resolve problems early in the production process, thereby avoiding expensive rework and product recalls.
CMM Inspection
CMMs are efficient and precise measurement systems that help manufacturers assess the dimensional accuracy of their products and compare them to the design specifications. They use a range of sensors and probes to compile data on the dimensions and geometry of a product, sending this information to specialised software that compares it to the original design. This ensures that the finished product meets the required standards and tolerances, reducing the risk of defects, recalls, and production delays.
A CMM can be programmed to automatically take repeated measurements, speeding up the inspection process and increasing productivity. It can also be used to verify the quality of a part prior to final assembly. CMMs are highly versatile, offering a variety of measurement methods to suit specific applications. For instance, they can be used to perform depth mapping through a combination of two stereo images or to collect a point cloud for dimensional analysis.
In addition to ensuring that the finished product matches the designer’s specification, CMM inspection can also detect unforeseen defects during production. This can be especially important in the case of complex parts, such as engine blocks or transmissions, which may be more likely to have errors than simple components like nuts or bolts.
A CMM’s software can identify areas of concern and provide suggestions for improvement, helping to streamline the manufacturing process. This reduces waste and increases productivity, boosting the bottom line for the manufacturer. In turn, this translates to lower prices for the customer, which can help boost sales.
There are several types of CMMs, including portable, bridge, and gantry. A portable CMM is a small, mobile machine that can be taken to the work area to measure a product. This eliminates the need to ship large parts to a dimensional lab for inspection and speeds up the quality control process.
Bridge CMMs are larger and can measure a greater surface area than portable CMMs, making them a good choice for oversized parts. They can also be customised for a particular application by changing the mountings or installing different attachments. In addition, bridge CMMs have a more stable structure than gantry models, making them better suited for long runs.
Industrial CT Inspection
Industrial CT inspection is a nondestructive inspection technique that uses X-ray computed tomography (CT scanning) to create high-resolution 3D representations of the internal structure of materials and components. This inspection technology enables nondestructive testing of complex geometries, multi-material assemblies, and the detection of internal defects such as inclusions, voids, and cracks.
This powerful inspection technique used by a company like ATI combines the benefits of visual and X-ray inspection, delivering an unparalleled level of dimensional and structural accuracy that is unattainable with traditional methods. The industrial CT scanner operates in a similar fashion to medical CT scanners, but it is designed for use in manufacturing, engineering, and quality control processes. The resulting data is instantly exportable into STL meshes, which can be used in reverse engineering, design modification, and repair of components.
CT scanning involves capturing a series of 2D X-ray images from multiple rotational angles, which are then processed by a computer to produce 3D data of the part or assembly. The software generates “tomograms” — virtual slices through the part — where different shades of gray indicate density differences.
Because the 3D representation is nondestructive, the data can be reconstructed at any time without retaking the scan or compromising the integrity of the object. This means that CT inspections can be repeated as needed to detect changes in a flaw over time, such as crack growth. The high-resolution and 3D visualization of the internal structure also makes industrial CT ideal for identifying casting flaws, welding defects, material shrinkage, porosity, and inclusions.
Compared to other inspection techniques, industrial CT is fast and reliable. In addition, its streamlined operation and intuitive software interface make it easy for technicians to use, even in a production environment. In addition to reducing inspection time, industrial CT helps reduce overall operating costs by eliminating the need for additional tests or equipment.
While dye penetrant inspection offers a valuable alternative to other inspection technologies, it has several notable limitations. Dye penetrant is a surface-specific technique, which limits its ability to detect subsurface or internal defects. This can impact the safety and reliability of a finished product, particularly in industries that require the inspection of complex geometries or intricate internal structures. As a result, industrial CT emerges as the most capable option for comprehensive defect detection and analysis, providing the fullest view of a component’s quality.