Sec 23 Inspection and Test

INSPECTION AND TEST
1
INTRODUCTION
gage, a nonvariable electronic or laser instrument, a nonvariable chemical or phy
Sec 23 INSPECTION AND TEST 2

INTRODUCTION
hod that will display data generated by physically measuring the characteristic,
tance inspection and acceptance testing.
oductive operation appraisal. Within this movement of proactive product acceptanc

PURPOSE OF INSPECTION AND TEST
body to become involved in the details of so many decisions. Associated with the
nswer is obvious—the nonconformance is so severe as to make the product clearly

PURPOSE OF INSPECTION AND TEST
departments to aid them in preventing a recurrence. In more elaborate data-collec

PREPRODUCTION EVALUATION
the customer’s requirements, we expose the organization to uncontrolled, inefficie
ision on conformance to standard consists of a lot. The true lot is an aggregatio
form, the true lot emerges from one machine run by one operator processing one mat

iner. In shop language, this mixture is a “lot,” but in more precise language it is
the batch. In continuous production, the lot is usually defined as an arbitrary am

fferent from that presently used as the method of measurement. It also should inc
r, the planning is done by a quality assurance staff planner, an inspection or tes
be covered: inspection instructions, instrumentation, cost estimates, space and wo

the planner lists the quality characteristics to be checked. To determine these,
ers
ut may call for modifications
parameters, such as
riteria for the checklist

ys:
spection or testing appraisal using standard inspection and testing equipment. Ho

departments, usually called process inspection or process testing As an integrati
ations may be sufficiently well in hand that no inspection stations are used betw

INSPECTION AND TEST DOCUMENTED INFORMATION
It may, in addition, include the seriousness classification of characteristics, to

odic reappraisal of the major forces in contention as well as analysis of the con

pection plans is done extensively. New customer orders, new product designs, new pr
issue inspection plans accordingly.
s. One technique is to do the planning by computer or by other means of mechanizi
-made planning by extending the use of inspection and test manuals that have broa
itself to the inspection supervisors and the

o people or to systems. Machines are superior for doing deeds that can be clearly
of people, machines, and system masquerades under a variety of names: human factor
rocesses that collectively or sequentially turn out the final product. To prepare


procedure contents and should reflect the path the product takes and the types o
pecting and/or testing and should be detailed as to how to fill out an inspection

CRITERIA FOR INSPECTION AND TEST DEVELOPMENT
product conformance decisions and in addition have accepted this very lot. In suc
y holes of correct size and in the correct locations. Such is the inherent nature
s who have not qualified. Suppliers who have established a record of good deliver

CRITERIA FOR INSPECTION AND TEST DEVELOPMENT
of process capability). The presence of uniformity through fluidity greatly reduc
tivities and hence can be had for the procedural cost of retrieval. Other knowledg

THE DEGREE OF INSPECTION AND TESTING NEEDED
check the lots in batches every so often is conducted. This skip lot will remain
ed “scientifically” once the tolerable level of defects in accepted product has be

THE DEGREE OF INSPECTION AND TESTING NEEDED
o provide redundancy against the unreliability of 100 percent inspection. In thes
es, since the accepted lots are usually no better than the rejected lots.
sical arrangements and personnel procedures must be changed. In many cases, attitu
urce of evaluation is the check list type.

OTHER TYPES OF CONFORMANCE INSPECTIONS
experimental or analytical approach .Examples of application:
ten time intervals, alleviate labor shortages, and avoid inspection monotony, among
g costs. The crux of justifying the investment lies in the amount of repetitive w

e vital few types are identified. Estimates are then made of the personnel, costs
original design, construction, and prove-in, the machine must be set up specially

g the operator of the machine’s state of adjustment. Specification data stored in
reducing the volume of inspections necessary and making the inspector function m
to increased consistency and productivity; equally important, they will help to im

miautomated concept provides high-confidence repeatability and a faster analytical
or, and in microseconds each part passing under the “eye” or segment of a continu

Instead of having to physically transport the part to the inspection station, ce
an existing machine.
rmance decision for almost any inspection situation, or both. The marriage of comp

and final inspection functions, as well as some testing operations. Yet, somewhat

quipped with an image-processing board, Moiré allows the operator to obtain a very
ning features with no sharp edges or lighting contrasts to define such shapes as

by counting the number of beams blocked by an object passing through the scanned
r includes a series of light-emitting diodes (LEDs) in a linear array. The control
d) so that each phototransistor only detects light from its corresponding LED in

INSPECTION AND TESTING FUNCTIONS
niversal. Some final inspection or test functions are staffed by fulltime inspect
of product, entire shipments or just samples are brought to the inspection floor.
onsequently, the sampling plans involve random and (often) large samples, employing

ltaneously:
ct conform to specification?
cess run or stop?
ess inspection involves observation of process variables as well as inspection of
tup is correct, the entire lot will be correct, within certain limits of lot size.

is usual to provide for periodic sampling to be conducted during the progression
de.
ed to a control chart. If the process remains in control, all product made since t
is based on the sampling criteria.
provided the process conforms to specification.


epartment has concluded its operations. Sometimes the product is moved physically
often automated, as are the data recordings. Testing may be done either at inspec

ons before enclosure into a container, a shipping inspection and/or test will prov
ts may be made daily, weekly, semiweekly, biweekly, etc. Whatever the frequency, it
s, and many other requirement criteria.
atch destruction test on its components or assemblies is subject to a random dest

QUALITY STANDARDS
use, are able to concentrate their efforts on the most important qualities. In mo

QUALITY STANDARDS
plication to the entire progression of product from design through use: in quality
ries of tasks:

QUALITY STANDARDS
administer. The actual plans in use consist of only several classes. While choice
ident that the classifications must simultaneously take into account multiple con
can see them as on whether the consumer can see them. It is found that some words

QUALITY STANDARDS
ecifications. The classification may be in any of several alternatives:
d”) requirements, it is important to make clear which is which.
he jurisdiction over waivers.
fication of defects. (The contention is often raised that the tolerances on the s

QUALITY STANDARDS
om the process capability of general use machines and tools. Once published, these
active review, and it also produces a better final result .However, some companie

SENSORY QUALITIES
ents. In common with other qualities, sensory qualities require:
ry qualities. The qualities under test may be “desirable.” For example, if an expen
extent of the quality or deficiency under investigation. These samples are submit

SENSORY QUALITIES
s principle may be subdivided as follows:
manufacturer should take action to make the quality to that level but not beyond
dom describe completely what is wanted, and often inspectors are left to make the
standard?
s. If a particular inspector lacks this knowledge, he or she is qualified to make

SENSORY QUALITIES
a stake in the standard consumers, supervisors, engineers, and inspectors. Based o

SENSORY QUALITIES
n exhibit of samples with varying degrees of defects intermingled with perfect un
different applications. Once limit samples have been agreed to, there remains a pr
ng distance, and so on. Standardizing these conditions is a long step in the direc

SENSORY QUALITIES
of them quite complex. Some of the basic forms are described below.
mples. One sample is identified to each panelist as the standard or “control”; the
ree, two of which are alike. He or she also may be asked to estimate the degree of
“control” to which she or he has been subjected previously
in the order of concentration.

SENSORY QUALITIES
ies formerly judged by human perception are now measured by instruments. This dev
hat permits, in theory, measurement by some inanimate instrument.

limited number (10 to 50) of samples with each of the various measurement methods
r of samples (100 to 1000) also chosen to reflect the entire range of quality vari

SENSORY QUALITIES
es a high correlation.
the human test panel is to state preferences along the scale of measure. Hence th

MEASUREMENT QUALITY : AN INTRODUCTION
of product and process characteristics. This quantification is done through a sys
permit conversion of abstractions (e.g., length, mass) into a form capable of being
units of measure.
which the product or process possesses the characteristic under study. This proce
ly
n the laboratory.”
erances.”
etrology, i.e., the science of measurement. This science underlies the entire syste

MEASUREMENT STANDARDS
for the kilogram, all units are defined in terms of natural phenomena. (The kilog
e construction and maintenance of primary reference standards. These standards con
measuring many hundreds of quality characteristics. These standard test methods de

ds the huge array of test equipment, i.e., instruments used by laboratory technicia
erarchy serves to “transfer” accuracy of measurement to the next lower level in t
ghly skilled metrologists, and their skills are a vital commitment to the high pr

t and process. Because of the wide variation in training, skills, and dedication am

ERROR OF MEASUREMENT
surement error. The starting point is to understand the nature of accuracy and pre
ue value is called the error (also systematic error, bias, or inaccuracy) and is t

inge of doubt. Consequently, the expression of accuracy must show the extent of th
Instead, the measurements scatter about the average, as exemplified in Figure . The


readings.
ndard itself is consumable (e.g., hardness test blocks), so material variation affe

is subject to its own unique array of troubles. These instrument troubles are mu
and buyer laboratories may be at the root of a major quality problem.

CALIBRATION CONTROL
continuing system of calibration control.
e tested to see if it is within its calibration limits. This test is often referr
mbination of checking the instrument and adjusting it to bring it within its tole

CALIBRATION CONTROL
ional standards, new units of test equipment, and expendable materials. These elem
Control is based on the supplier’s calibration data and on his or her certificati
pany unless the demonstrated performance of the supplier merits use of an audit o
wever, it usually embodies measuring instruments of various sorts and may well inc
reagents or photographic film.

CALIBRATION CONTROL
he historical origin of the item, its assigned serial number, the checking schedul
lable on the results of checking, it becomes feasible to change the schedules in t

CALIBRATION CONTROL
ccuracy. This deterioration takes place primarily though use and secondarily throu
identified and controlled within a traceability cone. Minimum TARs for each trace

CALIBRATION CONTROL
oratories and a relatively few associated technicians. In contrast, the test equip
for each class of equipment are, but they cannot recall what the date of the last

CALIBRATION CONTROL
ed to identify the grades of the standards themselves, whether primary, secondary,
m to be going smoothly. In these latter cases, interruptions for calibration can e
checked in the forthcoming week.

CALIBRATION CONTROL
in hardware or software, carries these signatures, as do the labels on the equipm
anner, panels and drawers of test equipment are lock-wired, and the wires are lead

CALIBRATION CONTROL
o keep a record of the results of checking calibration and of the extent of work
or
itive failure

CALIBRATION CONTROL
The best inspector is only as good as his or her gages. If the gage is in error, t
ion of all of the above. The determining factor is usually based on master calibra
ctitioner must consult with the available experts: equipment manufacturers, resear

HUMAN FACTORS IN INSPECTION
placed on it in inspection tasks. The effectiveness of the use of sight depends l

relatively simple triangulation and profiling to three dimensional object recogn
inspection costs.
recognition of an object or feature, to a quality decision, or to the control of a
tion, position analysis, character or bar-code

process and the model become disconnected, and the observer sees only what he or

INSPECTION ERRORS
ibutes importantly to inspection errors. Inspection errors due to the inspector, c

INSPECTION ERRORS
lack of knowledge due to insufficient education or job training; and lack of “ski
esulting data, when arrayed in a matrix (usually with defect type along one axis a
f his or her own prior results. The analysis of the resulting data discloses the

INSPECTION ERRORS
ray is known by various names, including job sample. All units were previously car

INSPECTION ERRORS
do differently from what I am doing now?” Unless the inspector is in a position t
the practice to require that the inspector be formally certified as qualified to

INSPECTION ERRORS
e inspector wants not to make any errors. The term inadvertent or unavoidable is
ld find all the defects. Numerous unpublished and published studies have since de

INSPECTION ERRORS
inspection work: redundancy, countdown, and fail-safe methods.

that makes no inadvertent (or other) errors once the setup is correct and stable.
devices to magnify the ability of the unaided human being to sense the defects.
gainst their memories of the standard. When such inspectors are provided with a p
template placed over terminal boards. Holes in the template mate with the projec

INSPECTION ERRORS
responsible and concentrate attention on the real responsibility.

lerance lines are drawn. The inspector’s task of judging the size or location of p
hased all the items you originally planned to buy. At the other extreme, a checkli
gue, due to inability to maintain concentration for long periods of time. Response

INSPECTION ERRORS
lt or that needless burdens are placed on inspectors. In such cases, product redes
e, i.e., critical to human safety and health. In such cases, the low tolerance for e
silently reads the copy while someone else reads the master aloud.
aloud, performs a calculation, etc.

INSPECTION ERRORS
ent errors in shipment of uninspected product or even shipment of rejected produc
ntity” to packers and shippers. Bar codes should be used where appropriate.
her purpose.
ally chosen personnel.
to bear an inspector’s approval.

INSPECTION ERRORS
be initiated by management, by the inspector, or by a combination of both. However
these deeds rather than from the propaganda.

management’s real interests are elsewhere.

INSPECTION ERRORS
one perpetrate such a fraud. The manager requires confederates who submit themselv
erstandings are a breeding ground for poor industrial relations.

INSPECTION ERRORS
tor is exposed to suppliers who have a good deal at stake in the lot of product i

INSPECTION ERRORS
especially when it is their own performance.
symptom (the unnatural pattern of reading) rather than the disease (recording fic

INSPECTION ERRORS
y inspectors is actually management-initiated through manager pressures that seem

s to the nearest scale division, Rounding off is easy to detect from analysis of

INSPECTION ERRORS
tors. If this measurement is made only occasionally, use can be made of standard s
ng out of documents, etc.

INSPECTION AND TESTING SOFTWARE
ween instructor and trainee and can provide alternate training schedules without
esses. Many manufacturers have integrated the measurement system directly onto the
These data can then be analyzed for trends or problem solving.

INSPECTION AND TESTING SOFTWARE
ccuracy, reportability, and gage performance. Features include gage type, gage due
nd many other inspection and test interfaces into production processing.

Sec 23 Inspection and Test

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Sec 23 Inspection and Test

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INSPECTION AND TEST

gage, a nonvariable electronic or laser instrument, a nonvariable chemical or phy

Sec 23 INSPECTION AND TEST 2

tance inspection and acceptance testing.

oductive operation appraisal. Within this movement of proactive product acceptanc

Sec 23 INSPECTION AND TEST 3

nswer is obvious—the nonconformance is so severe as to make the product clearly

Sec 23 INSPECTION AND TEST 4

departments to aid them in preventing a recurrence. In more elaborate data-collec

Sec 23 INSPECTION AND TEST 5

the customer’s requirements, we expose the organization to uncontrolled, inefficie

ision on conformance to standard consists of a lot. The true lot is an aggregatio

Sec 23 INSPECTION AND TEST 6

the batch. In continuous production, the lot is usually defined as an arbitrary am

Sec 23 INSPECTION AND TEST 7

r, the planning is done by a quality assurance staff planner, an inspection or tes

be covered: inspection instructions, instrumentation, cost estimates, space and wo

Sec 23 INSPECTION AND TEST 8

the planner lists the quality characteristics to be checked. To determine these,

riteria for the checklist

Sec 23 INSPECTION AND TEST 9

spection or testing appraisal using standard inspection and testing equipment. Ho

Sec 23 INSPECTION AND TEST 10

departments, usually called process inspection or process testing As an integrati

Sec 23 INSPECTION AND TEST 11

It may, in addition, include the seriousness classification of characteristics, to

Sec 23 INSPECTION AND TEST 12

Sec 23 INSPECTION AND TEST 13

s. One technique is to do the planning by computer or by other means of mechanizi

itself to the inspection supervisors and the

Sec 23 INSPECTION AND TEST 14

Sec 23 INSPECTION AND TEST 15

Sec 23 INSPECTION AND TEST 16

Sec 23 INSPECTION AND TEST 17

Sec 23 INSPECTION AND TEST 18

of process capability). The presence of uniformity through fluidity greatly reduc

Sec 23 INSPECTION AND TEST 19

ed “scientifically” once the tolerable level of defects in accepted product has be

Sec 23 INSPECTION AND TEST 20

o provide redundancy against the unreliability of 100 percent inspection. In thes

urce of evaluation is the check list type.

Sec 23 INSPECTION AND TEST 21

experimental or analytical approach .Examples of application:

Sec 23 INSPECTION AND TEST 22

Sec 23 INSPECTION AND TEST 23

g the operator of the machine’s state of adjustment. Specification data stored in

to increased consistency and productivity; equally important, they will help to im

Sec 23 INSPECTION AND TEST 24

miautomated concept provides high-confidence repeatability and a faster analytical

Sec 23 INSPECTION AND TEST 25

Instead of having to physically transport the part to the inspection station, ce

Sec 23 INSPECTION AND TEST 26

Sec 23 INSPECTION AND TEST 27

Sec 23 INSPECTION AND TEST 28

r includes a series of light-emitting diodes (LEDs) in a linear array. The control

Sec 23 INSPECTION AND TEST 29

Sec 23 INSPECTION AND TEST 30

Sec 23 INSPECTION AND TEST 31

is usual to provide for periodic sampling to be conducted during the progression

Sec 23 INSPECTION AND TEST 32

Sec 23 INSPECTION AND TEST 33

Sec 23 INSPECTION AND TEST 34

atch destruction test on its components or assemblies is subject to a random dest