Reducing Inspection Time Using the Latest Digital Inspection Tools

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The Issues

009-32 Process for DFT Measurement:

A side by side study will be performed to

gather data and provide metrics for the:

1. Completion Time2. Data Accuracy3. Data Processing

of three test methods used to evaluate Dry

Film Thickness (DFT) in a typical ballast tank

Method 1: Current shipyard practice:

Analogue or digital measurements

and hand written reports.

Three Test Methods

Method 2: Scanning

A new DFT scanning technology that

provides real time digital data.

Three Test Methods

Method 3: Auto Cal - to profiles

Three Test Methods

A new DFT device that requires little

training and yields both data storage

and digital data outputs.

Progress to Date

QA Inspector Questionnaires Completed

First week of inspections at BAE September 15-19.

Inspections at HII to take place before November 2014.

NASSCO Earl inspections TBD.

Inspections to be completed before end of December 2014.

Goals & Objectives

Project will quantify efficiencies of each method and

calculate cost savings with a goal of:

Reducing inspection time from the industry average of

1.5-4 hours to 20-40 minutes.

Reducing paperwork generation time from an industry

average of 3-5 hours to under 1 minute.

Reducing or eliminating erroneous readings and non-

conformances due to user error.

Reducing or eliminating transcription errors.

Reducing audit time by highlighting non-conformances in

a Paperless QA format.

Methods and Procedures

Required for Accomplishing

Goals and Objectives

A committee comprised of paint and coating QA/QC Managers from

HII-Newport News, BAE Systems Southeast Shipyards, HII-Ingalls,

NASSCO - Earl Industries, and Elcometer will provide trained inspectors

to:

Perform a DFT inspection of a seawater ballast tank according to the

legacy method

Perform the same inspection using the scanning technology Perform the

same inspection using the new inspection device

Each inspection will be timed and the inspectors will be asked for their

feedback on each method.

Each inspection will then be transcribed according to their legacy

method and evaluated for both time and accuracy when compared to the

digital transmission of the data yielded by the other two test methods.

Benefits and ROI

The first proposed new technology (scanning) will be validated for both

accuracy and speed against the current technologies used in the legacy

DFT measurement method.

As this technology is a productivity enhancement rather than a process

change, the technology will be presented to the 009-32 TWH as an "as

equal" measurement technology. Therefore, its use may not require a

SSRAC proposal for change.

The shortened production/process time can be measured across the

fleet once approved by the TWH.

e.g. an average savings of 3 man hours per tank on a carrier

yields 900 man hours of savings in ballast tank DFT

measurements alone.

When leveraged against all critical coated areas, the savings go up

exponentially.

Benefits and ROI

The second proposed inspection device will be validated for both

accuracy and speed against the legacy DFT measurement method as

well as against the productivity gains of the first proposed technology.

As this device is both a productivity and a process enhancement, the

results shall be presented to the 009-32 TWH as a "separate but equal"

device and method.

The shortened production/process time, when combined with features

that eliminate the need for complex calibration techniques (as the legacy

method requires) and expensive user training, will not only yield similar

cost savings to the first proposed technology but also have the added

benefit of eliminating calibration errors; which is often the difference

between a coating system passing or failing inspection.

Technology Transfer and

Implementation ApproachThe results of this project will be formally presented to the TWH and

discussed at SPC meetings.

A draft users guide will be submitted as an attachment to the 009-32

proposal, briefed to SSPC PA-2 committee, the SSPC Education

Committee, and to the NACE Education and Training Committee.

Committee will create their final report with calculated time/cost savings

and submit to the panel members for review.

An SSRAC proposal shall be submitted to the 009-32 TWH for

acceptance into the NAVSEA Standard Item.

THANK YOU

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