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NDTnet - March 1996, Vol.1 No.03

Automated NDT
Advantages and Disadvantages

Abstract:

Automation of NDT has both advantages and disadvantages. This discussion article tries to highlight these, and allows NDT users to decide for themselves if they should automate or not. The two main advantages of automation are reproducibility and man-power reduction; the disadvantages are the investment needed to implement this and the complexity of an automated system.

Table of contents

Automated NDT

Let's look at a definition of Automation, then at some of the points mentioned above, and try to analyze them. An automated NDT station can be as simple as a scanning guide combined with a monitor and audible alarm to warn of a defect to help the ultrasonic operator position his probe, ( a semi-automated system), or as complex as a multi-channel million dollar computer controlled machine that can fill a living room. Anything that mechanically or electronically assists or replaces the manual operator can be considered as some form of automation.

Reproducibility

An automated NDT system, be it Ultrasonic, Eddy Current or any other type, almost always has reproducible performance. It is not significantly dependent on how much beer the operator drank last night (or at lunch time), temperature or humidity, how tired the operator is, how many hours of overtime he has worked this week, or how attentive the operator is to his work.

Once the test system is set up, it will (or at least should) produce reproducible results, 60 seconds every minute, 60 minutes every hour, 24 hours every day. The overall sensitivity of the system may be a little less than that of a vigilant operator (but with signal processing, could provide significantly superior performance), but the reproducibility will be almost 100%. An automated system's performance is, however, so reproducible that if the operator does not adjust the machine correctly, it will test all parts incorrectly. For security, a well documented set-up procedure should be specified for the machine, to reduce the risk of this happening.

The manual operator has very poor performance reproducibility. In many industries, detection of 80% of observable defects is considered the normal performance of a human inspector (whether the system is Ultrasonic, Eddy Current, Visual, Magnetic Particle, Penetrant, or any other.)

Let us look at a manual ultrasonic operator testing components for defects. Under ideal conditions, such as when he is alert, just starting his shift and has just calibrated his instrument and probe, perhaps he can find defects 3mm long and larger. Assume also that an automated system can only detect defects of 5mm and longer, and that 3mm is the acceptance limit. Which is to be preferred? The more sensitive manual operator or the automated system that cannot meet the requirements of the specification ?

Investment

An automated NDT station will not be cheap. Depending on the complexity of the system, the price could range from $10,000 to $10,000,000, but let us assume that a machine costs about $100,000. In pure financial terms, if it can replace three operators, it may come close to paying for itself in just over a year. One has to consider, however, the interest on capital borrowed to purchase the machine (or at least loss of interest by not having the capital to invest), running costs etc., as well as possibly extra training for the operators in the new technology. Consider also the situation that you could be in if the machine breaks down, so you have to have a back-up of some type, or a significant investment in spare parts and a good TPM (Total Preventative Maintenance) scheme. For smaller companies, more complex test systems may prove to be too high an investment to make economic sense.

Complexity

Now let's look at the complexity of an automated system. It is not practical to take a 10 meter long ultrasonic immersion system into the field and test pipelines in production, but less complex systems could be considered, using contact transducers. A modern high-tech ultrasonic test system that is dedicated to one high volume production component can be as complex as the supplier likes, but it has to be simple enough for an operator to use without overwhelming him with technology. A more highly qualified engineer could possibly operate the system without problems, but will probably not remain in such a monotonous occupation for more than a few months.

The ideal system is one that is user friendly and not difficult to adjust for component changes. It can ideally be computer controlled, with the computer controlling all necessary adjustments, based purely on an operator's simple input to the system. This can be through a keyboard if he is computer literate, but if the level of personnel to be employed on such systems have no potential for computer literacy, then alternative arrangements have to be made.

If (for example) you needed 20 Level 2 NDT operators to manually test your production on a three shift system, you may have the potential to replace these with an automated system, one level 2 (or Level 3) operator plus perhaps 4 or 5 Level 1 operators, so the savings are not only in the numbers of personnel that you need, but also in the class of personnel. Based purely on quality requirements, automation scores very highly. For a mass production environment, automation can have a significant economic potential. When the lot size is very small, automation becomes less attractive, unless it can be compensated for by a more complex and versatile machine that is capable of simple adjustment from one production lot to the next. Issues of investment or complexity may, however, make automation infeasible. Each individual situation should be considered on its own merits. These conclusions are also valid for any automatable NDT systems.

Discussion Point

Taking mass production to its extreme, we need to consider if NDT should be employed in the production process at all. If your process is producing defective parts, then the process is potentially costing you money in the form of reduced throughput (due to parts rejected), as well as inspection costs. If the cause of the defects can be determined, and the process so controlled that these defects do not occur, then the need for NDT becomes questionable.

References

1. Quality Control Handbook Third Edition 1979 Page 12-53 by J.M.Juran
   
2. 'Some individual psychological factors leading to error in ultrasonic testing' Journal of the British Institute of NDT Vol. 31 No 12 Dec 1989 by Calum Webster

The author
Godfrey Hands started his career in NDT in 1968. His specialties are Ultrasonics and Resonant Inspection, and his NDT experience has encompassed many different industrial sectors from offshore industry and training to research. His employers have ranged from construction and the NDT service industry, through sales to his present position within a multi-national mass-production organisation.

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E-Mail: Godfrey@hands-ndt.co.uk
Homepage: www.hands-ndt.co.uk

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Rolf Diederichs 1.March.1996, info@ndt.net /DB:Article /AU:Hands_G /IN:Hands /CN:UK /CT:UT /ED:1996-03

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Vol. 3,Infrared and Thermal Testing
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