Inspection and Testing Approved for Public Release 1

Inspection and Testing Approved for Public Release 1

Introduction • All materials and services supplied to Electric Boat must be inspected and tested in accordance with Purchase Order invoked specifications, drawings, standard clauses, etc. – Determine if supplier or government have additional or more stringent requirements. Inspection and Testing 2 Approved for Public Release

Introduction (continued) • Purchase order imposes inspection systems via EB 2678 and Standard Clauses (60 -5, 60 -19, 60 -58) for MIL-I 45208, MIL-Q-9858, or ISO 9000 series – Accordingly, suppliers must establish and maintain a compliant inspection system – System must also address subtier suppliers – Be aware of Supplemental Technical Requirements (60 -58 STRs) for ISO 9000 Inspection and Testing 3 Approved for Public Release

Introduction (continued) • Inspection and Testing that result in OQE must be performed by a supplier’s organization independent of production, i. e. , the Quality Control Department. Inspection and Testing 4 Approved for Public Release

3 Basic Types of Inspection: • Receiving Inspection verifies acceptability of materials, services, and associated documentation at receipt. Inspection and Testing 5 Approved for Public Release

3 Basic Types of Inspection: • In-Process Inspection performed at manufacturing stages deemed necessary to verify: – internal compliance with requirements as production progresses, statistical process control charting, non-accessible assembly, etc. – as required by the purchase order, drawing, or specifications to be an EB or Government Hold/Witness Point (SC 37 -8 series). Inspection and Testing 6 Approved for Public Release

3 Basic Types of Inspection: • Final Inspection shall verify that the product is dimensionally acceptable, properly assembled, and the documentation is satisfactory in accordance with the purchase order. Inspection and Testing 7 Approved for Public Release

Requirements • Inspection and Testing must be accomplished using clear, complete, and current procedures and instructions • Inspection and Testing shall be performed in appropriate environmental conditions with respect to temperature, humidity, noise, vibration, etc. Inspection and Testing 8 Approved for Public Release

Requirements (continued) • Instruction needs to specify: – Source of the inspection or test criteria • drawing, specification, standard clause, etc. – Gaging or tooling required to ensure proper accuracy of measurements – Provision for recording the actual results as objective quality evidence for reference Inspection and Testing 9 Approved for Public Release

Requirements (continued) • When required by a standard clause (10, 60, 76 series), drawing, or specification, procedures shall be approved by Electric Boat on a Vendor Procedure Approval Request (VPAR), prior to performance of the testing. Inspection and Testing 10 Approved for Public Release

Requirements (continued) • Examples of Testing Procedures requiring Electric Boat approval: – NDT Procedures – Noise Testing Procedures – Shock Testing Procedures – Vibration Procedures Inspection and Testing 11 Approved for Public Release

Requirements (continued) • Examples of Testing Procedures requiring Electric Boat approval (continued): – Forging test specimen location drawings – Production Procedures (when specified by the Purchase Order or Procurement Specification) – Qualification and First Article Procedures (when specified by the Purchase Order or Procurement Specification) Inspection and Testing 12 Approved for Public Release

Electrical Testing Dielectric Voltage Withstand Test Ø Dielectric Voltage can be a Destructive test. Ø Voltage Level and time should be considered. • Example: Operating Voltage is 440 VAC • Test at 2 X 440 +1000 VAC= 1880 VAC Inspection and Testing 13 Approved for Public Release

Electrical Testing Insulation Resistance Ø An Insulation Resistance test is normally done with DC and is usually performed at a lower voltage level such as five (500 VDC) hundred volts. An IR test measures the quality of the insulation system and provides a measure in ohms or megohms. It is sometimes used before a Hi. Pot Test as both a predictor of a failure condition and to provide a quantitative value of the insulation system. Ø Often performed before, during and after Hydro on Electrical Hull Penetrators. Inspection and Testing 14 Approved for Public Release

Electrical Testing Continuity • Determines if there is an uninterrupted electrical connection between two points. • • Resistance or DC Resistance Measured in ohms The opposition to current flow Report actual results EX: > 1 Ohm Inspection and Testing 15 Approved for Public Release

Documentation • Inspection and test results shall be documented, preferably on a company form with letterhead. • Inspection and test results must clearly indicate: – – the type and number of inspections or tests performed the results of the inspection or test the signature/date of personnel performing the test additional requirements of the applicable SC 76 -9 series Inspection and Testing 16 Approved for Public Release

Documentation (continued) • When required by the Purchase Order, generally a Standard Clause, the Inspection and Test Reports shall be provided to Electric Boat. • Inspection and Test Reports shall not contain any qualifying statements, such as “to the best of our knowledge”, “while in our possession”, “approximately”, etc. Inspection and Testing 17 Approved for Public Release

Documentation (continued) • All instruments, gages, and tools used to perform official inspections and tests must be calibrated in accordance with a documented calibration program. • Actual instruments, gages, and tools used to perform official inspections and tests should be identified and listed in the inspection or test report: – provides additional objective quality evidence – traceability if gage out of calibration Inspection and Testing 18 Approved for Public Release

Documentation (continued) • Inspection Records and Test Reports shall be traceable back to the product being tested or inspected and the applicable procedures or instruction being used. • Corrections of errors on Inspection Records or Test Reports shall be in accordance with the requirements of Electric Boat Specification 2678. Inspection and Testing 19 Approved for Public Release

Suggestion • Initiate a method and procedure defining type and accuracy of gages to be used for dimensional inspection of particular attribute tolerance ranges – Gage for +/-. 020” tolerance different than +/ -. 0005” tolerance as is a 50 psig test different than a 500 psig test – 10% rule Inspection and Testing 20 Approved for Public Release

Suggestion • To better ensure that the integrity and caliber of the inspection system and the personnel are being maintained: – Implement an overcheck program that periodically confirms inspector results – Implement a refresher training and qualification program for inspectors (similar to NDT, welding, etc. ) Inspection and Testing 21 Approved for Public Release