NDT Training Methodologies used in Digital Radiography

Good Evening Guests & Attendees

Blair O’Connell, Senior Quality Manager, Digital Resp. Level III Element Rancho Dominguez

24 Years experience in Nondestructive Testing. 3 Years with Element

RT ASNT Level III, Non Film Level III certification, Rolls Royce, Safran, Pratt & Whitney, and GE

Worked in NDT, Operations, and NDT Management for a major Aerospace supplier in Portland OR

Trained in Lean Manufacturing methodology

6 years experience in Operation Management (Annual budget responsibility of 20M)

What we do

Liquid PenetrantInspection

Magnetic Particle

Inspection

Ultrasonic Inspection

RadiographyInspection

Digital Radiography

InspectionEddy Current

InspectionEtching Macroetch

Inspection

Our NDT and Etch Processing services include:

Our applications include:

Element provides a comprehensive range of nondestructive testing and etch services on all of the materials,components, systems, structures and engines utilized in most commercial aircraft in service today.

As the largest independent testing company operating in the global Aerospace sector, we support the increasinglycomplex technical and commercial challenges that our clients face, from R&D to production and in-service.

Aero structures

§ Air fuselage§ Center fuselage§ Nose section§ Fasteners§ Fittings§ Seals§ Wing leading & trailing

edge§ Slats and flaps

Airframe Systems

§ Actuators§ Shock struts§ Brakes§ Wheels§ Fuel systems§ Avionics§ Pumps§ Valves§ Seals

Engines

§ Fan blades§ Compressor blades§ Turbine blades§ Vanes§ Cases§ Combustors

Passivation

Discussion Points:

• How can we make training more effective • Why should we Train with OJT

• Yes this is a “We” decision• What is the benefit• Who is responsible• Training design Examples

• Trainer• Level I• Level II

• Production and Efficiency• Quality

Train vs. simple OJT model• What is the difference

• Train- Active learning and information retention through Written, Hands-On, and Video material

• On Job Training• Highly dependent in the technicians experiences

• Decision is more based on whether you want a technician or an NDT professional

What are the benefits?• What training can provide

• An individual that has the opportunity to become a NDT professional• Future Level II’s or Level III’s as the technicians become more involved in their

path• Better performance

• Productivity• Efficiency• Audit Results

• Performance-Helping with Productivity• Internal-Better Audit results• External-Less notifications & findings

• Problem solvers rather than “problem makers”

Who is responsible?• Employer

• Employer is the certifying agent• Employer provides the method of training for certification

• This includes who is responsible for the training programAC7114 Rev. M Question 5.1.7Does the employer have a formal plan showing objectives for obtaining certifications for trainees?

• Trainer • Works with Employer to make sure all Training and OJT meets Employers procedure.

• Does the company choose an Internal or External trainer • Is the trainer engaged or told to do it• How are they motivated (pay, advancement, preparation for Level III)

• Employee• Ultimately they are the one that will progress to their potential. The key is to give them

everything reasonable to meet their potential

• What to consider• Customer base• Methods your company is performing• What are your organizations needs (Old OJT method may be sufficient)• Personnel level- Trainee, Level I, Level II etc.• Preferred learning method

• Reading: Manuals, Procedures, and Specifications• Hands on: Let me do it• Watch it: Observation of people doing the tasks

• More than likely it is a combination of each• Investment

• Time• Cost

Training Design

Training Design Examples• Trainer Training-Yes it is a thing and it is very important

Training Design Examples• Level I Communication of What Will be Covered

Training Design Examples• Level I Training Module for “Start of Shift”

Training Design Examples• Level I Training Retention Documentation

Training Design Examples• Level I Documentation of Training Completion Prior To Certification

Training Design Examples• Level II Communication of What Will be Covered

Training Design Examples• Level II

Training Design Examples• Level II

Training Design Examples• Level II

Training Design Examples• Level II

Training Design Examples• Final evaluation of Level II trainee prior to their release to certification

testing• Level III and Trainer put together a “Design Test Part”

• Design Test Part:• Compilation of images that demonstrate all possible judgments that the

inspector may encounter• Poor Quality Images that require re-shots• Internal cast defects• External “Visual” defects• Max size allowed• Special note call outs (i.e. 2 discontinuities at max size in same area)

• This is also a good exercise for those individuals that require re-training due to an inspection failure or lack of time inspecting a particular component

• Can be designed to numerous customers/primes by changing acceptance criteria

Production & Efficiency• Productivity

• How much the technician can get done• Quantity

• Efficiency• How much did the technician do to get the work done

• Reshots/rework• Mistakes• Upstream rework• Upstream Mistakes• Customer rework• Customer complaints

A productive worker generates revenue. An efficient worker generates quality revenue with less hidden costs

Quality• What does training have to do with Quality?

• Training programs teach the trainee the reasons behind what they are being trained in

• Effective training programs test the trainee on their retention and understanding of the procedures and specifications that they work to and with

• Effective training includes preparation for internal, external, and 3rd party audits • Training programs help to provide points of documentation for customer issues,

NCR’s, and audit findings• Training documentation also assists when quality issues require disciplinary

actions

What we covered:

• Training vs OJT• “We” Employer, Trainer, and Employee

• Benefits of Training• Responsibility of the collective “We”• Training design ideas• How training can help with Production and Efficiency• How training is a key to Quality

Does emphasized training apply to your organization?

To find out more about Element Materials Technology, please go to www.element.com

Questions