INSTRUMENTATION &
MEASUREMENT
by
MERAZ AHAMMED
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INSPECTION
by
MERAZ AHAMMED
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Inspection
What is Inspection?
Procedure of checking of all materials, products or component parts at various stage during manufacture so that a
part or product feature, such as a dimension, is examined to determine
whether or not it conforms to design specification. The design specifications are based on international standards
Many inspections rely on measurement techniques, while others use gauging methods
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Inspection
✓ What is inspection
✓ Necessity of Inspection
✓ Procedure of Inspection
✓ Stages of inspection
✓ Types of Inspection
✓ DT and NDT
✓ Gauging
✓ Types of Gauges
✓ Differences
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Inspection
Need of inspection
1. To ensure that the part material or a component conforms to the established standard.
2. To meet the interchangeability of manufacture.
3. To control the performance of man/machine/process.
4. To maintain good customer relationship by ensuring that no faulty product reaches the
customer.
5. The result of inspection are forwarded to the manufacturing department, thus helps in
improving the quality.
6. It produce the parts having acceptable quality levels with reduced scrap and wastages and
judges the possibility of rework of defective parts.
7. It provides the means of finding the problem area for not meeting the established standards,
8. It helps to purchase good quality raw materials, tools and equipment’s that govern the quality
of finished products.
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Procedure of Inspection
Planning and Scheduling:
Define inspection scope and criteria based on product specifications and industry standards.
Determine sampling methods (e.g., random sampling, full inspection).
Assign inspectors and schedule inspection times.
Preparation:
Gather necessary inspection tools and equipment (measuring devices, gauges, checklists).
Access relevant documentation (drawings, specifications, quality control procedures).
Selection of Inspection Process
Inspection Process: Doing Inspection
Documentation and Reporting:
Record inspection findings on standardized forms, noting any defects or non-conformities.
Capture relevant data like measurements and inspection dates.
Generate inspection reports highlighting identified issues and recommended corrective actions.
Corrective Action:
Address identified defects by taking necessary actions like rework, repair, or material rejection.
Implement process adjustments to prevent future occurrences of issues
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Inspection
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Inspection
Types of Inspection
Inspection involves the use of measurement and gauging techniques to determine whether a
product, its components, subassemblies, or materials conform to design specifications
Inspections divide into two types:
1. Inspection by variables - product or part dimensions of interest are measured by the
appropriate measuring instruments
2. Inspection by attributes – product or part dimensions are gauged to determine whether or
not they are within tolerance limits
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Inspection
Manual Inspection:
Inspection procedures are often performed manually
The work is boring and monotonous, yet the need for precision and accuracy is high
Hours may be required to measure the important dimensions of only one part
Because of the time and cost of manual inspection, statistical sampling procedures are
often used to reduce the need to inspect every part
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Inspection
Sampling Inspection:
When sampling inspection is used, the number of parts in the sample is usually small
compared to the quantity of parts produced.
• Sample size may be 1% of production run
Because not all of the items in the population are measured, there is a risk in any
sampling procedure that defective parts will slip through
The risk can be reduced by taking a larger sample size
Fact is that less than 100% good quality must be tolerated as the price of using sampling
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Inspection
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Inspection
100% Inspection:
1. Theoretically, the only way to achieve 100% good quality is by 100% inspection
2. All defects are screened and only good quality parts are passed
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Inspection
100% Inspection:
Examples of situations where a 100% inspection might be done:
Medical devices:
Every single medical implant or surgical tool would be thoroughly inspected before being used
on a patient due to potential life-threatening consequences of a defect.
Aerospace components:
Critical parts of an aircraft, like engine components, would undergo a full inspection to ensure
safety during flight.
High-value electronics:
Expensive components in a high-end computer or server might be individually inspected to
minimize the risk of failure.
Food safety critical products:
Certain food items like baby food or products with high risk of contamination could be subject
to 100% inspection to ensure safety.
Custom-made products:
When a product is made specifically for a demanding customer with strict quality
requirements, a full inspection may be conducted.
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Inspection
100% Inspection:
Disadvantages:
Costly: Inspecting every item can be time-consuming and labor-intensive, so it is typically only
used when necessary.
Not foolproof: Even with a 100% inspection, human error can still occur.
Advantages:
Accurate
More reliable Suppose you are the manager of the quality
Useful for sensitive product assurance dept. of PRAN-RFL. You have got an
order of 1000 piece of bucket to
manufacture. What type of inspection process
will you choose?? Justify your answer
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Inspection
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Inspection
Inspection with destructive testing
Destructive testing means testing that destroys an item or is performed in a manner that reduces the
value of the item.
For example, in cases involving destructive tests such as :
Product life tests, accelerated degradation tests, destructive strength tests, tensile tests of metallic
materials, impact tests of non-metallic materials, heat generation tests of injectable drugs, and
degradation tests of electronic devices
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Measurement of the Properties of Materials
Tensile/compression Test Hardness Test
Impact Test
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Inspection
Inspection with destructive testing
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Inspection
Inspection with destructive testing
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Inspection
Inspection with destructive testing
Advantages For material properties measurement/test
Reliable (direct measurements) you must need to choose Destructive testing.
Quantitative Do you agree with this statement?? Justify
Directly relates to material properties your answer.
Disadvantages
Cannot test in-service structures
Requires a model
Costly & Time Consuming
Multiple tests are sometimesr equired
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Inspection
Inspection with Non-destructive testing
Non-destructive testing (NDT) is a testing and analysis technique used by industry to evaluate
the defects/integrity of a material, component, structure, or system for characteristic differences or
welding defects and discontinuities without causing damage to the original part.
NDT is also known as non-destructive examination (NDE), nondestructive inspection (NDI), and non-
destructive evaluation (NDE).
EX: Ultrasonic test, X-ray, Bearing vibration & temp
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Inspection
Inspection with Non-destructive testing
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Inspection
Inspection with Non-destructive testing
NDT Applications
• Flow Detection and Evaluation
• Leak Detection
• Location Determination
• Dimensional Measurements
• Structure and Microstructure Characterization
• Estimation of Mechanical and Physical Properties
• Stress (Strain) and Dynamic Response Measurements
• Material Sorting and Chemical Composition Determination
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Inspection
>>Gauging determines simply whether the part characteristic meets or does not meet the
design specification
>>Gauging is usually faster than measuring, but not much information is provided about
feature of interest
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Inspection
>>What is gauges??
A gauge is an important measuring device in the field of design engineering. It is a device used to
provide certain dimensional information, according to a specified standard or system.
Some gauges are meant to measure the size of the object. But, most gauges are mainly used to
specify if the dimensions of the measuring object are less or greater than defined standards that are
within the tolerance range. Gauges can be operated electrically or mechanically.
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Inspection
Caliper Gauge
The gauge that is similar to a snap gauge and used to check the inside and outside
dimensions of the product is known as a caliper gauge. One end of the caliper gauge is used
to check the internal dimensions, and the other end is used to check the outer dimensions.
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Inspection
Vernier caliper vs Caliper Gauge
Depth Inside Diameter Outside Diameter
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Inspection
Difference between Gauges & Measuring Instruments
Gauges Measuring instrument
1. Check the dimension a part whether is within a
range or [Link] measures the actual dimension of a part
not
2 No adjustment is required while is use 2. Adjustment is required
3 Quick method 3 Time taking Method
4. These are specially meant 4. These are general purpose instruments
5. Less skill is required during use 5. Skill is required during use
Ex. Limit Gauges Ex. Micrometer, Varied calip
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Inspection
Types of Gauges
Gauges are used to measure different types of objects having various sizes, shapes, and thicknesses,
the gap in space, diameter of materials, or pressure of the flow. Specific types of gauges are used to
measure each parameter. Gauges are classified into eight types, they are:
• Plug gauge
• Ring gauge
• Taper gauge
• Snap gauge
• Feeler gauge
• Thread gauge
• Form gauge
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Suggestions!!!
1. Define Inspection .
2. What are the necessities of inspection?
3. Write down the procedure of Inspection process with flowchart.
4. Suppose you are working in a quality dept. of RENATA PHARMACEUTICALS. You are told to select
an inspection process for inspecting PARACETAMOL SYRUP. Which type of inspection process will
you choose and why?? Justify your answer.
5. What is Destructive And Non-Destructive inspection?? Give examples
6. Among DT and NDT which will you prefer and why?? Justify
7. Suppose you need to inspect the quality/ corrosion /blockage of pipeline. Which type of testing
process will you choose and Why?? Justify
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Suggestions!!!
1. What is Gauging??
2. Discuss the difference between gauging and measuring instruments
3. Mention some gauging tools.
4. Short Notes: Manual , sampling, 100% inspection
5. What are the Advantages & Disadvantages of 100% sampling? Will you still use 100% sampling despite
disadvantages?? If yes justify your answer
6. Identify which one is gauging and which one measuring tools: Vernier, screw gauge, depth gauge, plug gauge, snap gauge, scale
7. Discuss the advantages and disadvantages of DT & NDT.
8. Mention some DT & NDT methods.
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Thank You All..!
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