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In high-safety industries, such as aviation and nuclear power, reliability assessments are a mandatory requirement. These assessments play a crucial role in determining the intervals between inspections, which are based on estimations of the testing method’s reliability. However, in cost-sensitive sectors, like the automotive industry, the use of reliability concepts is not common. The main reasons cited for this discrepancy are expenses associated with statistical evaluations as well as the substantial effort which is required to attain meaningful results. Nonetheless, innovations in testing equipment and the current industry trends led to the evaluation of reliability, also known as probability of detection, which transformed from being an “optional consideration,” in the automotive sector, into a “necessity.” This is essential for optimizing the utilization of testing methods within the production process. The current chapter introduces an approach to integrate reliability assessments into the production process and to strengthen the connection between the testing process, the quality management, and even the design and production phases. This approach aligns with the overarching goal of NDE 4.0, making “reliability” the key to unlocking additional potential of NDE 4.0. The chapter serves as a unique example, clearly illustrating how reliability is the key to unlocking the potential of NDE 4.0 and highlighting the necessary challenges. The cyber-physical interconnection hinges on the latest reliable information regarding the quality of components—an essential piece of information that was not readily available in the past. Moreover, without objective information about the reliability of an NDE application, every aspect of the system may come under scrutiny, including method of standardization, testing procedures, and even the qualification process. This scrutiny could potentially pave the way for external NDE solutions, posing a disadvantage for the entire NDE industry. However, the solution will be presented in this chapter as an industry-suited reliability evaluation on the production floor.

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An Industry-Suited NDE 4.0 Approach: Validation of Automated Ultrasonic Testing Application Using POD on the Production Floor

  • 工具书词条

  • 发表日期：

    2025年

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  • Nico Lehmann,
  • Daniel Kanzler

摘要

In high-safety industries, such as aviation and nuclear power, reliability assessments are a mandatory requirement. These assessments play a crucial role in determining the intervals between inspections, which are based on estimations of the testing method’s reliability. However, in cost-sensitive sectors, like the automotive industry, the use of reliability concepts is not common. The main reasons cited for this discrepancy are expenses associated with statistical evaluations as well as the substantial effort which is required to attain meaningful results. Nonetheless, innovations in testing equipment and the current industry trends led to the evaluation of reliability, also known as probability of detection, which transformed from being an “optional consideration,” in the automotive sector, into a “necessity.” This is essential for optimizing the utilization of testing methods within the production process. The current chapter introduces an approach to integrate reliability assessments into the production process and to strengthen the connection between the testing process, the quality management, and even the design and production phases. This approach aligns with the overarching goal of NDE 4.0, making “reliability” the key to unlocking additional potential of NDE 4.0. The chapter serves as a unique example, clearly illustrating how reliability is the key to unlocking the potential of NDE 4.0 and highlighting the necessary challenges. The cyber-physical interconnection hinges on the latest reliable information regarding the quality of components—an essential piece of information that was not readily available in the past. Moreover, without objective information about the reliability of an NDE application, every aspect of the system may come under scrutiny, including method of standardization, testing procedures, and even the qualification process. This scrutiny could potentially pave the way for external NDE solutions, posing a disadvantage for the entire NDE industry. However, the solution will be presented in this chapter as an industry-suited reliability evaluation on the production floor.