1、Lessons Learned Entry: 1189Lesson Info:a71 Lesson Number: 1189a71 Lesson Date: 2002-03-27a71 Submitting Organization: JSCa71 Submitted by: Clinton S. DennySubject: Cost Savings from Use of Photographic Weld Mapping Techniques Description of Driving Event: JSC SR&QA was tasked with performing a quart
2、erly visual weld inspection of the Motion Base Simulator (MBS) located in the Shuttle Mission Simulator facility. The MBS is a dynamically loaded large aluminum structure with over 300 welds, of which approximately 80 welds have exhibited cracking over the past ten years. The 80 welds had been repai
3、red, but many continue to exhibit cracking after a short time due to repetitive dynamic loading resulting from motion and vibration. As a result, these problem welds require continued inspection/evaluation. Previously it took 3 certified welding inspectors (CWI) 6+ hours to locate, access and inspec
4、t the 80 welds. Even though the welds were marked with labels, the configuration of the MBS prevented most welds from being readily located. The CWIs spent approximately 4+ hours locating the welds and 2 hours to perform the inspections. Inspection personnel divided the MBS into five separate areas
5、and took high-resolution digital photographs of each area. On each photograph the weld locations were labeled with the appropriate weld number and an arrow pointing to the exact location. A trial run was conducted and all of the welds were located in less than 30 minutes. During subsequent quarterly
6、 weld inspections the overall inspection time for three inspectors has been reduced to less than 3 hours. The result is a more than 50% savings for each inspection cycle.Lesson(s) Learned: Significant efficiencies can result from use of Photographic Weld Mapping especially for complex configurations
7、 involving numerous weldsRecommendation(s): Photographic mapping can be implemented to document inspection, test or work locations on various types of hardware or systems, regardless of size or configuration with potential for significant time Provided by IHSNot for ResaleNo reproduction or networki
8、ng permitted without license from IHS-,-,-and cost savings.Evidence of Recurrence Control Effectiveness: Digital Photographs can be updated as needed to ensure effective control and accuracy.Documents Related to Lesson: N/AMission Directorate(s): a71 Exploration Systemsa71 Space Operationsa71 Aerona
9、utics ResearchAdditional Key Phrase(s): a71 Aircrafta71 Configuration Managementa71 Facilitiesa71 Flight Equipmenta71 Ground Equipmenta71 Hardwarea71 Industrial Operationsa71 Parts Materials & Processesa71 Safety & Mission Assurancea71 Spacecrafta71 Test & Verificationa71 Test Articlea71 Test FacilityAdditional Info: Approval Info: a71 Approval Date: 2002-05-06a71 Approval Name: Ronald A. Montaguea71 Approval Organization: JSCa71 Approval Phone Number: 281-483-8576Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-
