Accurate defect quantification is crucial for ensuring the serviceability of
aircraft engine parts. Traditional inspection methods, such as profile
projectors and replicating compounds, suffer from inconsistencies, operator
dependency, and ergonomic challenges. To address these limitations, the 4D
InSpec® handheld 3D scanner was introduced as an advanced
solution for defect measurement and analysis.
This article evaluates the effectiveness of the 4D InSpec scanner through
multiple statistical methods, including Gage Repeatability and Reproducibility
(Gage R&R), Isoplot®, Youden plots, and Bland–Altman plots. A new
concept of Probability of accurate Measurement (PoaM)© was introduced
to capture the accuracy of the defect quantification based on their size. The
results demonstrate a significant reduction in measurement variability, with
Gage R&R improving from 39.9% (profile projector) to 8.5% (3D scanner), thus
meeting the AS13100 Aerospace Quality Standard. Additionally, the 4D InSpec
scanner improved detection accuracy, provided automated defect quantification,
and eliminated the need for time-consuming replication processes.
Beyond performance improvements, the adoption of the 4D InSpec scanner led to a
75% reduction in direct labor time, significant cost savings, and the
elimination of ergonomic risks and human error associated with traditional
inspection methods, and enhanced defect reporting and data collection. The
article closes with implementation requirements and areas for future
improvement.
