CASE STUDY: Visual Inspection Protocol Optimization in Defense Manufacturing

CASE STUDY: Visual Inspection Protocol Optimization in Defense Manufacturing

Jason recently assisted a client in the defense and aerospace manufacturing sector to undertake a detailed analysis of welding and fabrication standards. The objective was to provide recommendations on the appropriate quality gate visual inspection protocols for their fabrication and assembly line—balancing structural integrity with production efficiency.

The work involved a comparative review of U.S. military welding standards—specifically TACOM 12479550 REV-A and MIL-STD-3040A—and how these standards influence inspection intensity. While TACOM is more stringent in visual inspection (including internal and non-visible welds), MIL-STD-3040A emphasizes modern non-destructive testing methods like PAUT (Phased Array Ultrasonic Testing) and focuses inspection efforts on functional and safety-critical areas.

Drawing on global aerospace practices, including:

• The Cranfield University Case Study (2018) on interpretive flexibility for non-critical surfaces,
• The NDE India 2020 Paper advocating for function-first inspection,
• And the ASA Aircraft Parts Inspection Guide, which supports reduced inspection intensity for internal components,

Jason recommended a hybrid approach. This involved adopting TACOM protocols for structural weld quality while applying MIL-STD visual inspection principles to reduce unnecessary rework and production delays caused by cosmetic non-conformances—such as minor weld splatter or slightly rolled beads on internal surfaces

The result: a risk-based, ISO 9001-aligned inspection framework that maintains structural integrity while improving workflow efficiency and reducing bottlenecks on the fabrication floor.