Proactive parts testing is an important supply chain activity because it makes manufacturers aware of potential issues before they cause severe problems that could erode trust, risk lives, and bring regulatory scrutiny. What should professionals know about it before implementing the practice in their organizations?
What is Proactive Parts Testing?
Proactive parts testing encompasses the steps taken and processes used to verify that components meet specifications and expectations. These measures have become particularly useful as supply chains have become increasingly complex.
Many parties order products that pass through multiple entities before reaching the purchaser. That reality makes checking that the items are authentic and free from defects more challenging. Rather than risk trusting what the supplier promises, many supply chain professionals conduct specific testing to confirm the quality themselves.
Although remanufacturing cannot solve all such issues, it can allow brands to reclaim value from parts they would otherwise discard. After remanufacturing, these components must pass tests to show they meet or exceed original specifications.
Proactive Testing’s Relationship to Supply Chains
Testing is critical when companies supplement their supply chains with remanufactured parts, which are previously used but restored to ensure high performance. Research showed that 33% of entities experienced very significant supply chain disruptions between 2020 and 2023, citing material shortages as the reason.
Businesses also run stringent tests before bringing new products to market. The results of those examinations show whether the items meet standards as they are or require further development and perhaps redesigned parts before reaching consumers.
Government authorities may even support stringent testing procedures, as in South Korea, where those parties backed the opening of a dedicated center for manufacturers to examine different possibilities for OLED displays. Local and national governments collaborated to invest the equivalent of $112 million into the facility, believing it necessary to make the country’s domestic parts supply chain more competitive.
Types of Proactive Parts/Materials Testing
In addition to evaluating parts within the supply chain, professionals may also examine various materials in fatigue tests, checking how well they resist water or putting them under strain. Regardless of the items tested, the methods are either destructive or nondestructive. Those in the first category involve intentionally breaking, cutting, crushing, or otherwise damaging a product to learn more about its physical, chemical, or mechanical properties.
However, nondestructive testing allows parties to obtain the necessary data without making the item unsellable. It has become popular because it enables enterprises to test every product made theoretically rather than taking a representative sample to destroy. There are various methods to consider depending on what individuals want to verify.
The simplest option is visual testing, which involves people using their unaided visual senses or magnifying glasses to inspect items. Alternatively, ultrasonic testing relies on high-frequency sound waves to find internal flaws like cracks or voids they cannot see. If a part features ferromagnetic materials, experts may use magnetic particle testing, which uses magnetic fields and iron particles to detect defects on or below an item’s surface.
Some nondestructive testing companies also combine technologies for high-tech results. One example is Adaptix, which uses low-dose X-rays and algorithms. It began as a medical startup that provided 3D data of patients in seconds with much less radiation than CT scans require, and now offers nondestructive testing of products such as aircraft parts.
How Comprehensive Testing Strengthens Supply Chains
Proactive parts testing gives professionals more confidence in their supply chains and allows them to intervene before identified problems worsen. Suppose the components from a particular supplier repeatedly failed a manufacturer’s internal tests. Such outcomes may justify scheduling a site visit, reminding the supplier of previously stated standards, or taking other actions to address the problem.
Supply chain professionals cannot deal with issues until they know about them. A proactive parts testing strategy can increase their awareness, giving them time to react before it is too late. People would much rather know about quality shortcomings when they can do something about them rather than once recall or other severe consequences occur.
Failure to proactively address these issues can have massive ramifications on one’s business. An infamous example is the supply chain disaster of the mid-2000s that befell Boeing, the aircraft manufacturer. Attempts at cutting corners and saving profits led to a neglect of proactive testing or comprehensive supply chain processes. The result was out-of-control system glitches, lost parts, and supply bottlenecks, and falling years behind schedule.
Underestimating risks can have drastic consequences.
Proactive Testing Adheres to Safety and Compliance
Safety is one of the most important reasons for performing parts and materials tests. These examinations prevent failures by demonstrating that the items can withstand the expected circumstances. Relatedly, if testing is an ongoing activity within a business’s quality control process, employees can do in-depth investigations to determine why some items fail those checks. Is it because a machine is out of alignment, the people on a specific shift do not have enough training or another factor?
Parties in tightly regulated industries may need to submit periodic testing to authorities to maintain compliance. Alternatively, auditors may request historical data if their visits reveal abnormalities.
Meeting Supply Chain Needs
Proactive parts testing is also valuable if manufacturers produce some components internally to make supply chain shortages less disruptive. Boeing uses that approach, reducing raw materials by 90% while lowering emissions by up to 70% compared to traditional processes. However, regardless of the production method, the brand must inspect all safety-critical parts. Since some of the highest-value parts consolidate 70 components, testers use nondestructive techniques to prevent costly waste.
Modern supply chains are diverse, expensive, and ever-changing. Parts testing ensures consistency despite many factors outside professionals’ direct control. Their proactive plans keep quality high and preserve customer trust.
Conclusion
The strength of proactive parts testing lies in its ability to prepare oneself and their business for any potential errors or challenges, long before they may actually occur. Reactive testing and maintenance attempts to salvage tricky situations after they have begun. By being proactive and prepared instead, supply chains can remain operational, efficient, and agile, even in the face of hardships.
About the author:
Lou Farrell
Lou is a Senior Editor at Revolutionized and has written about technological advancements and their impacts on the fields of Industry and Manufacturing for years. His greatest love in life is writing, and he enjoys sharing his knowledge with others.
