The Business Case for Involving Your NDT Level III Early

Too often, Non-Destructive Testing (NDT) is treated as a final quality check performed just before a component ships. This reactive approach is a costly mistake. When a flaw is found at the end of the production cycle, the only options are expensive rework or scrap. For project managers and engineering leaders, understanding the business case for Level III involvement early is critical to moving from a reactive to a proactive quality control model. This guide explains how early NDT consultation saves money, reduces risk, and improves project outcomes by leveraging your top technical experts from the start.

What “Early Involvement” Means in Real NDT Terms

Early involvement means treating your NDT Level III as a planning consultant, not just a final inspector. It is the practice of bringing them into the conversation at the design, procurement, and fabrication planning stages of a project.

Instead of asking, “Can you inspect this finished part?” the question becomes, “How should we design and build this part so it can be inspected effectively and affordably?”

This proactive approach shifts the Level III’s focus to:

• Method Selection: Advising engineers on the best NDT method (UT, RT, PAUT, etc.) based on the material, geometry, and types of flaws being sought.
• Design for Inspectability: Reviewing part designs to ensure there is physical access for probes and equipment, preventing costly redesigns later.
• Procedure Development: Writing and qualifying the NDT procedures before production begins, ensuring a clear and compliant inspection plan is in place.
• Supplier Qualification: Reviewing supplier NDT programs to ensure they meet project requirements before contracts are signed.

The Proactive vs. Reactive NDT Model

The financial difference between these two approaches is stark. A reactive model catches errors after they have already cost time and money. A proactive model prevents them from happening in the first place.

How to Integrate a Level III into Your Project Workflow

Integrating your Level III early does not require a complex new process. It simply means including them in key conversations that are already happening.

1. The Design Review: Have the Level III review initial drawings and 3D models. Can the part be inspected as designed? Is a specific weld joint accessible? A few hours of their time here can save weeks of redesign later.
2. The Materials Selection Stage: The Level III can advise on how different material choices (e.g., specific alloys, composites) will impact NDT method effectiveness and cost.
3. The Fabrication Plan Review: Before the first weld is made, the Level III should review the fabrication sequence. They can identify hold points where an inspection should be performed before further value is added to the component. Inspecting a sub-assembly is almost always cheaper than inspecting a complex final product.
4. Before Finalizing Contracts: The Level III should approve the NDT sections of supplier and client contracts to ensure all requirements are clear, achievable, and compliant with the necessary codes.

Risks, Compliance, and the Cost of Getting It Wrong

The financial risk of late-stage NDT involvement is immense. According to quality management experts, the “cost of poor quality” can represent 15-20% of a company’s sales revenue.

• Compliance: An NDT Level III is your designated expert on codes and standards like SNT-TC-1A and the more stringent NAS-410 used in aerospace. Involving them early ensures that the entire inspection plan is compliant from day one, preventing a failed audit that could halt a multi-million dollar project.
• The Cost of Rework: Finding a flaw in a single weld is a minor repair. Finding that same flaw after the component has been heat-treated, machined, and assembled can mean scrapping the entire part. The cost multiplies at every stage of production.
• Incorrect Method Selection: Choosing the wrong NDT method can lead to either false calls (rejecting good parts) or, far worse, missed defects. A Level III’s expertise in selecting the right method for the application is your primary defense against catastrophic failure.

The Financial Realities: Consulting vs. Catastrophe

The cost of a Level III’s time for early consultation is minimal compared to the cost of rework or scrap. An in-house or contract Level III may bill at a rate of $150−$250 per hour.

Consider this scenario:

• Proactive Cost: 4 hours of Level III consultation during design = ~$800
• Reactive Cost: One complex, multi-thousand dollar component is scrapped due to an uninspectable design flaw found after fabrication = $50,000+ loss, plus schedule delays.

The return on investment for early consultation is exceptionally high.

Next Steps: Make the Strategic Shift

The business case for Level III involvement early is clear. It is a strategic decision that shifts NDT from a cost center to a value-adding function that actively reduces financial risk and improves project predictability. Review your current project workflow and identify the key stages where your Level III’s expertise can be leveraged before production begins.

If your team lacks the in-house Level III expertise to implement this proactive model, you have a critical capability gap. We can help you post a role for a Level III to build your team or request help on a tough search to find an expert with the specific industry background you need.