Abstract:
A quality assurance system is provided to collect and store data of quality characteristics of a painted surface. These characteristics may be the date and time of the data collection, ambient temperature, lowest substrate temperature, dew point, humidity, abrasive blasting, preservation, anti-fouling, conductivity, dry film thickness, wet film thickness, preservation minor deficiencies, and sound damping deficiencies. The system is provided with a computer having a user interface capability and read and write capabilities for the data. The system is also provided with a variety of clearance levels for the users of the system that pertain to the read and write capabilities. A method of quality assurance is also provided. The method involves providing a computer system with a user interface and collecting data of quality characteristics of a painted surface.

Description:
CROSS-REFERENCE TO RELATED DOCUMENTS 
       [0001]    This application claims priority to and benefit under 35 U.S.C. § 119(e) to U.S. Provisional App. No. 60/978,212, filed on Oct. 8, 2007, the entire contents of which are herein incorporated by reference. 
     
    
     TECHNICAL FIELD 
       [0002]    A surface treatment quality assurance tool and method. 
       BACKGROUND 
       [0003]    Ocean environments present unique and harsh conditions. Accordingly, ships that travel the oceans must be able to withstand these conditions. For instance, the building material of ocean-going vessels must be able to withstand humid, salty environments. To accomplish this, many rust prone portions of vessels are given a protective coating during the ship-building process and again at staged maintenance intervals. 
       SUMMARY 
       [0004]    A quality assurance system is provided to collect and store data of quality characteristics of a painted surface. These characteristics may be the date and time of the data collection, ambient temperature, lowest substrate temperature, dew point, humidity, abrasive blasting, preservation, anti-fouling, conductivity, dry film thickness, wet film thickness, preservation minor deficiencies, and sound damping deficiencies. The system is provided with a computer having a user interface capability and read and write capabilities for the data. The system is also provided with a variety of clearance levels for the users of the system that pertain to the read and write capabilities. A method of quality assurance is also provided. The method involves providing a computer system with a user interface and collecting data of quality characteristics of a painted surface. 
         [0005]    A particular embodiment of the present invention provides a method of quality assurance. The method has the steps of providing a data acquisition device; providing a data aggregator; providing a database server for a central database; and providing a report generator; synchronizing data from the data acquisition device to the data aggregator; aggregating data collected by said data acquisition device at said data aggregator; storing the aggregated data at the database server and central database; and generating a report at the report generator. The report generator and the database server are connected via a network connection. The data acquisition device is adapted to collect and store a plurality of quality characteristics of a painted surface. Also, the data acquisition device prompts a user for identification credentials. 
         [0006]    Another particular embodiment of the present invention provides a tool kit for quality assurance. The tool kit has a data acquisition device; a data aggregator; a database server for a central database; and a report generator. The data acquisition device is adapted to prompt a user for identification credentials. The data acquisition device and data aggregator are adapted to synchronize data between one another. The data aggregator is adapted to aggregate data collected by the data acquisition device. The database server and central database are adapted to store the aggregated data. The report generator is adapted to generate a report. The report generator and the database server are connected via a network connection. The data acquisition device is adapted to collect and store a plurality of quality characteristics of a painted surface. 
       BRIEF DESCRIPTION OF THE ILLUSTRATIONS 
       [0007]    Embodiments of the invention are illustrated in the following illustrations. 
         [0008]      FIG. 1  is a schematic diagram of a hardware architecture of an embodiment of a surface treatment quality assurance tool kit. 
         [0009]      FIG. 2  is a schematic diagram of software architecture of an embodiment of a surface treatment quality assurance tool kit. 
         [0010]      FIG. 3  is a schematic diagram of the data flow of an embodiment of a surface treatment quality assurance tool kit. 
         [0011]      FIG. 4  is a schematic diagram of the database functions. 
         [0012]      FIG. 5  is the diagram of  FIG. 4  with greater detail. 
         [0013]      FIG. 6  is a layout of software functions. 
         [0014]      FIG. 7  is a detailed schematic of the data acquisition device function and QA toolkit inspector client of  FIG. 6 . 
         [0015]      FIG. 8  is a detailed schematic of the web service of  FIG. 6 . 
         [0016]      FIG. 9  is a detailed schematic of the web application of  FIG. 6 . 
         [0017]      FIG. 10  is a detailed schematic of the web application of  FIG. 6 . 
         [0018]      FIG. 11  is a detailed schematic of the web application of  FIG. 6 . 
         [0019]      FIG. 12  is a detailed schematic of the web application of  FIG. 6 . 
         [0020]      FIG. 13  is an entity relationship diagram of a database of the present invention. 
     
    
     DETAILED DESCRIPTION  
       [0021]    Referring now to  FIG. 1 , an embodiment of a surface treatment quality assurance system  100  is provided. The tool kit hardware  100  may comprise a data acquisition device  200 , a data aggregation element  300 , a central database server  400  with a job order or task group instruction (“TGI”) data store  400   a,  a data reporting element  500 . 
         [0022]    Referring now to  FIGS. 2 and 3 , the tool kit software  1000  is provided with a data acquisition device program  2100  and a data acquisition device upload program  2200 , a data aggregator  3000 , a TGI database  4000 , a report TGI generator  5000  and a TGI report  6000 . The system may be Microsoft Windows based. 
         [0023]    The tool kit data flow  1000   a  may be provided as follows. Data  2000   a  from a data acquisition device  200  is transferred to and aggregated at the data aggregation work station  300 . This data  3000   a  is then transferred to the central TGI database  4000  where there is free communication between the central database  4000   a  and the TGI data store  4000   b.  This data  4000   a,    4000   b  is transferred to the data reporting step  5000   a  and on to the TGI Report  6000 . 
         [0024]    Referring back to  FIG. 1 , the data acquisition device  200  may be a laptop or tablet computer  202 , personal digital assistant (PDA) or pocket PCs  204 , or specialty measuring equipment  206 . Such a specialty measuring equipment may be a device such as the Elcometer  456  coating thickness gauge that is manufactured by Elcometer, Inc. of Rochester Hills, Mich. The data aggregation element  300  and the data reporting element  600  may be a computer work station, such as, for example, a desktop or laptop computer. Either of these elements  300 ,  500  may be any number of IBM or McIntosh compatible computer platforms. The central database  400  that stores the TGI data store  500  may be any of a number of database servers, such as, for example, a blade server. 
         [0025]    Connections between any of the aforementioned elements may comprise a wide area network, such as the internet, a local area network, any other computer network, a direct connection, or any combination thereof Such networks may be wired, wireless, or a combination of wired and wireless technology. The connections may also comprise encryption technology for secured communications. 
         [0026]    The surfaces being treated and subsequently measured may be in confined areas and possibly exposed to the elements. In addition because users of these devices may be hindered by safety equipment, the device  200  may be fumbled and subjected to drops on hard surfaces. Due to these harsh conditions, the data acquisition device  200  may be “ruggedized” to withstand such harsh conditions but should also be considered dispensable. 
         [0027]    The device  200  may further comprise a back lit display. Potential values of measurements may be synchronized with the database  400 . The user may be able to select these values from a drop-down type menu or push values up and down. The device may also incorporate large buttons to accommodate gloved hands. 
         [0028]    Before the data acquisition device  200  may be used, it may prompt the user for identification credentials. Users may uniquely identify themselves in order to successfully interface with each component of the software. This unique identification may be attached to each data record entered. Such identification may be a user&#39;s Department of Defense (DoD) issued Certified Access Card (CAC). Accordingly, security for this software may conform to the DoD Information Technology Security Certification and Accreditation Process (DITSCAP) standard. Thus, the DoD training CD for DITSCAP may be provided to all users of this system. Further, the identification may distinguish a user&#39;s access level. Such levels may be, for instance, technicians, supervisors, or other levels of management. These levels may further determine the functions that a user may perform. A similar login procedure may be instituted at any of the other hardware pieces. 
         [0029]    If the data acquisition device  200  is a computer  202  or PDA  204 , then data entry may be performed with a stylus and may further be performed via calculator-pad-style selection keys, pick lists, option buttons, and similar structures that display potential values to the user. Potential values may be loaded from a database. If the data acquisition device  200  is a specialty measuring equipment  206 , the device buttons and sensor are the data entry tools. The data acquisition device  200  may preserve the data until it is successfully synchronized with a secure database. The desktop/desktop application  300  retains the information for the database. An acquisition application interfaces with the handheld instruments  200 . The user may use a computer  202 , a PDA  204 , a specialty measuring device  206 , or any combination thereof 
         [0030]    The data acquisition equipment may do any one or more of the following.
       Present and record values of the correct type for each datum   Allow for correction of erroneous values   Flag out-of-range values using business rules that describe the acceptable values for each datum   Flag transferred data   Allow for deletion of transferred data   Run on a Pocket PC, Tablet PC, or Palm device   Provide for survival of the data and application state in the event of the following error conditions:
           Untimely ejection of the memory card   Battery failure on the acquisition device (especially during synchronization)   Power failure on the part of the synchronization partner   Failure of serial communications lines   Operating system failure on the acquisition device   Operating system failure on the synchronization partner   Operator error such as:
               Assigning incorrect identifying values to the data set (ship, TOI number, etc.)   Synchronizing the wrong data set   Accidentally unplugging a communications cable   Terminating the application using the stylus at an inopportune time   Failing to activate the synchronization manager before attempting synchronization   Canceling the synchronization process   Providing incorrect OS or application settings to either synchronization partner   Log user actions so that data may be reconstructed, as necessary   
               
               
 
         [0053]    As discussed, multiple types of data acquisition devices  200  may be used. These devices  202 ,  204 ,  206  may synchronize data to a central database  400  in a variety of ways. Some devices may manage synchronization through embedded firmware. For these devices, data will be acquired through at least two separate data streams. These streams need to be combined and the data aggregated during synchronization. The data acquisition devices  200  may synchronize through a variety of hardware conduits. Such hardware conduits may comprise, for example, serial connections, such as a multi-pin serial connection, USB connection, IEEE 1394 interface, or a combination thereof. Such connections may incorporate standard or proprietary connectors, or both. Further, synchronization may occur through an infrared serial port or parallel port. Synchronization may be initiated by either synchronization partner. Synchronization may also be capable of cancellation from either synchronization partner. The synchronization conduit may:
       Transfer data via serial communications   Guarantee the integrity of the data both during and after transfer   Mark transferred data as transferred at the data acquisition device  200     Make the data available to a data aggregation manager at the synchronization partner   Preserve the state of both the application and the data during errors like the following:
           Untimely ejection of the memory card   Battery failure on the acquisition device (especially during synchronization)   Power failure of the synchronization partner   Failure of serial communications lines   Operating system failure on the acquisition device   Operating system failure on the synchronization partner
               Preserve both the state of the application and the data if the user cancels synchronization   Run on a Pocket PC, Tablet PC, Palm device, or client computer   Log activity at both partners so that data may be reconstructed, as necessary   
               
               
 
         [0068]    Because data may arrive from multiple serial streams, an aggregation element  300  may reconcile the streams and insert the data into a database. The character of the streams is markedly different. Data arriving from a PDA or Tablet or Pocket PC  200  may be under programmatic control and may be properly formatted for insertion into the database when it arrives. Data  200   a  arriving from an instrument may arrive from proprietary, embedded software  2100   2200 , and the aggregation element  300  may parse the data stream and correctly format the data for insertion into the database. 
         [0069]    There are four realistic aggregation scenarios: 1) Instruments and PDAs synchronize with a desktop PC that manages aggregation; 2) Instruments synchronize to a PDA, which then synchronizes with a desktop PC that manages aggregation; 3) Instruments and PDAs synchronize to a tablet PC that joins the network and manages aggregation; 4) Instruments, PDAs, and Tablet PCs synchronize to a desktop PC that manages aggregation. The aggregation manager may run on Pocket PCs, PDA devices, Tablet PCs, and desktop or laptop client computers. It may:
       Receive the data from the serial data streams   Mark unidentified data with the correct ship, inspection, TGI number, and other identifiers   Insert the data into the database (or store data in a temporary format)   Protect the state of the application and the data in the event of:
           Failure of synchronization because of:
               User cancellation   Failure of serial communications related to:
                   Untimely ejection of a memory card   Untimely unplugging of a cable   Failure of either of the synchronization partners&#39; OS   
                   
               Failure of the database connection   Loss of network communications   Traffic load on the network   Database connection overload   Database request overload   
           Log all data transactions so that they might be repeated manually, if necessary       
 
         [0086]    The database  4000  may be stored under an Oracle or SQL Server. Standard tools provided by these vendors may manage the databases. All data manipulation may take place through explicitly defined transactions in stored procedures. Procedures may provide return codes that define the success or failure of the intended action. Procedures may have names descriptive of the action performed. If procedures are tied to a particular form or web page, an abbreviation of that form or page name may appear as a part of the procedure name. 
         [0087]    The database  1100  may be structured according to the Entity-Relationship diagram of  FIG. 13 . A web-based user interface may be provided to:
       Allow managers to modify incorrect data   Allow managers to identify, update, and delete coherent sets of data   Allow managers to update lists of standard items       
 
         [0091]    Ideally, the database will reside on a central server. However, the data may also be maintained as a copy in a database located on the data-recording-side of the web-based database. Synchronization of data to the central web-based database may be performed at specified intervals. Acceptable delay increments may be pre-selected. All database connections may be managed by ADO.Net objects. 
         [0092]    A central report manager running on a web server may provide reports to interested parties. Reports may be written in and managed by Crystal Reports. Data for reports may be structured and formatted by a stored procedure. The Crystal Reports template may format and display the data. Preferably, reports may run from a central web server. However, reports may also need to run from a local database at the clients&#39; site. Various reports may be provided, such as a Task Group Instruction (TGI) or a Naval Sea Systems Command (NAVSEA) Standard Item Requirements. 
         [0093]    The contents of the TGI report are determined by the type of structure being treated for preservation at sea. Such structures may include Ballast tanks, Torpedo Ejection Pump/Torpedo Tube Recess, Aft Free Flood tanks (Mud Tanks), Retractable Bow Plane Recess, bilge sumps, bilge collection tanks, waste oil collection tanks, sanitary tanks, Bow tanks, Trim tanks, Water Round Torpedo tanks, auxiliary tanks, Impulse tanks, sea water expansion tanks, Vertical Launch System bath tub recess, Fairwater interior, Potable water tanks, and Reserve Feed Tanks. 
         [0094]    NAVSEA standards provide instruction for assessing the cleaning, surface preparation, and painting processes. NAVSEA Standards are updated on by the Navy on an annual basis. Therefore, the software may preferably have version tracking capabilities. This will assure that the proper requirements are used for new measurements. 
         [0095]    The types of forms required by 009-32 prescribed work are listed below. 
         [0096]    a. Environmental Readings 
         [0097]    b. Surface Soluble Salt Conductivity Log 
         [0098]    c. Surface Profile Log 
         [0099]    d. Dry Film Thickness Measurements 
         [0100]    e. Checkpoints and Milestones Completion Log. 
         [0101]    f. Certified Coating Inspector&#39;s Checkpoint Sign-Off Log 
         [0102]    g. Paint Application Equipment and Paint Consumption Log 
         [0103]    h. Wet Film Thickness Measurements 
         [0104]    I. Test for Assessment of Surface Cleanliness—Pressure-Sensitive-Tape Method 
         [0105]    j. Test for Assessment of Surface Cleanliness 
         [0106]    Accordingly, the tool kit  100  may measure these conditions. 
         [0107]    The tool kit  100  may track ambient and metal surface temperatures, relative humidity, and dew point at pre-determined intervals during the preservation process. These may be recorded from conditions onsite, in close proximity to the structure being coated. Coatings can only be applied when the temperature of the prepared substrate is within a certain range, such as greater than 50° F. and a minimum of 5° F. above the dew point (x&lt;dew point+5&lt;50). 
         [0108]    Prior to coating or other treatment, a surface must be properly prepared. Such preparation may include blasting or water jetting operations. After such operations, surface peak-to-valley profile may be checked. Five profile readings may be taken for the first 1,000 ft 2 , and 2 profile readings taken for each additional 1,000 ft 2 . Each group of profile readings must average 0.002 to 0.004 inches, with no reading less than 0.001 inches or more than 0.005 inches. The automation of this module should include a user prompt, “Estimate area (ft 2 ) Involved.” An algorithm may also compute the number of readings required based on the requirements stated above. 
         [0109]    Readings may be associated with several external factors, such as, for example, Paint information, Temperature, Manufacturer, Formula, and Type, Batch No., and Receipt Inspection Record Number, and may be input through the use of pull-down menus. 
         [0110]    Using the Bresle Method or an approved equivalent, 5 measurements may be made for every 1,000 ft 2 . Therefore, information derived from “Estimate Area (ft 2 ) Involved,” required for Surface Profile readings must be applied here, as well. Areas less than 1,000 ft 2  will have 5 measurements taken. Conductivity measurements must not exceed 30 microsiemens/cm 2  for critical-coated areas, or 50 microsiemens/cm 2  for non-critical coated areas. 
         [0111]    Using specialized measuring equipment, such as Elcometer&#39;s 456 Dry Film Thickness (DFT) Gauge, the DFT of each coat applied may be measured. Each coat and type of material used will have a specified minimum and maximum DFT values. 
         [0112]    Wet Film Thickness (WFT) readings may be obtained in lieu of DFT readings for any coat that must be in a tacky state when the next coat is applied. 
         [0113]    This module may be used for any deficiencies that do not require Engineering Department resolution. However, any and all deficiencies that are found must be cleared before proceeding to the next coat; any item entered in this area also requires reinspection by a QA inspector. 
         [0114]    Preservation Minor Deficiencies houses the required information. “Deficiency Found Sign and Date” requires the date stamp generated by the user&#39;s CAC-card insertion and digital signature. The “Location and Description of Deficiency” field, initially, will require a description field where the user may type in the applicable information. Once the system is in place at any given location, however, the “location” field can be customized to better meet the users&#39; needs with an acceptable pull-down menu. The “description” portion of this particular column can be filled with a pull-down menu which lists the most common deficiencies and a continued descriptive (typing) field for deficiencies not yet included in the pull down. 
         [0115]    A Sound Damping Deficiencies module may be used to record any deficiencies noted in the sound damping/acoustic tile inspection required after sand blasting operations. 
         [0116]    At various times throughout the preservation process, checkpoints fail, rework is accomplished and a new inspection may be accomplished. All previous inspection results for the failed inspection must remain in the system and the new results posted. A re-inspect module may be used to track these inspections. 
         [0117]    Deficiencies noted during inspections may be handled in many different ways depending on the activity and the type of deficiency (whether it is minor or major). There are many effective deficiency tracking systems in use and this system may support interface with those systems and also provide a stand alone capability. (i.e., if the activity has a functioning electronic deficiency tracking system this system should be able to capture the deficiency and note it has been entered in and is being tracked on the in house system. In addition, this system may be capable of providing the deficiency information to decision makers via an alternate path if desired by the end user. If no electronic system exists, this system may provide that capability. 
         [0118]    Readings taken during preservation in-process inspections are required to fall within certain limits. These limits are established by NAVSEA, SSPC, NACE and paint manufacturers for their products. The data includes coating thickness, environmental conditions, surface roughness measurements, soluble salts readings, etc. out-of-tolerance conditions recorded need to be annotated in some fashion (i.e., color-coded red is one possibility) to notify supervisors of the condition. The initial reading must be tracked and retained as part of the permanent record even after the condition has been adequately adjudicated (i.e., color change to yellow). Requirements vary by product, manufacturer, end use, etc. These requirements change as products change, and test results indicate new limits are warranted. 
         [0119]    A variety of management reports may be required by both in-house and external organizations. These reports may need to be automatically generated under certain pre-specified conditions and time intervals. Additional reports may be generated as called for by authorized users. Various metrics may be required and data trend analysis conducted. 
         [0120]    Navy and private facilities doing preservation work are located all over the world. The majority of the data transfer and reporting services for this project will be conducted via the internets. The latest inspection data needs to be available 24 hours a day, 7 days a week to inspectors doing in-process inspections. Reports may be generated and posted as rapidly as the incoming data will allow. For instance, managers in Hawaii may need access to work conducted over the weekend on their ships in West Coast shipyards. The preservation process data is both business sensitive and Navy sensitive. The web services must be secure and password protected, allowing only specified end users access. The data and reports must also be segregated to allow specific users access only to the various data sets under their purview. 
         [0121]    The tool kit  100  database function architecture is shown in  FIG. 4 . The architecture comprises the quality assurance (QA) central tool kit database  4000 . The functions preferably required of the architecture include managing QA data  4100 , generating standard reports  4200 , answering ad hoc query and report requests  4300 , generating and displaying job status and trending charts  4400 , and supporting system administration  4500 .  FIG. 5  shows each function in more detail. 
         [0122]    Referring now to  FIGS. 6-12 , a flowchart example of the tool kit functions will now be discussed. Data acquisition device function scenario  11000 , QA toolkit inspector client scenario  12000 , a web service scenario  13000 , a ship setup scenario, a creation of new user scenario  15000 , a adjudication procedure scenario  1600 , and a creation of documentation scenario  17000  are provided. 
         [0123]    Referring to  FIG. 7 , various measurement collection functions  11002 - 11012  of the data acquisition device are laid out. These measurements are collected by a user of the system. These measurements are aggregated by the QA toolkit inspector client  12000  at the aggregation work station. The user logs into the workstation to upload the data from the data acquisition tool. If the user is not in the system, then they will need to be added to the system.  FIG. 10  provides a scenario for creating a new user. These measurements are then associated with the appropriate job order and uploaded to the database. The process is repeated for multiple measurements. Once this process is completed, appropriate documentation may be created. 
         [0124]    Referring now to  FIG. 8 , a web service scenario  13000  is provided. As information is uploaded to the database, the measurements are compared to the various acceptable data values  13006 . It is then determined whether or not the measurements are within spec. If they are within spec, the data is uploaded to the database. If the measurements are out of spec, then an adjudication process is initiated (see  FIG. 11 ). 
         [0125]    Referring now to  FIG. 9 , a TGI creation and ship setup scenario  14002 - 14038  is provided. When a ship building process is initiated, appropriate information about it needs to be entered into the QA tool kit. If the ship is in the system, then a TGI (job order) may be created. The TGI is created by selecting the appropriate ship, the surface(s) to be treated and the appropriate coating materials. If the ship is not in the system, then the ship, compartment and coating may need to be entered in the system before selection. 
         [0126]    Referring now to  FIG. 11 , an adjudication scenario is provided. If a measure is determined to be out of spec in step  13014 , then an adjudication process is initiated. A contractor is notified of the defect and initiations a plan to correct the defect, a higher authority is notified of this plan and negotiations may be needed to come to an acceptable plan. Once this is reached, the defect may be corrected. 
         [0127]    Referring now to  FIG. 12 , a documentation scenario is provided. A request for documentation is provided from step  12034 . whether or not the measurements are in or out of spec, an appropriate report may be generated.