Learning path

Inspector onboarding: caliper to decision rules

A route for newly hired inspectors: the caliper, micrometer and dial indicator first, then tolerances and how a part is judged, part inspection practice, and finally decision rules and gauge R&R so verdicts hold up.

1. Caliper fundamentals

   Start with the caliper you will use every day: outside, inside, depth and step measurements, the vernier, dial and digital readouts, and the mistakes that ruin readings.

   The whole course

   1. Caliper basics
   2. Reading a vernier caliper
   3. Reading a dial caliper
   4. Using a digital caliper
   5. Measuring common parts
   6. Avoiding common mistakes
   7. Pass or fail against a tolerance
   8. Planning how to measure a part

2. Micrometers

   Then the micrometer for finer outside dimensions: reading to 0.01 mm, the force ratchet and the zero check.

   The whole course

   1. The screw and the reading
   2. Checking and setting zero
   3. The ratchet and measuring posture
   4. Depth, inside and bore micrometers
   5. Common micrometer mistakes

3. Dial indicators and comparative measurement

   Add the dial indicator and gauge blocks for comparative measurement when reading a size directly is not accurate enough.

   The whole course

   1. Dial indicators
   2. Lever indicators and cosine error Coming soon
   3. Gauge blocks Coming soon
   4. Comparative measurement
   5. Bore gauges Coming soon
   6. Radial and axial runout Coming soon

4. Tolerances, limit gauges and pass or fail

   Tolerances and fits: what the limits on a drawing mean and how a part is judged against them.

   The whole course

   1. Limits and fits
   2. IT grades and fundamental deviations Coming soon
   3. General tolerances Coming soon
   4. Acceptance limits and safety margins Coming soon
   5. Go and no-go limit gauges Coming soon
   6. Choosing an instrument for the tolerance

5. Part inspection in practice

   Put it together on real parts: plan the measurement, measure feature by feature, record the results.

   The whole course

   1. Finding the characteristics on a drawing
   2. Planning the measurements
   3. Shafts, bushings and flanges
   4. Prismatic parts Coming soon
   5. First article inspection
   6. Inspection records and reports

6. Measurement data, uncertainty and decisions

   Finish with decision rules — acceptance limits and guard bands — and gauge R&R, so your pass/fail calls and your gauge can be trusted.

   Selected lessons

   1. Decision rules and guard bands
   2. Gauge R&R Coming soon