Materials testing - the case for outsourcing

This article looks at the commercial materials testing industry and the pros and cons of in-house and outsourced test services with special emphasis on outsourcing analytical services to India.

Much of the focus and controversy in the engineering and related industries in recent months, and in fact years, has been on outsourcing services to India.

The implications of it, the negative aspects of it, and when it will be implemented all seem to depend on which person you talk to on which day.

The whole issue is seemingly in a constant state of change.

But regardless of which statutory changes, amendments, and revisions are finally adopted, and no matter which special interest group is most influential in getting their version of the way things should be written into the law, there is one thing that will remain true: material quality is a necessity.

Enterprises who wish to compete and win business in today's competitive world economy must provide products that perform as specified.

And quality products depend on quality materials.

In petrochemical, aerospace, nuclear, defence, and commercial applications, America and the world cannot afford the implications of inferior materials and subsequently inferior end engineering goods or products.

As enterprises increase importing material goods from countries like India and China, the need for quality materials testing becomes an absolute necessity.

From this perspective, this article presents an overview of the commercial materials testing industry and discusses the pros and cons of in-house and outsourced testing services with special emphasis to outsourcing analytical services to India.

The ethical and practical reasons for making sure that materials, products, and services are what they are supposed to be is the heart of the commercial testing industry.

Today there are around 100 labs in India.

There is variety not only in types of testing performed but also in the size and structure of individual testing labs which range from the "one-man show", usually an engineer or scientist, to a multilocation, multidiscipline lab with both vertical and horizontal integration.

In India, the National Accreditation Board for Testing and Calibration Laboratories (NABL), an autonomous body under the aegis of Department of Science and Technology, Government of India provides government, industry associations and industry in general with a scheme for third-party assessment of the quality and technical competence of testing and calibration laboratories.

In order to achieve this objective, NABL provides laboratory accreditation services to laboratories that are performing tests/calibrations in accordance with ISO/IEC17025.

Whatever the size or configuration of a test lab, and no matter which technologies and methods it uses, it performs a valuable role in assuring the quality and reliability of a multitude of products.

This need for product testing is met both by in-house laboratories and outsource or independent labs.

In-house labs in the USA offer the company direct involvement with the testing methods and procedures.

A company using an in-house testing procedure is not dependent on outside sources for meeting its required turnaround deadlines.

Also, knowledge of the product and the required testing procedures already exists within the company.

The outsourced or independent lab overseas in India is theoretically free from influence and is able to provide unbiased results.

The objectivity of independent laboratory testing procedures is monitored by and subject to a variety of outside audits and evaluations as per ISO17025 established standards.

As labs are businesses, the profit motive dictates that independent labs remain competitive with an emphasis on innovation and efficiency.

Technologies are constantly changing and independent labs are generally better able to keep up with the latest technological advances.

In their third-party position, these labs can also add product credibility via their independent test results.

In some cases, using the services of an independent lab can be highly cost-effective.

It can save a company the expense of capital investment in testing equipment and the payroll and benefits expenses of hiring testing department personnel.

An important factor in deciding to test in-house in the USA or use an outsource testing lab in India is the cost of a given test or inspection from an independent lab and the frequency of the test versus the cost of investing in testing equipment and paying labour costs.

A single micro-hardness test for example would cost $50.00 in America, whereas the same test costs less than $8.00 in India performed on identical machines and with the lab adhering to ISO17025 guidelines.

Many US enterprises are taking advantage of the low-cost, high quality material testing services in India.

TCR Engineering Services (TCR), founded in 1973, is India's most reputed and best established materials testing laboratory.

TCR, located in Mumbai, India, undertakes testing as per international standards and specifications as defined by ASTM, NACE, BS, JS, GR, IS and others.

Testing at TCR is also done to client-supplied specifications.

TCR provides material testing services to more than 1500 companies in India and global enterprises such as Tyco Sanmar, Fisher Xomox, Unilever, Fisher Rosemount India, Bechtel International, Toyo Engineering, Tecknip Italy, SGS, Kirby Building Construction Co, Mistsubishi, Samsung and Hyundai.

Today, many global enterprises source engineering goods from India including castings and forgings, sheet metal, bars, pipes, cast iron, stainless steel sheets, nuts, bolts, engineering goods, ferrous and nonferrous metals, nonmetallic materials (such as polymers, ceramics, glass), machined parts and tool components.

Virendra Bafna, Managing Director of TCR says: "TCR's laboratory, with proximity to a suppliers/manufacturer's location in India or China coupled with our state-of-the art testing facilities and inspection services allows global enterprises to be assured of the quality of materials".

There are many things to consider when choosing an independent laboratory.

The lab's experience in business is a prime consideration.

Look at how things are run and the kind of service the lab provides.

How much experience does it have in the specific kinds of testing you require.

Does it have the right kind of equipment to efficiently perform the tests you need.

Logistics and the mechanics of delivery must be taken into account.

Is the estimated turnaround time acceptable.

Is rush service available.

Does the lab provide pickup and delivery for your supplier/manufacturer.

Does the laboratory have online access to deliver results.

Look at the depth of the lab's staff and equipment.

Is there backup equipment available.

What kind of reputation and accreditation does the lab have.

The core services TCR provides include mechanical testing, chemical analysis, positive material identification (PMI), nondestructive testing, metallography, corrosion testing, failure analysis, raw material inspection, metallurgical product evaluation, engineering research and consultancy.

TCR has pioneered in introducing latest analytical facilities and has upgraded the same every decade.

TCR has facilities for testing of engineering goods, ferrous and nonferrous metals, nonmetallic materials such as polymers, ceramics, glass and similar materials.

Engineers, chemists, metallurgists and technicians at TCR have the qualifications, the education and the experience to meet rigorous standards in the testing field, whether serving the private and public sector, government or the military.

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