​Author: Tom Martin – JetSoft CEO

Recently I had the task of sourcing some information for a proposal we are working on.

Due to the varied deployments, we have now delivered, doing this mostly consists of searching the back catalogue of closely related jobs we’ve done and pulling material from them.

During this search I found, at the proverbial back of the drawer, a proposal that detailed a roadmap to full automated inspection. This proposal was for a large international aerospace defence company and designs a four-phase approach to achieving a ‘lights out’ (their term) inspection process. I’d largely forgotten this ‘whitepaper’ but rereading I was reminded how good it was, and felt it was too good to sit in the drawer. So, I thought I’d redact the sensitive information and share it.

The full paper can be download from the link at the bottom of this article.
 
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The Four-Phase Roadmap
The roadmap is divided into four distinct, yet interlinked phases, each designed to bring incremental improvements while driving the overall goal of “lights-out” inspection. Each phase adds value and contributes to the larger vision of automation.

In general, these four phases are designed to:

• Improve “right first time” and reduce waste through understanding the causes of defects and driving process changes
• Aid faster iterative continuous improvement
• Reduce variable manufacturing costs and increase yield by making intelligent decisions on the direction of components following each manufacturing process via virtual assessment
• Expose data in a form that can be used as part of a digital twin
• Introduce automation in a controlled and measured way to the testing department, reducing the human requirement for inspection, and delivering a faster more consistent evaluation

 
The whitepaper certainly champions our solutions, but looking past that, I think the roadmap itself presents a realistic and valuable approach to achieving fully automated inspection.
 
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Key Takeaways
Two critical points emphasized in the whitepaper, which are often overlooked in industry discussions, are:

• The separation of indication detection and part sentencing. In the paper defining these separate process as Automatic Indication Detection (AID) and Automatic Part Sentencing (APS) respectively. The distinction between, finding something, and evaluating it is a difference that I think is often overlooked when automatic defect detection (and its many names and guises) is discussed.  
• The importance of supplementary data when evaluating. For an automatic system to be as good as inspector, it must have all the information that a human uses to make an evaluation. Under the manufacturing framework that the paper is written, this is the manufacturing process data.

 
I encourage you to take a closer look at the whitepaper and let me know your thoughts.
 

Progress on the Roadmap
While the company this proposal was written for didn’t end up taking us up on the proposal, we have forged ahead with other customers on this roadmap (somewhat inadvertently). Including very recently completing the first installation of our virtual machine engine, therefore completing the 3rd phase of this plan. 
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OverSeer in Action 
We are working on one of our most exciting projects to date, this project for a major UK aerospace company, pushing our OverSeer solution further than ever before.
 
This high-value aerospace manufacturer operates many inspection processes at various stages of manufacture. Their inspection processes were disparate, didn’t scale, lacked connectivity, had poor archiving functionality, and didn’t integrate with their wider systems. This global FTSE100 manufacturer identified that this was becoming unsustainable and was placing a large maintenance overhead on the team. Whilst their existing analysis programs used Excel and Visual Basic, this limited the opportunity for large-scale, real-time, cross-technique data analysis. Following in-depth meetings and discussions with the client to discover exactly what they required, we came to the conclusion that OverSeer and our other associated modules directly solved their problems. 
 

Overcoming Manufacturing Challenges 
From the outset, this project introduced some distinct challenges for us, as we were required to retrofit our solutions into existing processes and data outputs. While our systems are designed to be extensible, the quantity and age of some of the data proved to be a large body of work. For example, some of their data had artificial historical dates used to combat the Y2K incompatibility.
 
We translated existing VB code and Excel tools into our framework, enabling automatic analysis across a greater data volume and multiple datasets, with stakeholders notified in real-time of results.
 
Additionally, OverSeer integrates with the customer's active directory to enable a more streamlined and centrally controlled experience, for a more efficient production line.
 

A Bespoke Solution 
Using our OverSeer solution, we designed a tailored system that delivers maximum benefit, by merging data from ultrasound, digital x-ray and visuals, from formats including TIF, DICONDE, CSV, C-Scan, UT Thickness and JPEG2000, combining this alongside their other manufacturing data. In addition to using OverSeer’s UI tools, we also incorporated several existing analysis programs for inline, in-depth, real-time analysis across inspection datasets. By reading all their data formats and aggregating this into a single solution, we are able to build this into their existing analysis tools. The solution offers many additional advantages to the client, including web-based access, alerts, cross technique data analysis.
 
Whilst this project is still ongoing for one the largest companies in the UK, the client is extremely happy with the results, being able to regain full control of their NDT data. 
 
If you are looking to produce an efficient production line with tailored technological solutions, get in touch to find out how we can help you.

​Can you give us a full run through on exactly what changes have been made to the NADCAP regulations?
 
A significant change has been added to the NADCAP checklist that requires certain NADCAP approved companies which perform inspection processes to gather statistics on inspector pass rates.
 
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Why are these regulation changes so important within the industry?
Actually, these new regulations are quite controversial. And I’m not sure I entirely agree with them. They’re there to detect anomalies in testing results generated by human factors. Unfortunately, often other factors will mask these, especially in low production environments. A change in upstream manufacturing processes can have a huge effect on quality and defect rates, we see this everyday at JetSoft. In this case the change in defect rate, which is nothing to do the inspector, will skew the results of this assessment. Even worse, should the inspectors have knowledge of these rates it could add another bias into the inspection process. However, human factors are a cause for concern, and it’s right that methods should be put in place to prevent them from influencing defect detection.
 

How are these changes likely to affect manufacturers?
It adds another requirement to inspection department managers, which most aren’t currently equipped to deal with. Cue hastily designed spreadsheets and yet another overhead requirement. And remember you can’t ask operators to complete this as they should be concealed from the results, to prevent bias, so the responsibility completely falls on the inspection department manager.
 

What can be done to lessen the impact on manufacturers?
Get Inspection Results Monitor! If you’re reading this and have gotten this far, download it and give it a go. If you don’t like it or you find that it doesn’t meet your needs, get in contact with us and we can see how we can adapt the software to meet your specific needs.
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Why did you choose to develop IRM?
JetSoft is all about creating software solutions to help with the management and utilisation of inspection data. This is what we do, therefore, we felt we were in an ideal place to develop a solution to help companies meet this newly revised NADCAP AC7114 Rev R regulation. And I must say we are very proud of the result; Inspection Results Monitor is a lightweight application that is designed to meet these new regulations as easily and simply as possible.
 

Any other thoughts on this area?
Interestingly these requirements are not applied to automated indication evaluation. There is potential, especially if the requirements get more onerous, that this could this be a driver for automated analysis. However, I suspect this won’t be the case unless the requirements drastically increase.
 
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If you are looking for a digitised solution to meet and adhere to the NADCAP regulations and requirements, look no further. Get in touch with a member of our team to find out how Inspection Results Monitor can benefit you.
 

Inspection is a multistep process. Luckily at JetSoft, we have developed a solution that can help you take back control of your entire operations.
 
Operating an effective NDT company or department get more and more demanding. Investing in next-generation technological solutions is paramount, to meeting these growing requirements head on. Software systems are crucial to meeting growing consumer demand and fulfilling market regulations.
 
 
A Full Inspection Management System  
Over the past several years at JetSoft, we’ve had several enquiries asking us to supply a solution that manages the full inspection process lifecycle – from receiving parts at the factory door to shipping them back to their clients. Whilst our DigiOps solution satisfies part of that demand, we felt we could drive it further.
 
Introducing WorkStream. WorkStream manages the full inspection process from booking jobs, contract reviews, managing inspection results and shipping. Having a single system, removes duplication of processes, increases traceability, aids in the management of work and maximises asset utilisation.
 

WorkStream 
The WorkStream system provides a flexible solution for managing and tracking inspection workflows. The multi-site implementation enables the standardisation of data across sites whilst allowing the necessary process differences between sites and methods.
 
Key features for WorkStream include:

Nadcap (National Aerospace and Defense Contractors Accreditation Program) the worldwide industry-managed accreditation, brings together highly qualified technical experts from both the government and industry to conduct audits using criteria that are specific to a process.
 
Under revised Nadcap regulations, companies must monitor defect rates across operators, part types, and inspection methods. That’s where JetSoft comes in, with our Inspection Results Monitor solution!
 
 
Nadcap Regulation
Nadcap is based on specific processes used by suppliers, with the goal to establish accreditation requirements, issue accreditation to suppliers and define operational program requirements.
 
Before Nadcap, aerospace companies audited their own suppliers using their own process requirements to verify compliance. This created duplicated audits that were proved redundant and created increased workloads with no added value.
 
 
Regulating Non-Destructive Testing 
New requirements mandate that companies must collect inspection results, alongside the inspector who performed the evaluation and part types. This process creates a baseline of quality that can be defined and compared to identify outliers.
 
Paperwork can quickly add up for those Nadcap-approved companies who haven’t moved away from a paper-based logbook to record their audit results. Using inspection-based technology allows manufacturers and test houses to trace and highlight the root cause of failed components, whether that’s through machinery or specific materials to mitigate failure risks associated with a flawed process.

What is AC7114 Rev R? 
AC7114 is an audit criterion used to assess companies that are performing non-destructive testing. Rev R is the revision issue within Nadcap. A huge number of companies must adhere to AC7114, and the new requirement it entails. Revised requirements lead to a huge impact on those companies that don’t have the digital systems in place to record the necessary data and have it readily available for analysis. In essence that creates extra paperwork for the non-destructive testing department.

 
Inspection Results Monitor 
JetSoft’s software is built explicitly for monitoring defect rates across a plethora of manufacturing streams so that aerospace companies meet the new requirements under the Nadcap regulations. Inspection Results Monitor has been designed specifically to aid in the collection and analysis of inspection results to help you meet these new requirements under the AC7114 Rev R section 10 regulation. As Nadcap updates its requirements, Inspection Results Monitor is constantly evolving and adapting.
 
Inspection Results Monitor includes three core areas to support non-destructive test houses and manufacturers in adhering to the new regulations:
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1. Digital Logbook 
Inspection results are recorded, amongst notes and serial numbers within a logbook. Many companies still use a paper-based logbook which isn’t sustainable, highly time-consuming, and prone to human error. Inspection Results Monitor works across inspection methods to digitise logbooks into one place. This enables quick and simple input of inspection data and effortless filters to easily find, isolate and sort data across inspection stations, sites, and users. Our solution incorporates configurable fields so that you can easily match them to your work practices.
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 2. Trend Monitoring  
JetSoft’s trend monitoring function analyses inspection results to gain insight and understand more about processes. Once inspection data is stored in the digital logbook, we have designed a purposeful use of graphics and analytic tools to examine results as a dataset. These dedicated graphs and charts automatically analyse data and reveal in-depth insights. The different filters make it easier to isolate trends based on part types and inspection methods and automatically detect inspectors who deviate from the baseline. The deviation rate is configurable to meet company requirements. 

3. Reporting Capabilities 
Implementing reporting capabilities allows output analysis results to report documents for dissemination and retention. With one single click, the solution automatically generates a report in a Microsoft Word format, which is designed in the correct report layout to meet the new AC7114 Rev R section 10 requirements. Our reporting capabilities reduce time in producing reports to satisfy auditors and provide consistent information to stakeholders.

If you are looking for a digitised solution to meet and adhere to the Nadcap regulations and requirements, look no further. Get in touch with our team.

Another chock-full year has ended! And as we start to ease our foot off the throttle and look forward to our well-deserved Christmas break, we sit down with Tom, our CEO & Founder and reminisce on everything we’ve achieved in 2022.
 
From expanding our team to new client wins, we’re really proud of what we’ve accomplished. We’re inviting you to relive the best moments with us.
 
 
Sum up 2022 for JetSoft in a sentence...
After the bounce-back year of 2021, 2022 has been a year of growth. It’s been an exciting year that has seen us expand our team, our products and our customer base.
 
 
What stood out for you in 2022?
A lot of exciting things have happened this year, it’s hard to pinpoint one overall achievement. So, here are my top 7 …

1. It was quite obvious earlier in the year, that we needed to expand the team to keep up with the demand from our clients and the increasing interest, as the benefits of better management and utilisation of inspection data were being realised. We also experienced several interesting opportunities and challenges that presented themselves. To service this need we expanded our development team. 
2. We experienced a very successful year with record turnover and profit. Especially pleasing was that significant turnover came from new orders from our existing clients, which highlighted the high regard our solutions have with our customers and the positive impact that we are delivering. 
3. Ultimately JetSoft is an engineering firm that likes to take on new challenges. We were fortunate this year to be presented with some especially exciting ones, such as developing algorithms that nest parts based on quality. These algorithms factor both material use maximisation and underlying inspection data to maximise the quality of output components. These work exceptionally well and is something which we are incredibly proud of. We also used inspection data to automatically validate physical metrology measurements and act as a belt and braces inspection for the final sign. We are currently working with a client on reapplication to determine, how following indications in inspection,  material can be reallocated and reclassified automatically to minimise scrap and waste. 
4. This year we were pleased to work with 2 new large global companies, with projects which expand into 2024. 
5. We’ve signed an order to develop a Virtual Assessment for a major global manufacturer. This three-year project will see us perform virtual inspections following each manufacturing stage. This will enable the customer to spot defects earlier and make smart decisions on materials and components, ultimately reducing the cost of scrap. This I believe will be revolutionary for the manufacturing industry and a true exemplar of smart manufacturing. 
6. We’ve worked with an existing client to apply our Artificial intelligence technology, which examines and automatically spots defects in NDT images to use visual system data to great success. This enables our client to detect previously impossible macro defects in materials automatically. Our existing analysis tools then enable them to determine the cause of these defects and put measures in place to prevent them. 
7. It was enjoyable to be back catching up with old industry friends and making new ones face-to-face at events we attended around the globe. We were proud to be invited to be part of the Made Smarter stand at MACH22. We also presented and caught up with lifelong industry friends at the annual BINDT conference, which was especially special.

 
 
Given that we are nearing the end of the year, what’s in the pipeline in 2023?
We’ve started work on several new software products to be launched in 2023. Hush hush for now, but we’ll be revealing more in Q1!
 
 
Are there any new clients or projects to announce?
As we know, this industry is secretive - I wish we could tell the world what we have been working on. Unfortunately, when you’re delivering serious proactive benefits, our customers don’t want their competitors to find out.
 
 
What are your aims and hopes for JetSoft in the new year?
Our progress thus far has come from growing organically, working on challenges we know we can deliver success on and reinvesting the rewards in our products and people. It’s encouraging to see the industry coming to us for help and advice. It highlights that we starting to be recognising as experts in what we do and a level of trust in our abilities.
 
 
To round it up …
The success of this year wouldn’t have been possible without the hard work of the JetSoft team, and our extended support network, from friends and families to customers and associates! You know who you are and thank you.
 
In the meantime, from everyone at JetSoft we’d like to wish you a happy end to the year, and a prosperous new year. We are really excited to see what 2023 brings!

Once a far-fetched sci-fi dream, now the near future of transportation. Technology advancements and huge capital investments are moving drone taxis into a reality, to make our journeys across cities faster, easier, and cleaner.
 

The Drone Taxi Market is Taking Off 
The global market for drone taxis is expected to grow from $74m in 2025 to $860m by 2030 – a compound annual growth rate (CAGR) of 63%. A funding package of £273m has been unveiled by the UK Government for the UK's aerospace sector to invest in technology such as solar-powered aircraft, flying taxis and drones to carry medical treatment. The plan will see the UK build a 164-mile automated drone superhighway within the next two years, connecting towns and cities.
 

The Future is En-Route 
Drone taxis will be landing even sooner than we might expect. Several companies like Boeing, Airbus, Hyundai and Joby are currently developing eVTOL vehicles (electric vertical take-off and landing vehicles). eVTOLs are quiet, comfortable, and carbon-free and are the future of easing urban transport issues, whilst getting passengers to their destinations in record time.
 
Many developers believe drone taxis will be safety certified and clear to take off by or even before 2025. Vertical claims they have the highest number of conditional pre-orders for their VA-X4 vehicle as of yet. The VA-X4 carries four passengers and a pilot. In the rear of the drone taxi, passengers will sit facing each other, like you would in a London black cab. The VA-X4 flies by using quiet electric rotors that produce less carbon than a Tesla would driving the same distance on the road below.
 
Joby’s JAS4-1 is a four-passenger drone taxi that is designed to lift off like a helicopter but fly horizontally like a plane. However, multiple hurdles like governments and the FAA creating new regulations remain in place before Joby can begin transporting passengers.
 

Flying Taxis 
French officials are looking to test drone taxis in the 2024 Summer Olympic and Paralympic Games in Paris. The program is set to shuttle spectators via two air routes during the Games. In 2021 trials had already begun at the Pontoise airfield, where they are evaluating components, such as boarding and disembarking procedures, noise and vibration levels, battery charging and how to integrate the drone taxis with conventional air traffic.
 
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Fit to Fly 
Electric propulsion, lightweight composites and super-efficient batteries are the future of quieter, cleaner and more sustainable aviation. But are NDT testing requirements ready for this new innovation?
 
Recently Boeing has urged regulators to give drone taxis the same strict safety standards as commercial jets, even though drone taxis carry far fewer passengers, they still fly above crowded urban areas. Commercial jets are required to have redundancies on a critical system that would lead to a catastrophic failure if they could not function.
 
Since 2009, Joby has been designing and flight-testing a prototype aircraft that’s capable of serving in a network of drone taxis. NDT will be required to push onward with certifying the drone taxis with the Federal Aviation Administration, high-rate production and preparing for commercialisation with their launch target in 2024.
 
NASA has been testing one of Joby’s drone taxis, where they have a rigorous test plan to perform, which includes collecting data on noise, movement, and communications from the various forms of flight.
 
As companies aim to provide this safe, affordable and fully electric air transportation that’s accessible to everyone, they will require non-destructive testing (NDT) to see it through certification and high-rate production. If you’re developing new and innovative products and need managing your NDT data, get in touch.
 

The impact of the energy crisis has dominated the news over the past few months. A sharp rise in global energy demand, a weakness in supply, and a change in the energy model has led to an energy shock. The price of fuel, transport and materials are putting pressure on production prices and forcing manufacturers to adjust.
 

The Energy Crisis 
The manufacturing and industrial sector accounted for 16% of the total consumption of energy in 2019. Consuming 2,615 ktoe, placed them as the 4th highest business energy consumer. Energy usage is predominantly used to fuel the production line; however, the intensive use of energy has exposed the industry to the energy crisis.
 

Improving the Production Line 
Whilst some costs for manufacturers are abating, unsustainable high energy market prices continue to be a key concern. As the industry is under extreme pressure, improving your operations performance should be of paramount importance. Due to the increased cost of energy inefficiencies in your production line are becoming more and more costly, and could be causing your business major commercial losses.
 

Defects in Manufacturing 
Times of crisis and turmoil also create opportunity, ultimately, it is likely that we will see the inefficient business go out of business and the efficient ones become stronger and grow their market share. The key to this efficiency is the reduction of both time and material waste. Defect data and inspection information is integral to finding the inefficiencies in your production line and that’s where JetSoft can help.
 
In manufacturing, defects can occur at any point however may may only be detected during the final stages of production at the testing phase. Time, money and energy may have been put into products that were always destined for the scrap bin because of an earlier defective stage. Products that are found to be defective either, have costly re-work or are scrapped. The duplication of manufacturing and the process of dealing with the flawed product causes an often-unnecessary increase in energy consumption that could have been avoidable in the first place.

At JetSoft, we’re always looking to be in the know about the latest tech and advances across the sectors we work in. The most recent news that has piqued our interest is that of the return of interest in supersonic flight and even hypersonic travel.
 
Hypersonic is defined as Mach 5, (5 x the speed of sound). Venus Aerospace recently announced they have raised $33Million in funding to build stargazer, a hypersonic aircraft.
 
As with many technologies advances can be initiated through military applications, and hypersonic is likely to be no different; Hypersonic missiles have been identified as the US defence's next largest goal and the hypersonic race is on. In this blog, we are going to be deep-diving into this emerging technology, (specifically hypersonic missiles) the competition in the market and the steep curve that needs to be achieved in testing procedures.
 
 
Hypersonic History 
You may be wondering how hypersonic missiles work and the unique threat they pose. A vehicle being described as hypersonic means it flies faster than the speed of sound. For reference, passenger jets typically travel at slightly under 600 mph, whilst hypersonic systems operate at speeds of around 3,500 mph, which is around 1 mile per second.
 
Hypersonic systems are not a new invention and have in fact been used for decades. When the first US crewed flight around the earth re-entered the atmosphere, it was moving at hypersonic speed. All intercontinental ballistic missiles within the world’s nuclear arsenal move at hypersonic speed, reaching around 15,000 mph or 4 miles per second at their maximum velocity.
 
The Main Three 
There are three types of hypersonic weapons in development for use in defence:

​But throughout the research and development phases, gaps have been surfacing within in-situ process monitoring, non-destructive testing, and data analytics. So, how can these gaps be bridged?
 
Huge Market Potential
 
Annual unclassified defence spending requests for hypersonic technology in the US already equates to more than $2.6 billion. This includes $157.4 million for hypersonic defence programs in 2020. This huge annual spend is expected to grow even further to $5 billion by 2025.
 
But the question is, who will be crowned the winners of the hypersonic race? Understanding your key points of competitive differentiation will be vital. So, the question that needs to be asked is, are you properly funding internal R&D that will allow you to lead the market?
 
The Testing Gap
 
In the midst of the development of these hypersonic weapons is the challenge of ensuring that advanced defence system components are produced reliably. The key areas needing to be implemented for the hypersonic challenge are rapid post-build non-destructive inspection and defect detection for flight-qualified hypersonic metallic structural applications. 

​Industry 4.0 is transforming the manufacturing industry. Manufacturers across the globe are digitally transforming their operations to leverage new capabilities, reduce costs, meet net-zero targets, and inform decision-making. Ultimately smart manufacturing creates new and improved ways of manufacturing.
 
Digital Thread
 
The term “digital thread” might seem to be a relatively new concept in manufacturing; however, it has been used for some time. The digital thread is defined as a communication network that closes the loop between the digital and physical world, by creating digital twins from their physical counterparts. The digital twin of a unique asset is connected to form the digital thread, showing a time lapse story of each asset and their digital twin. The digital thread is about getting the correct information from the plant floor, organising it all, and ensuring the right people see it in real-time. Afterall, NDE 4.0 is all about revolutionising inspection and maintenance processes to increase reliability, safety, and the economics of an asset. The process of a digital thread is formed throughout each stage of a product lifecycle such as:
 

1. Idea generation
2. Design
3. Production of raw materials
4. Manufactured components
5. Product assembly
6. Inspections
7. End of life – Dissembled product or recycled

 
During each of these stages, a digital twin is captured to form a digital thread. During the lifetime of a product, a digital twin may be produced from different departments, suppliers, and companies.
 
Digitisation
 
The digital thread concept is therefore integral to digitisation. which is key to driving an efficient production line and creating traceability of all information produced from manufacturing operations. In manufacturing and NDE processes, huge amounts of data are produced and analysed to uncover insights into production line efficiency and asset performance. The digital thread captures and documents everything digitally, instead of through paper processes. Digitising traceable data is an effective way to analyse operations and inspections, track manufacturing history, and identify defects.
 
Advantages of Digital Thread
 
Applying the digital thread throughout manufacturing comes with a series of benefits:
 

• Improve product quality by limiting mistakes of manual input of data.
• Improve communication to make informed decisions.
• Increase the efficiency of digitally capturing and analyse data related to product manufacturing.
• Improve inspection equipment.
• Optimise maintenance plans such as identifying equipment that needs to be replaced.

 
LNS Research states that the digital thread can increase supply chain efficiency by 16%.
 
Digital Weave
 
The digital thread weaves through the many facets of manufacturing operations. For example, each component thread weaves through a manufacturing process thread throughout different points of its lifecycle. Examples of these include various equipment and inspections. Assets and the manufacturing process threads weave together to create a digital weave, as shown in Figure 1. 

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Digital Weave in Action
 
JetSoft produces software which helps companies to understand how their process affects quality and yield. Jetsoft’s Overseer solution pinpoints the processes and cause of waste.
 
For example, we were able to diagnose that potential scrap inducing issues were being introduced by a process. This wasn’t due to the parameters of that process but due to what the system had been producing beforehand.
 
Let us explain
 
The process we analysed was material rolling, where the temperature of the rolls heats up during the manufacturing process. The amount of heat and thermal mass introduced is dependent on the product that is being produced. A heavily rolled material will introduce a lot of heat into the system. If enough time is not given for the system to return to ambient, then this will influence and potentially cause a defect to the next material that is due to be rolled. By analysing the manufacturing and inspection data we were able to identify and quantify this effect, which provided a much greater understanding of how processes, and affects quality.
 
JetSoft can help you produce an efficient production line, by digitising your inspection processes. Get in touch to find out more.

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It’s difficult to truly measure the devastation the pandemic caused the aviation industry. To put it into numbers, in 2020 the estimated impact COVID had on airlines was around a $370 billion revenue loss versus 2019. By early 2020, international flights had fallen by nearly 80%. Whilst some airlines shifted operations to focus on cargo and charter flights, 16,000 passenger jets were grounded, which represents about two-thirds of the global fleet.
 
However, airlines are still under major financial pressures two years on. Many planes were forced to decommission to avoid extensive maintenance costs when there were no revenue streams, alongside the majority of planes going into long-term storage. As flights are taking off again and there is renewed passenger demand, there are critical procedures that need to be followed to ensure the airworthiness of an aeroplane after being grounded. Airlines are now, where possible, are trying to bring their old fleet back into operation, rather than purchasing new planes as an interim method, whilst their capital is still low.

 
Protecting Wide-Body Fleet 
During the pandemic, planes were placed in either short-term or long-term storage. Even whilst in storage, they required regular maintenance and services. Some were kept ready for immediate use, whereas others were grounded for months on end. To maintain and secure this multibillion-dollar fleet, airlines followed a comprehensive aircraft parking and reactivation programme, that strictly follows manufacturers' guidelines and maintenance manuals. Deterioration of an aircraft structure, surface, systems, and components can occur if preservation procedures aren’t followed correctly.
 
An engineering team would complete periodic checks at 7-15 and 30-day intervals, which includes walk-around inspections, to ensure things like: covers haven’t slipped and there isn’t any damage or leaks. Examples of more complex checks include: removing the covers and testing aircraft and flight control systems, idling engines, and checking the engine bleed air.

 
What Does it Take to Bring a Plane Back to Service? 
It’s a complex process, that involves a huge amount more than collecting the jet and flying it to the airline’s hub. Due to inactivity and reduced regular maintenance checks during storage, a large list of problems could occur.
 
The increased integration and complexity of software and hardware in aircraft systems means that after extended downtime, airworthiness, the operational status of aircraft systems and aeroplane configurations must be verified before the initial flight.
 
Airbus and Boeing have a set standard reactivation programme which must be followed to bring a plane back to service after long-term storage. This involves draining moisture and remaining fluids, inspecting the engine, APU and tires, lubricating all bearings and putting back the avionics which, most likely, would have been removed.
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Storing Inspection Data 
Inspections from not only aircraft parking and reactivations, but the continual inspection through service would need to be conducted globally to keep planes running and their air trustworthiness viable. These inspections are conducted by a large workforce of engineers, who utilise different inspection techniques and collect extensive quantities and varying amounts of data.
 
At JetSoft our solutions provide a centralised system for the service centres to aggregate and manage inspection data to aid the aviation workforce. Whilst inspections are needed to meet safety requirements and audits, the data collected creates an opportunity to understand the operational health of aircraft in more detail.
 
Successful asset management and inspections compromise of three vital areas:

​Our solutions improve communication between stakeholders, supply instant validation and feedback and perform automated analysis of data. Get in touch to revolutionise your inspection data.  

​At JetSoft we create manufacturing feedback loops using inspection data to guide upstream processes to help deliver higher yields. However, did you know we also aid decision-making in downstream processes too?
 
Take the example of one of our metal manufacturing clients who utilises our technology to create an efficient production line. As with many metal manufacturers, slabs of metal are created from which customer parts will be cut from. With certain grades of material, each slab must be thoroughly inspected using NDT methods to check the integrity of the material before the customer's parts are cut. Working closely with this client, we help them to collate their inspection data to determine the overall properties of this slab and identify any anomalies that would lead to a sub-par cut. Our OverSeer solution allows the user to make intelligent decisions on which areas of the slab would yield the highest-quality cut.
 
By understanding where defects and anomalies are positioned, we can direct the following processes to drive a number of key benefits, such as:

• Reposition part cuts to improve quality.
• Re-classify material to minimise waste.
• Analyse order book to maximise profitability.

 
Our solutions automatically integrate complex NDT inspection data alongside other manufacturing data. To perform these impressive benefits it’s imperative that we don't just understand the quality of the material, but are able to consolidate additional information about the material, metrology readings and the final output, including component drawings. The data is combined into a single database to help manufacturers easily analyse and create findings from the information and create consecutive processes. 

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​Part Cut Positioning 
When inspecting material, sometimes an anomaly or defect might be found, which reduces the quality of the product. However, by utilising our solutions we can detect the position of the defect, but also the locations of discontinuities (non-defective anomalies that may indicate non-maximal quality). This means that we can position part cuts, in the areas closest to nominal to deliver components of the highest quality.
 
Our nesting algorithms enable users to balance output quality with material maximisation, which aids manufacturers in ultimately improving the quality of their products. Producing high-quality products consequently drives customer satisfaction and helps to stay ahead of the competition.
 
Reclassification of Material 
Using metal materials in production can sometimes lead to deviations in their physical properties, which often can be difficult to identify. With the help of JetSoft’s digitised solutions, it allows manufacturers to automatically integrate additional information about the material, including its chemistry. Our OverSeer solution can automatically reclassify material based upon inspection information, which may include material grade or even alloy.
 
Minimising Waste 
There is an urgency to find alternative ways to reuse defective materials, because of the increasing cost of energy needed to do remelt and rework. Manufacturers have added pressure from governing bodies to reduce their environmental impacts. Our intelligent solutions can help you minimise waste and reuse materials for other purposes. Reusing existing resources minimises production costs and the resources used to dispose of materials which are defective and ultimately manufacturer of new products. Repurposing material is a step towards conserving energy.
 
Order Book Analysis 
When analysing the client’s order book, we can repurpose material for maximum efficiency. When a defect prohibits the intended use of a plate, our solutions search for alternative orders that the material could fulfil. To do this, the solution considers various material attributes including gauge, heat treatment and size. If another alternative pending order is not found, the solution will explore historic orders and report matches to the user. By analysing current and historic orders, manufacturers can make informed decisions on whether to repurpose, hold as stock for future orders or re-melt the material.
 

Get in Contact

By providing intelligent suggestions, JetSoft can help manufacturers minimise factory-wide costs. Every time an element is found to have an anomaly, the material must be either melted down or scrapped for landfill, which not only creates a loss in productivity and resources but contributes to greenhouse gas emissions. By using our solutions, we can help you mitigate these losses.
 
JetSoft can help you create a streamlined production cycle to stay ahead of competitors whilst increasing return on investment.
 
Whatever field of manufacturing you may be in, costs and supplies and energy are rising at an unprecedented pace, meaning minimising waste and seeking cost-efficiencies is more critical than ever. Speak to one of our experts to find out more.

A rapidly developing manufacturing landscape, known as Industry 4.0 is revolutionising how companies manufacture, improve, and distribute their products. Manufacturers are leveraging to build more efficient production lines and facilities.
 
From the subset of Industry 4.0, non-destructive evaluation (NDE) 4.0 has emerged. The digital transformation is shifting the industry into performing new inspection and maintenance processes, to leverage an efficient production line.
 
NDE 4.0 
But what exactly is NDE 4.0? In short, NDE 4.0 allows manufacturers to rely on automated machines and sensors, to collect smart data, which they can ultimately learn and make production decisions from. NDE 4.0 is seeing inspections take advantage of emerging technologies, such as:

Big Data
Big Data helps to integrate systems so that manufacturers can obtain a complete visualisation of the inspection processes, through automated collection and analysis.

Artificial Intelligence
AI is a system that optimises manufacturing processes and automates complex tasks, by interpreting data and images.

Digital twin
A digital twin is a virtual copy of a real-world component in the manufacturing process. The digital replica mirrors the real component’s status interaction and functionality with other devices.

Cloud
Cloud manufacturing allows you to monitor and record and store each process on a secure server network.

Internet of Things
Data, machines, and sensors are connected through IoT. IoT enables the greater access to data in a faster and more efficient way.

Blockchain
Manufacturers are developing blockchain implementations, to streamline processes, gain greater visibility and track assets. With blockchain, data cannot be changed without detection, which helps to improve traceability.
 

Advantages of NDE 4.0 
Manufacturers can harness the power of this digital transformation. At JetSoft, we have deployed NDE 4.0 techniques into our solutions, to automatically analyse inspection and manufacturing data. Our OverSeer solution can detect anomalies within production output and correlate them directly to the upstream processes that created them. JetSoft’s solutions are helping manufacturers; stay competitive in the market, drive the reduction of scrap and become efficient within their operations.
 
Easier Data Transfer
Inspection and testing creates a huge amount of data, which is typically recorded through paper-based processes. Utilising the OverSeer solution means manufacturers can switch to digital processes. Managing and centralising digitised data from a range of sources into one accessible place helps create a highly efficient process and ensures nothing goes amiss.
 
Improved Data Evaluation
NDE 4.0 makes direct feedback possible. OverSeer utilises AI technology to perform assessments to detect anomalies and patterns within the data. Using legacy formats, our cutting-edge technology can even analyse historic data to instantly detect anomalies and defects.
 
Production Process Improvement
The inspection of manufacturing data can be challenging, due to the complexity of the data retrieved. NDE 4.0 and OverSeer provide a solution to this. If an anomaly or defect is highlighted within the data, action can then be deployed to fix the problem, without interfering with the production line.
 

Deploying NDE4.0
The integration of NDE 4.0 platforms into manufacturing processes, is leading the way to automate inspection practices and provide enhanced customer experiences. AI techniques also mean when early detection of anomalies is pinpointed, it reduces waste and scrap by minimising the ongoing use of defected machinery or materials.
 
Blurring the line between NDE and Agile Development

NDE 4.0 is helping the industry achieve huge milestones. However, looking at the smaller benefits of NDE 4.0 is allowing manufacturers to gain more traction and wins, than falling into the trap of trying to deploy everything at once. Traditionally, production steps are followed one after the other, with no back-and-forth until the final product is obtained. In an agile model, manufacturers work on sprints by dividing feature sets into sub-features and concentrating on those before developing the next set of features.

​The typical structure follows a plan, develop, test, deliver and assess format. Agile development allows manufacturers to reduce the time lag between business needs and technological developments, to create a stronger focus on rapid response to the customer. Planning a development roadmap in an agile way reaps better benefits overall, as you always remain flexible and open to changes. The goal of an agile development life cycle is to create and deliver products as soon as possible and turning speed and agility is a key competitive advantage, in today's fast-moving marketplace.
 
At JetSoft we have seen customers reduce their scrap rates by over 60%, and saved in excess of $2m a year, by adopting our solutions. We have a proven methodology of incorporating NDE 4.0 through an agile process to gain commercial benefit by delivering value quickly and return on investment earlier.
 
NDE 4.0 is accelerating the industry to the next level of manufacturing and JetSoft can help you get there. Speak to our experts to find out more.   ​

​Artificial intelligence is being implemented within nearly every aspect of our lives and is slowly changing the face of manufacturing. We only need to look at Industry 4.0 to see its vital part within a manufacturer’s roadmap. Technological advancement is a prime candidate to optimise manufacturing processes, automate complex tasks and identify unknown patterns in workflows.
 
The manufacturing industry is leveraging this game-changing technology with a 60% adoption rate in 2020 (using in at least one business function). This means manufacturers are starting to realise the huge potential of utilising AI to increase their commercial advantage.
 
What is Holding Manufacturers Back?
 
AI is revolutionising almost all sectors, giving empowerment to companies across the globe to gain immense value from their data. Utilising AI can help manufacturers increase operational efficiency, reduce downtime, and deliver high-quality products. If this sophisticated technology is the epitome of Industry 4.0, why is the install rate relatively small?
 
Outdated Technological Infrastructure
 
Manufacturers often use a wide variety of machines, tools and systems that use different and competing technologies. Some of these may be outdated and not compatible with their other technological infrastructure. This combined with a lack of digitalisation is preventing manufacturers from capitalising on the potential.
 
Confidence, Uncertainty and Trust
 
A significant barrier to AI adoption is the trust and confidence in the capabilities of abstract algorithms. Personnel within manufacturing who don’t hold a data science background struggle to validate how predictive modelling and data science work together.
 
JetSoft’s Use of AI in Manufacturing
 
JetSoft employs AI techniques to automatically analyse inspection and manufacturing data, to detect anomalies in product output and associate them with the upstream processes that created them. Manufacturers gain deep insights to understand the correlations in inspection failures and deploy targeted process improvements, to reduce the likelihood of that anomaly occurring again.
 
Our OverSeer solution automatically manages inspection data and techniques from different sources. OverSeer reads and places the data automatically into a central database to perform thorough assessments. Data from new inspections can be tracked as it passes through each module that has an output. Working on legacy formats means our cutting-edge AI technology is able to analyse historic data from manufacturers to instantly spot anomalies and defects.
 
 
JetSoft deploys AI technology into a customer's site, which analyses images and inspection data to automatically detect anomalies and patterns within the data. The AI functionality pinpoints which processes have created the specific anomaly without having to stop the entire production to detect and fix the problem. Manufacturing personnel are then able to analyse the anomaly against a defect specification to gain a deeper insight into if the anomaly has become a defect.
 
Benefits of AI in Manufacturing
 
The applications of using AI are widespread and revolutionising, offering actionable insights into reducing waste and scrap. So, what are the overall benefits of using AI in manufacturing?
 
Predictive Analytics for Increased Production Output
 
AI systems are able to learn from machine learning algorithms and make use of predictive analytics. The manufacturing industry holds a large volume of data, which predictive analytics is powered from. Manufacturers can easily pinpoint anomalies without disrupting the production process.
 
Improved Process Quality
 
AI technology creates an efficient production process, resulting in higher product quality. The software ensures that products going through the inspection stage don’t just meet quality standards but are of higher quality and closer to nominal. 
 
Reduction of Scrap and Waste
 
Early detection of anomalies using AI techniques allows manufacturers to make quick industry-related decisions that won’t further impact production and create more waste. Reducing waste and scrap has a direct correlation with profit generation and the bottom line. When high-quality products are always created, manufacturers are maximising their output without having to scrap any materials. Utilising assets more effectively creates a reduction in the variable cost of each component, meaning lower prices can be introduced to become more competitive. Minimising component costs ultimately creates a more profitable company.
 
Implementing our solutions has allowed established clients to benefit from huge commercial gains. One JetSoft customer who using our solutions has reduced their scrap rates by over 60%, resulting in savings in excess of $2m a year.
 
AI solutions allow manufacturers to utilise their assets more effectively and take advantage of commercial gains. If you want to know more about how JetSoft can help you, get in touch.

Production loops can surface within any manufacturing sector, from pharmaceuticals to aerospace. The costs and implications of production loops can be detrimental to a business, meaning it is vital to acquire a stringent testing process to identify errors and meet those output expectations.

 
Production Loops   
 
In manufacturing, production loops generally materialise because of an error or an unknown, resulting in a good or component having to be remade or reworked. As high investments are spent in design, production and delivering a product, all components must match the specification, even the smallest defect or error could have damaging effects. Errors can happen due to defective equipment or material issues. For example, a batch of materials may unknowingly be of lower quality and therefore too weak for its intended purpose, leading to sub-standard products.

 
Production Errors
 
Production loops cost manufacturers unnecessary expense, the time spent re-manufacturing or fixing a product or component leads to additional costs and delayed output.
 
Remaking a component essentially doubles the cost and time to dispatch and delays other goods that were planned to be on the production line at that time. Brand reputation, customer relationships and trust are paramount to profit and growth. Delays to customers receiving their goods can drastically impact brand reputation and, in some circumstances, could even lead to clients going elsewhere.
 
Alongside this, defective products arising creates excessive consumption of materials and energy, significantly affecting profitability. These losses not only impact performance and production costs but also directly increase the carbon footprint with the additional CO2 emissions that are released.
 
 
Identifying the Root Cause
 
JetSoft’s solutions create visibility over the production line, which enables manufacturers to operate more reliable production and mitigate production loops. By centralising inspection data alongside vital production data, our OverSeer framework can derive further intelligence on your operations manufacturing process.
 
To receive detailed inspection data, our solution DigiOps allows manufacturers to digitise the inspection process, collating all the data formats into the OverSeer platform, where it will be combined with the array of production data you have available. Our specialised machine learning algorithms will analyse all the data inputted, in order to spot anomalies to identify common problems occurring.
 
  1. Reduce Extra Production Costs 
As an example, our solution may find that products going through equipment are experiencing higher inspection failure rates than those on other lines, indicating a problem with the equipment. Our solutions can help you identify exactly where a defect is originating by integrating inspection alongside other manufacturing data, so that maintenance of equipment can quickly take place to prevent another component facing the same failure and therefore the associated costs in re-make.
 
  2. Minimise Delayed Output 
Digitising paper-based processes through our solutions helps you to gain end-to-end visibility of all inspection data, to make quick and informative decisions. If a material defect rate is higher from a certain supplier, alternative materials may be sourced to ensure fewer defects and thereby fewer delays.
 
  3. Reach Net-Zero 
JetSoft can help you meet those looming carbon emission targets. Gain complete control and traceability over your inspection and manufacturing data, to identify the root cause of any production-related complications before they become a production nightmare. OverSeer can help you drive sustainability, by increasing quality control, spotting defects earlier on and where from, minimising the chance of a production loop. Fewer production loops mean the associated energy required is taken out of the equation and so are the carbon emissions.
 
  4. Meet Customer Expectations 
OverSeer curates an in-depth data process through our user-friendly analytics dashboard, allowing you to input all formats of data, from complex 3D images to the simplest of forms. Our solution can cross-compare real-time and historic data, to monitor trends and help you gain in-depth insight to produce high-quality products. Minimising production loops is integral to reaching quality controls to exceed customer expectations and stay ahead of competition.

 
A Framework for Success
 
Implementing a digital framework is critical to driving efficiency in your production line and paramount to reducing production loops.
 
By deploying JetSoft’s solutions, you are able to identify defects to improve future production processes, increasing your output and decreasing waste. High-quality and reliable output will create major opportunities to gain a competitive advantage in the manufacturing landscape, get in touch to find out more.

In an ever-changing global market, it is crucial for manufacturers to strive for a more efficient production line to maintain a competitive advantage within the industry. Pursuing digital transformation is key to uncovering insights into production line efficiency, reliability of equipment and asset performance. Capturing and integrating inspection and production data helps to ensure productivity and reduce downtime, through the intercommunication between multiple processes.
 
Data-Driven Manufacturing
 
Manufacturers are one of the most data-rich industries, generating an average of 1.9 petabytes a year. Various systems including Enterprise Resource Planning (ERP) and Manufacturing Execution Systems (MES), help to improve production lines and reduce variability, but inspection data is one the most valuable forms of data captured, giving insights into suppliers, compliance practices and quality management. Quickly gathering and distributing the enormous volumes of data across shop floors, vendors, suppliers, and other factories can be challenging. Many companies continue to use fragmented data capturing methods which are often not utilised, and the benefits aren’t realised. Traditional methods are not only prone to human error but are highly time-consuming, inefficient and don’t generate the required quality for deep analysis to implement change.
 
Expose the Unknowns
 
As the industry is under extreme pressure to reach carbon neutrality, ignoring a chance to improve efficiency can’t be overlooked. Production inefficiency can cause major losses for manufacturing companies, by accumulating unnecessary expenses and waste within different areas of production, adding an increasing amount of strain onto other areas of the supply chain.
 
Inadequacies within production can cause major defects in products and can be caused by poor quality materials, human error or machine performance. Raw materials can cause deviations in physical properties, which can be difficult to identify with just the naked eye. Examining defective materials may sound simple, but the situation quickly becomes complex without the correct tools. Similarly, machine performance may also lead to quality loss when they aren't running effectively. The instability of machines can occur at any time throughout the manufacturing stage, making it difficult to have visibility over when and how a defect was caused, and these defects are usually only identified during inspection. Defective products have to be either scrapped or re-manufactured, with manufacturers absorbing the costs of replacement. Traditionally, engineers would pursue intensive root cause and resolution processes, that can take several hours or days to complete.
 
With the help of JetSoft’s digitised solutions, you can gain instant deep insights on inspection data to find the exact cause of the defect, fundamentally reducing downtime and becoming more proactive.
 
The Key to Change
 
JetSoft integrates complex NDT inspection data alongside other manufacturing data, into a single database where trained algorithms will analyse the data to highlight areas of concern. Complex inspection data holds integral information to reduce waste, minimise business risks and improve productivity. To drive change in quality control, manufacturers must have visibility over their production line.
 
Overseer is a central database for all inspection and production data, to monitor trends, gain insight and create reports around production processes and systems from different touchpoints. Our solutions understand the complexities of inspection data from simple pass/fail to complex 3D images.
 
OverSeer can perform an automatic assessment on data and cross compare with historic results to gain new insight.
 
The highly configurable dashboard allows users to isolate the diverse types of data to look at statistics from individual alloys, specific autoclaves parameters, or defect types. Overseer can aid personnel to identify the root cause of defects, from individual machines to specific material suppliers. Manufacturing can be thought of as a set of linear processes, any of which can introduce a defect what our technology is able to do is identify the process which created the defect. Additionally, our solutions make it easy to see the impact of changes process procedures or equipment has on quality.         
 
Like the old motto “learn from your mistakes”, this is exactly what Jetsoft’s solutions can do. Pinpointing where the defect was originated, allows you to put in mitigation measures, to reduce the likelihood of the problem rising again in the future.
 
Maximise Efficiency
 
JetSoft aims to improve the accessibility of data to revolutionise manufacturing and meet quality standards. Integrating integral data types is a powerful tool to enhance predictive decision-making, by revealing and highlighting processes that are affecting the physical and financial performances of assets to ultimately produce high-quality products. Data and digitisation are at the centre of an efficient and profitable production line. Get in touch to discuss our solutions.

​​As we emerge from the climate conference in Glasgow, all manufacturers are facing the challenge of the journey to net-zero, and many are utilising digitalisation to reach these goals. The manufacturing industry is one of the largest contributors to greenhouse emissions globally. Manufacturing in the US accounts for 23% of the total direct carbon emissions, according to the Environmental Protection Agency. Most of the direct emissions produced are generated during the production process. 
 
The manufacturing industry must accept their heavy responsibility for contributing to greenhouse emissions, as they edge closer to the 2050 net-zero target. Drastic reductions in emissions need to be seen throughout the next several decades and the industry must adopt new and clean approaches by planning and investing in a comprehensive roadmap to commit to action.  
 
A New Identity 
 
When the manufacturing industry embraced digital technologies, it paved the way to a new identity of smart manufacturing. The adoption of artificial intelligence, the internet of things and 3D printing are among the technologies that are linking systems and processes, across areas of production, design, and services, to reduce costs and stay ahead of competitors. The innovation of digital technology is now vital to enable the transition to net-zero and can help reduce global emissions by 15%. The transition to digital enhances processes and redefines decision making and monitoring performance, whilst preventing the likelihood of defects, downtime and rework. Digitalisation has the potential to provide manufacturers with the architecture, technology, and concept to enable a circular economy and transition to a sustainable production system.  
 
Reducing the Footprint with Efficiency  
 
The manufacturing industry carbon footprint is largely due to its intensive energy processes. Although the industry cannot completely eradicate their carbon emissions, processes can be put into place to balance and reduce their output to reach carbon neutrality, whilst saving money. There are a number of ways manufacturers can achieve this, whether its integrating IoT sensors to reduce energy consumption, embracing automation for efficiency or digitising operations to spot efficiencies and areas of excess waste. 
 
Preventative Waste 
 
Waste is not only lost productivity but a wasted resource and therefore an unnecessary contributor to greenhouse gas emissions. Industry 4.0 is allowing manufacturers to tackle this huge problem, by giving manufacturers an overview of historic wastage data to change their processes in the future. Every time a component fails its inspection, the materials are either melted down to go back into production or scrapped and taken to landfill. Not only is this a financial burden, but the duplication of production results in an even higher emissions output.  
 
Visibility  
 
Leveraging digital technology, manufacturers can gain in-depth visibility over their facilities, to drive sustainability through waste management and energy efficiency. Pulling in data from the supply chain, production process and inspections means insightful analytics of failed inspections and wastage data can be gained to identify trends that can help to limit wastage going forward. Gaining overall visibility of production output provides insightful knowledge on where manufacturers can drive efficiency or even carbon offset the emissions they can't afford. 
 
The Next Generation of Inspection Technology 
 
JetSoft has the ability to redefine manufacturing with tools that provide traceability and visibility. JetSoft’s solutions aggregate inspection and production data into a central system that utilises AI to pinpoint the direct cause of the defect along the manufacturing process.  
 
Overseer enables users to gain complete control and clear insights into their inspection and manufacturing data. Overseer integrates a range of different data types from both inspections and production. Overseer supplies user-friendly dashboards, curating analytics in a visual manner in real-time and without the need for unsustainable paper documentation. Manufacturers cannot create a circular economy without in-depth data into their processes. 
 
If your scrap rate is not zero then you should be working on reducing it, not only to increase productivity, but to increase output quality, and our solutions have the capability to extensively reduce this figure. JetSoft’s unique solutions aid the manufacturing process, to understand the root cause of defects and help manufacturing managers to make better-informed decisions and reduce potential waste and energy consumption.  
 
If a component created from a material, that is being produced from a particular supplier has a higher inspection failure rate, this would demonstrate a critical problem within the supply chain that urgently needs to be rectified. JetSoft’s tools allow manufacturers to have complete traceability to identify production-related issues early before they become critical, not only increasing quality control but implementing circular economy principles. 
 
JetSoft can help manufacturers stay ahead of the competitor curve and increase profits, whilst reaping the rewards to cut cost, carbon, and reduce environmental impact. Our solutions accelerate the manufacturing industry towards a circular economy by driving sustainability, contact us to find out more. 

The manufacturing sector is in the midst of a digital revolution, embracing the likes of IoT, robotics and AI, so why is it that so many paper-based processes remain? According to a recent study, roughly 62% of manufacturers still utilise some form of paper-based system, yet those same respondents were aware that is where the greatest productivity improvement could be derived. Enter digitisation.
 
 
Shifting to digitised processes
 
Whilst many manufacturers haven’t dropped their pen and paper just yet, more and more manufacturers are considering digitising their processes to transition to the digital age effectively.
 
The past couple of years have only amplified this, with proportions of the workforce working remotely, there was a greater need for employees to be able to access relevant information remotely and with paper records, this just isn’t possible. Digitising paper processes is the first step on the digital road, there is no point in having a manufacturing facility with IoT sensors connected to assets to conduct predictive maintenance if that same maintenance procedure is being documented on paper. You have to digitise before you digitalise.
 

The potential of digitising
 
The manufacturing sector is evolving and paper-based processes are holding manufacturers back from their true productivity potential. So, what exactly can be gained from digitising these processes?
 
1. Time 
If we take inspections as an example, a record of every inspection has to be collected, however filling in paper-based forms is an arduous task and often leads to a lot of unnecessary repeats and the information sometimes has to be manually inputted into a central system. Digitising this process means inspections can be logged digitally and automatically stored in a central location. Also, pre-generated forms can be developed with certain aspects automatically filled-in to reduce unnecessary repetitions. IDC research states the manufacturers could gain a 50% increase in productivity by going paperless.
 
 
2. Minimising Errors 
Everybody makes mistakes, we’re human at the end of the day. However, paper-based systems only increase the probability of mistakes appearing in records. It gives way to incorrect entries or inconsistent records, leading to a lack of data integrity. The ability to replicate forms means less data entry is required, and less chance of an incorrect data entry.  
 
3. Actioning Data 
As paper-based systems are more time intensive, the route to action is longer. For example, when workers are registering deviations or maintenance issues these are done so on paper, which then must be manually inputted and flagged with relevant members via email or in-person, which could be days later. Whereas a digital platform can instantly highlight any recorded deviations on a shared interactive dashboard, so issues are resolved faster.
 
4. Sourcing Data 
Due to the compliance nature of the manufacturing industry, records are constantly being kept throughout the production processes but once they are done, they are simply stored away and never seen again until an audit, where there’s often a scramble to source critical information. Digitising these documents will mean each record, in various formats can be stored in one location, where it will be accessible for other applicable colleagues. Utilising software means the required information is easier to source through filters and refined searches, reaching records in a few simple clicks. Valuable data is now made accessible.
 
5. Conduct Analysis 
Not only is filling in paper documentation time-consuming, it also loses any opportunity to derive value from the results and data is the new oil! Documents are being filled in purely from a compliance perspective, whereas digitising could allow the stored data to be analysed to give greater insight into operational performance. Data becomes more centralised when the processes are digitised, meaning production, inspection and financial data could be stored in one central location. And when utilising a digital platform that incorporates business intelligence the data can be analysed to detect trends and patterns that can drive more valuable decisions and continuous improvement. For example, the analysis may show that one particular component is failing inspections at a higher rate, which could indicate a design flaw or a problem on the production line.
 
6. Sustainability  
Many manufacturers have set sustainability agendas for their businesses to reduce their environmental impact and printing thousands of sheets of paper won’t help achieve a carbon neutral goal. In addition, the potential for analysis means failed inspections and wastage figures can be analysed and detect areas for concern, so that production waste can be limited in the future.
 
Digitisation is the next step for manufacturers, the move can deliver end-to-end data visibility for continuous improvement and elevated quality control.
 
 
Introducing DigiOps
 
As much as the benefits of digitising processes are clear to see, transitioning to an electronic format is no small feat. Our DigiOps solution is designed to replicate and replace paper and spreadsheet systems, with smooth integration in mind and tailored to your specific needs.
 
Built on our OverSeer framework, DigiOps has the capacity to create digital replicas of your paper forms and the ability to create and revise form templates to be distributed to shop floor team members. These forms from then can be completed digitally from several devices and be shareable with other colleagues. DigiOps comes with business intelligence built in, so data is easily viewable via interactive visualisations and simple filtering systems, and data analysis to develop key insight, delivering actionable information.
 
 
Futureproof your data management with DigiOps. Speak to our experts to find out more.  

​It has been a long time since our last blog post. Rather than indicating a lack of activity, the opposite is true. 2021 has been an incredibly busy year for JetSoft, balancing a record turnover with some impressive product development and innovation.
 
[Announcement]
We’ll shortly be launching two new products to the JetSoft suite of applications.

1. CoPlot: A desktop application that improves data capture and traceability for inspection, enabling companies to continue to use existing methods and equipment while generating 3D inspection datasets.
2. DigiOps: A flexible solution that enables companies to digitise operations, empowering them to create and manage tasks, collate data across many formats, monitor progress and output documents. This is deployed on premise for maximum security.

​[Developed with industry]
These applications have been developed in conjunction with Babcock, in conjunction with of the Made Smarter technology accelerator programme.

This programme, which is run by Digital Catapult, brings together manufacturers (Babcock International) and innovation companies (JetSoft) to enable advanced technology to tackle industry identified challenges.

What is great about this programme is that developments are crafted with the direct input of an industry partner, a company who has a clear and defined problem and a strong motivation for developments to succeed. This coupled with access to Digital Catapult’s knowledge and skills, creates a rich dynamic environment for fast agile developments. This supplies clear benefits for all parties, Babcock’s problem is resolved, JetSoft’s products and range expands, and value is generated for UK businesses.
 
[The Challenge]
Early in 2021 Babcock International set the challenge: improve the quality of inspection data collected while improving operational efficiency. The Warrior land vehicle maintenance repair and overhaul (MRO) facility was the testbed and the key objectives were:
​

• 3D measurements and NDT to be collated and assessed as one, with the data available to assure hull integrity and suitability for overhaul
• Visualise and track information digitally so that this process will no longer be conducted through a combination of standalone laptops and manual data. A solution that improves capacity to recall and compare information and records, as well as traceability and time reduction

​The challenge resonated with us for several reasons:

• This is what we specialise in, software solutions for improving the capture, management, and utilisation of inspection data
• We have the relevant skillsets and can leverage some of our existing applications to solve the challenges presented
• Solutions to solve these problems were on our development roadmap and we have already identified a clear and strong commercial demand

 
[The solution]
After reviewing the challenge documentation, we concluded that this was in fact two distinct challenges to be solved with two different approaches.

​The first challenge aimed to improve the data collected at the point of inspection. For this we designed a desktop application that would connect to different pieces of equipment, gather inspection and positional data and fuse together. We have called this solution CoPlot.

​The second challenge focused on data management. This is where we were able to leverage our existing applications.  OverSeer, EyeView and NDT Office already have a large proportion of the capabilities required, however Babcock had demands that exceeded this functionality. To enable us to meet these demands we have overhauled NDT Office and developed an exceptionally powerful software application that enables users to digitise their operations. We’re calling this software DigiOps.

​We are extremely proud of what we have developed, which we will be officially launching shortly. 2022 looks set to be an exciting year as we look forward to the next stage on JetSoft’s future

If you have an immediate need or would just like more information, please do not hesitate to get in contact.

Wishing all our friends, colleagues a happy and healthy 2022

​The JetSoft team

Exciting news.
 
JetSoft is delighted to announce that Sam Cunningham joins us today as our new Head of Sales and Marketing.
 
Sam is well known in the British NDT community, and has a broad range of experience in the industry, which includes being Non Executive Director of the British Institute of Non Destructive Testing (BINDT).
 
JetSoft is committed to making high quality appointments as we look to build a world class team, and Sam’s experience, aptitude and communication skills make him the perfect fit. JetSoft is approaching an exciting period, and Sam will be key to ensuring we realise our growth strategy and capitalise on our industry leading, game changing products.
 
 
“I have known Sam for a while, and I have always thought that he would make a great addition to the JetSoft team. I was ecstatic to get a positive reaction from Sam when we were able to present him with this exciting opportunity. We have an amazing array of innovative and revolutionary products that are already delivering significant commercial benefit to our clients, and with Sam’s help we can expand our offer and reach. All of us at JetSoft are thrilled to welcome Sam into the team. ”
Tom Martin, CEO

Please drop him a call or email to say hi, or to get a rundown on how JetSoft can help you!

[email protected]
​+44 (0) 113 4931007

​This month (August 2020) marks the second anniversary of our first AI, Automatic Defect Recognition (ADR) system being installed in a production environment.
​
To date we haven’t promoted our ADR system publicly, deciding to concentrate on working with select companies and individuals to fully develop it. However it has formed a natural addition to OverSeer’s framework. OverSeer collects inspection data and performs validation and calculations upon it, notifying stakeholders of results and storing data for further analysis. ADR is just another calculation.

​
This flagship installation at an aerospace metal production facility was installed in August 2018 and utilises many of JetSoft’s software features. We are gathering positive feedback from the site about the quality and productivity benefits it is delivering, including:
​

• Automatic defect and characteristic recognition
• Combining factory wide data with inspection information
• Driving process change
• Generating new insight and enabling predictive maintenance
• Reducing the requirements on downstream processes

In a series of upcoming posts, I will discuss these areas in more detail to explain how our processes deliver these benefits, starting with an insight into our ADR software.
 

A note on ADR
Firstly, this article uses the term ADR, which is an industrial term to mean the automatic detection of a problem within a component. ADR isn’t clearly defined yet within the industry, as explained in the previous post ADR - what’s expected? 

​The installation discussed in this article is an Automatic Indication Detection (AID) system, where inspections are still signed off by a qualified human operator.
 

How it works
JetSoft’s core mission is to provide systems that automatically aggregate and catalogue inspection data into a single database. We understand inspection data, and we gather it into a convenient format to take advantage of it. Our solutions combine quality control information with data from other manufacturing systems. These include details about the processing conditions that the part has gone through, details of the component structure and the customer specifications. Combining this information, and making it available for all, has the huge benefit of keeping quality at the forefront of everyone’s mind. I will talk about this in more detail in a future article.

This collated data is passed through an extensible list of models which are trained to look for particular faults or certain characteristics. Each model outputs a confidence level based on the likelihood that the inspection contains a positive match. Any disagreement between the system and inspector is highlighted to the responsible level 3 or automatically sent for a second opinion. This drastically minimises the potential for misdiagnosis. Additionally, the output of these models is stored in the system and is made available for analysis. 

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Thresholding of output confidence enables the user to select the desired level of Probability of Detection (POD).

Model training is in depth and employs a hybrid approach using a combination of pre-processing, AI machine learning techniques using historic data and deterministic algorithms.

One of the key advantages of this system is its ability to subcategorise defects. For example, this system can differentiate between a lamination crack caused by rolling and a quench crack caused by heat treatment. Detecting this distinction is non-trivial for a human inspector, requiring further analysis

​Similar defects which are caused by different process may look very similar to inspectors, but it is important to differentiate them to target improvements towards the appropriate processes. For inspectors to make this distinction may require additional training and further analysis, whereas the systematic solution is automatic, quick and consistent.

​I mentioned earlier that the system can be configured to identify any characteristics, not just defects. This is important as there are many things we may want to observe and track that could indicate future problems which in time could lead to defects, or just a general reduction in quality. The time and cost investment of training inspectors to manually identify such trends or patterns would not be justified, however by recognising these warning signs early, there is time for mitigating action to be taken to reduce scrap rates in the long run.

 
Key benefits summary
An independent assessment – this system provides an independent assessment alongside the inspector. If there is any difference between the system and the inspector, the responsible level 3 can be alerted or it can be automatically sent for a second opinion. This improves quality and reduces the chance of mistakes or misdiagnosis, without increasing operating costs.

Sub categorisation of defects – this is the big commercial driver behind the software. It is the application of this feature that has seen scrap rates plummet. An inspector’s job is not necessarily to interpret the cause of a defect, but to highlight its existence. By training models to examine for defects with a known cause, we can target our time and efforts on improving process where we will see the most commercial benefit. This creates a feedback loop of high-quality, useful, data from inspection to all other departments.
 
Next time
Quality should be everyone’s responsibility, but this is only achievable if everyone has a clear vision of quality, and their impact upon it. JetSoft is providing the tools that deliver real time statistics which demonstrate and communicate quality to all.

​Next time we’ll look in more detail at how we’re achieving this and how JetSoft’s is helping everyone to take ownership of quality.
 

​​Automatic Defect Recognition (ADR) is a term that is gaining traction within the NDT world. However, neither ADR or the functions such a system should deliver are clearly defined.

​At JetSoft we prefer to split ADR into two stages, using the terminology Automatic Indication Detection (AID) and Automatic Part Sentencing (APS).
 
The problem with ADR
The scope of ADR isn’t clear. It seems, depending upon your source, ADR can range from a system which highlights abnormalities to an inspector, to one which can perform full sentencing (go/no go), eliminating the need for an inspector at all. In practice, most end users anticipate a solution resembling the latter, but this may not be true of the products promoted by equipment vendors.
 
AID and APS
At JetSoft we don’t use the term ADR, due to the lack of clarity on what this means, instead we use the terms:

• Automatic Indication Detection (AID)
• Automatic Part Sentencing (APS)

Defect detection is a two step process. The first step is the discovery of an indication or discontinuity, the second step is evaluating that indication against a specification to determine whether it is a defect. ADR may (or may not – depending upon who you talk to) be considered to be the automation of this two-step process. However, in JetSoft’s experience each stage can be automated separately, indeed it would be difficult not to.

JetSoft refers to the automation of the first step as Automatic Indication Detection (AID) with the results highlighted to an inspector or used as an independent assessment and compared with the manual outcome.
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The second step, qualifying the indications against defect specifications, JetSoft calls Automatic Part Sentencing (APS). Because once a system is confidently automatically qualifying defects it must logically be able to decide if the part passes or failed.

​Is ADR overhyped?
News about ADR (go/no go) using deep learning and machine vision is rife and in my view racing towards the peak of inflated expectations on the Hype Cycle. 

The Hype Cycle, developed by the technology firm Gartner, details the phases a new technology goes through to reach maturity and widespread adoption. 

The scale of the peak and trough of this graph is exacerbated by the lack of clear definition of ADR. It is not difficult to imagine a situation where customers and suppliers differ on the expected functionality, resulting in a negative view of ADR and its possibilities.

However, ADR will happen. There is a large commercial appetite to reduce the cost of inspection and new advances in computation technologies prove that it is possible technically. But it may take a while to get there and require more investment (time and money) by users than anticipated. The market should be prepared not to expect a single turnkey algorithm that performs ADR on any component for any defect, but, should rather, anticipate solutions that require dedicated configuration, development and training based on what the users is looking for and the component/material type.

We hear a lot about the benefits involved with ADR, but perhaps less so of the realism of implementing and delivering them.
 
What to expect
JetSoft is amongst several companies utilising these new technologies, with working systems, using deep learning and machine learning techniques in place in production environments.
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It is JetSoft’s experience that performing accurate automatic detection of defects takes dedicated time, development, and extensive testing. Furthermore, for an AID system to be effective, additional information beyond inspection data is required. Including component details and upstream process data, both of which are critical.

​It is important to note that in every case the preceding step to achieving an APS must be a fully working, and empirically proven AID system.
 
Contact us
As always, we would love to hear your thoughts on this, and if you have any questions, or would like to know more about what we do and the systems we have developed please get in contact.

​It is with great pride that we are officially launching our NDT Office software package, a solution dedicated to helping NDT departments manage their vast amounts of documentation and paperwork.

Background
For several years now, Jetsoft’s solutions have been helping companies to capture, manage and utilise their testing data, and to aggregate it across many formats and techniques, improving accessibility, efficiency, and communication.

From here, we spotted an opportunity to add value by transforming the way NDT departments manage their documents. Documentation is the lifeblood of NDT departments and underpins the operation and day to day activity of all personnel. Inspection results are inextricably linked to the documentation which drives the processes, including customer specifications, work instructions, equipment calibration and inspector certification and qualifications.

The problem
Most NDT departments are poorly setup to manage their documents, using unsuitable products such as the Microsoft Office suite, PDFs and in many cases, still using paper records.

My statement that Microsoft Office is unsuitable my surprise some of you, but Word, Excel etc, are not designed for our dynamic needs. They are great for single, standalone documents but are missing a lot of functionality that testing departments require. NDT documents are living, breathing records with dependencies, cascading impacts, and multiple relationships.  Some simple examples of missing functionality include:

• Expiration alerts. Many documents have an expiration date, and Microsoft Office has no way to specify an expiry date and to send alerts as that date approaches.
• Traceability and versioning. Process and specification documents are often updated and revised. Accurate version control is imperative in understanding which documents were in use when. Microsoft tools are inadequate for this.
• Data lookups. Completion of an inspection report requires the inspector to provide details on the equipment used and which specifications were followed. The designer of the template is left with the choice of a free text box which is versatile but lacks any validation, or an inbuilt dropdown box that rapidly goes out of date.

NDT departments implement workarounds for these inadequacies, which adds considerable time to the management process, for example maintaining separate excel sheets or constantly updating report templates. These workarounds not only add significant time overhead, but are not scalable in a business looking to grow the NDT department, operate more machines, test more components and take on more customers (and so specifications). In this scenario, management by a single Excel spreadsheet will very quickly become problematic.

​The Solution
JetSoft is a software company dedicated to developing solutions for NDT. We are ideally placed to both understand the needs of NDT departments and prescribe the best approach to solve them. We put our heads together, engaged with both existing and new clients, and have designed and developed NDT Office. This application fits neatly into our existing framework and expands our capabilities from managing resultant inspection data to integrating the surrounding documentation.

OverSeer and NDT Office are centralised solutions, which store data and documents in one accessible place, and can be created by all colleagues who are granted access by the administrator. JetSoft solutions use cloud technologies, so can be accessed from any networked device without the need to install software. Note, it’s important to point out that while the solution is built using cloud technologies, individual instances can be installed on premises, meaning all data and access is via the internal network only and no data or connection is exposed externally.

NDT Office is an incredibly versatile solution containing a vast number of useful features including:

• A complete and flexible toolkit to create forms and documents, with in built traceability
• Configurable expiry dates and alerts via email as expiration approaches
• Configurable validation to minimise input errors and eliminate missing data
• Create wrappers for multiple files, e.g. an inspection report of a component may be a collection of tests, combined with other related documentation to form a single entity
• Automatically restrict access to create inspection reports based on existence of other documents. For example, it is possible to prevent an operator from creating an inspection report if they don’t have valid credentials.

• Create and manage lookups so that options within forms are always up to date. As this is centrally administered, lookup options are managed and instantly applied to forms. When a new item of equipment comes online, with NDT Office, it can easily be added to the list of active equipment from which the operator can select when completing a report.

NDT office is built on top of the OverSeer framework and so benefits from its existing functionality including comprehensive search tools and business intelligence features.

These features are helping companies to reduce the time demands on key personnel, to reduce risk, become more efficient and put them in a position to scale and grow.

Use Cases
NDT office has already been installed and is in use at several locations. Our clients range from large manufacturers using NDT Office to manage data entry and non-conformance reporting, to test houses exposing the NDT Office interface to field engineers to recall previous inspection results and enter new reports, all of which are immediately accessible to head office.

​I’ll be writing some case studies in the coming months.

Well, more precisely, it’s 5½ years, but our anniversary in December passed us by as we busied ourselves with deadlines.

The current situation is allowing us some time to both look forward to the future and to reflect on our achievements.

JetSoft was incorporated in 2014 with nothing more than an idea and the aim of helping companies to manage and unlock the potential of their testing data. Over the past 5 years, we are extremely proud to have successfully developed a respected product suite and delivered it to companies both in Europe and the States. Our solutions are reducing time demands on key personnel, increasing our customers’ value proposition and supplying insight enabling companies to operate more efficiently.

​Projects have been a heady mix of being interesting and varied, challenging and rewarding. JetSoft customers and projects can be split into 4 categories:

1. Manufacturers looking to reduce time demands on key personnel, improve traceability and reduce scrap
2. Test houses wishing to improve their digital systems as well as increase their value proposition by providing additional information and statistics beyond pass/fail
3. Commission based customers wishing to use our skillsets to build them something specific
4. R&D projects

JetSoft enjoys the work we do and are proud of the relationship we have with our customers and the solutions we have delivered. I have detailed a few highlights below.

Manufacturers​
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The first installation of OverSeer, JetSoft’s core framework, was for an aluminium plant in Birmingham, UK. I will always have gratitude for the team there that had the vision to take the leap and be the first install. In addition, their feedback has been instrumental in forming the product that we have today. This was the start of a continuing trend for developments and features to be customer and market led.

Test houses

We work with several test houses, who are generally looking for us to help them with digitising their documentation and supplying a scalable software solution for managing the way they process components.

Software commission​
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Another of JetSoft’s early projects was a commission for NewGen NDT to design and build NxtGen a solution for digitising and monitoring the dye penetrant process. A combination of hardware and software, the inline system takes and tracks sensor readings over time and alerts should conditions go out of specification. The versatile product is under constant improvement with features including tracking parts through the process, improving traceability, automating reporting and generating operator and quality performance metrics. The architecture of the system means the system is incredibly adaptable and can be applied to many different manufacturing processes, not just NDT.

Another commission based piece of work was for a Dutch aerospace company who were (and still are) running unsupported inspection equipment from a manufacturer which is no longer operational. Aerospace requirements require the data to be retained, with the ability to be accessed and viewed, for the lifetime of the aircraft. To solve this business critical problem, we reverse engineered the format and provided a simple application for converting the inspection files to a format that they could open.
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R&D
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In 2018 and 2019 we were part of an exciting consortium working on the c£900k RASCAL research project. This project aimed to reduce the reliance on Computed Tomography NDT techniques for safety critical additive manufactured components, a well know problem in the industry. The project used a multimodal approach combining data from different inspection techniques. As the ‘software company’ we played an important role in developing the very well received robotic system, developing a software package capable of performing an extensible list of automatic assessments, fusing data, performing automatic defect recognition and integrating the results into a digital manufacturing environment.

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​As you can see, our first 5 years have been very successful which wouldn’t have been possible without the hard work of the JetSoft team, and our extended support network, from friends and families to customers and associates! You know who you are and thank you.

If you would like any more information on any of the projects discussed here, think we may be able to help you, or would just like a chat, please do not hesitate to get in contact.
 
Thanks
The JetSoft team.

We’re offering free Cloud instances of OverSeer and EyeView to help people to work from home.

JetSoft has instigated a work from home policy following the latest UK government recommendations. This advice is designed to stem the spread of the Covid-19 virus to keep infection levels within the capacity of the heath service (to squash the sombrero [curve] as The UK Prime minister put it).
 
It is our collective duty to do what we can during these unprecedented and frankly bizarre times. Whilst it is easy for us to implement home working (we’re a software company, all we need is a laptop and access to caffeinated drinks) this is not true of most people, including in the NDT world. The added pressure of school closures is compounding the problem, and some individuals will be forced to stay home. This got us thinking, is there any way we can help?
 
A major feature of JetSoft’s solutions is a centralized repository for all NDT information, providing access from any device and location. Our software is built using Cloud and web technologies and data is accessed and viewed from a web browser, therefore our tools can be used from any computer. While many NDT tasks require you to be close to the point of inspection, others such as analysis and report writing can be undertaken remotely.
 
We’re offering to setup free instances of our software hosted in the Cloud. Data can be uploaded from the factory and then will be available via a secure portal, for viewing and analysis from any location, plus you’d get access to all the other great tools we have.
 
Designed to be technique and format agnostic, OverSeer accepts and understands lots of different data including:
   Caldata
   .csv
   Matec
   Midas
   Mistras
   DICONDE
   .pdf
   ScanMaster
   Testia
   Tiff
   USL
   .xlsx
 
For a full list, please get in contact.
 
Note: Cloud technologies are not for everyone so we can also setup an on-premises instance, hosted on your company network, which means data doesn’t leave your environment and will be available from home if you’re able to VPN into your network.