Having spent the last 12 years in the nondestructive testing education sector, developing training curriculum, and delivering education to thousands of students, one glaring weakness has always been clear: the lack of industry guidance for the required on-the-job training portion of NDT education.

The NDT industry has established in-depth guidelines and requirements for formal classroom training, but a shortfall in the standardization of on-the-job training (OJT) requirements remains. This undermines the effectiveness of NDT training, jeopardizes workforce consistency, and poses risks to safety and quality. The industry must address this issue by developing much-needed OJT standards to ensure that NDT technicians are equipped to meet the demands of their roles. I am aware that many companies have done a respectable job creating internal OJT competency requirements because they understand and value the importance of such, but there remains a dire need for industry-wide guidance and implementation.

The Dual Structure of NDT Training

NDT training comprises two components: formal classroom education and practical OJT. Classroom training has been clearly defined, with globally recognized organizations such as the American Society for Nondestructive Testing (ASNT) and the International Organization for Standardization (ISO) providing detailed guidelines. Industry standards and recommended practices outline the theoretical knowledge, topical outlines, and classroom hours required for each NDT method and certification level. For example, apprentices pursuing certification in ultrasonic testing must study topics such as basic principles of acoustics, equipment calibration, and transducer operation and theory, among many others.

On the other hand, OJT is where apprentices apply theoretical knowledge to practical skills under the supervision of experienced technicians. This firsthand experience is critical for mastering the nuances of NDT, such as interpreting complex signals and examination results to determine whether the item being inspected meets various acceptance criteria. Industry standards and recommended practices, such as ASNT’s SNT-TC-1A, ISO 9712, or NAS 410, mandate a minimum number of OJT hours based on the NDT method and certification level. These hours are meant to ensure that entry-level technicians gain sufficient real-world experience performing inspections independently.

However, unlike classroom training, the NDT industry provides little to no guidance on what these OJT hours should include. No universal requirements, competency milestones, or topical outlines specify the tasks, skills, or scenarios technicians must encounter. This lack of standardization creates a significant gap in NDT training.

The Consequences of Unregulated OJT

I can’t count the times over the years that I have had conversations with clients about the lack of consistency in the capabilities of technicians that they have hired. The candidate comes to the interview with past level II experience and employer certifications, only to require retraining. The absence of standardized OJT requirements leads to considerable variability in training quality, as the content of OJT depends heavily on the employer, the supervising technician, or the specific worksite. Let me be clear, I do not believe that every NDT technician can be proficient in applying every NDT method in every scenario by creating OJT guidelines and requirements. There are many different intricacies to be considered in each industry, such as aerospace, oil and gas, nuclear, power generation, among many others. This being said, there are core competencies in each NDT method that can be applied universally to create a more well-equipped, broadly competent, and versatile NDT technician, therefore reducing the additional training that may be needed when a technician moves from one industry sector to another. This lack of industry guidance manifests itself in several ways:

• Lack of Oversight and Accountability: In some cases, OJT hours may be logged without meaningful engagement, with trainees performing repetitive tasks or observing rather than actively participating. This negates the purpose of OJT, produces technicians with superficial skills, and complicates workforce mobility.
• Employer Burden: Employers often bear the cost of retraining technicians whose OJT was insufficient. Inconsistent OJT also complicates hiring decisions, as employers cannot rely on past experience alone to gauge a candidate’s readiness.

These challenges highlight a fundamental flaw in the NDT training system: while classroom education provides the theoretical foundation technicians need, the lack of OJT standardization jeopardizes the industry’s ability to produce consistently skilled technicians.

The Case for OJT Standardization

Standardized OJT guidelines would ensure that all technicians, regardless of employer, region, or worksite, receive consistent, high-quality on-the-job training. Such guidelines could include the following components:

• Core Competencies: A detailed list of universal skills and tasks apprentices must master during OJT, tailored to each NDT method and certification level. Competencies that can be applied across a wide spectrum of industries.
• Supervisory Standards: Qualifications and training for OJT mentors to ensure effective guidance and evaluation. Supervisors should be trained in mentorship techniques to provide constructive feedback, foster skill development, and provide a clear pathway for the apprentices’ development.
• Documentation and Assessment Protocols: Standardized methods for logging OJT activities and supervisor evaluations. Regular assessments, such as practical exams or competency checklists, could verify progress and ensure accountability.

Standardized OJT would yield numerous benefits. For technicians, it would provide a clear roadmap for skill development while building confidence and ensuring they are fully prepared for certification and professional responsibilities. For employers, it would reduce the need to retrain new hires and streamline hiring by establishing a reliable benchmark for competency. For the industry, it would enhance workforce mobility, as technicians could transition between organizations and verticals with confidence in their qualifications.

A Path Forward

Addressing the OJT gap requires collective action from NDT industry stakeholders, including standards organizations, employers, and regulatory agencies. The following steps could guide this process:

• Develop OJT Guidelines: Industry bodies like ASNT, ISO, and the NDT Management Association (NDTMA) should collaborate to create comprehensive OJT standards. Experienced technicians should develop these guidelines to ensure that the standards are realistic and relevant.
• Train Mentors: Mentorship is critical to effective OJT, but not all supervisors are equipped to teach. Throughout the years, I’ve met many amazingly talented level three technicians. They were experts in procedure and technique development, personnel certification, and quality control, but did not have the skills to transfer theoretical knowledge to students. Industry organizations should offer mentorship training programs, focusing on instructional techniques, feedback delivery, and apprentice evaluation. Certification programs for OJT supervisors could further professionalize the role.
• Pilot and Refine: Pilot programs could evaluate proposed OJT guidelines in diverse settings, from large aerospace firms to small inspection companies. Feedback from these pilots would inform refinements before widespread adoption.

Overcoming Challenges

Implementing OJT standards will not be without challenges. Small employers may lack the resources to adopt structured OJT programs, while large organizations may resist changes to established practices.

Conclusion

Nondestructive testing training programs are only as strong as their weakest link. While classroom education requirements and guidance have been well addressed to provide a solid theoretical foundation, the lack of standardized OJT requirements risks producing technicians with inconsistent skills. By developing clear, universal guidelines for OJT, encompassing core competencies, supervisory standards, and standardized documentation, the NDT industry can ensure that its workforce is equipped to meet the demands of an ever-evolving field.

The stakes are high: inconsistent training not only undermines technician confidence and employer efficiency but also jeopardizes the safety of critical infrastructure. Industry stakeholders must act swiftly to bridge this gap, leveraging collaboration, technology, and innovation to create a training ecosystem that reflects the precision and reliability of NDT itself. Standardized OJT is not just a need but a necessity for the future of the industry. By addressing this shortfall, the NDT community can uphold its commitment to excellence, ensuring that every inspection is performed with the skill, confidence, and integrity that the world depends on.