Issue: Extra Welds

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Definition
Additional welds on a workpiece compared to current workpiece design.

Detection
Detection is typically made with a visual inspection of the workpiece by counting the welds and comparing with a quality inspection chart.

Significance
Quality, Workplace Issues, Cost, Downtime, Maintenance, Throughput (cycle time; PPH) are all potentially affected by this condition. Special considerations are noted below:

Quality: Extra welds may modify crash energy management.

Possible Causes

Strong Possibilities

• Incorrect workpiece selected
• Welds wrongly located by fixture/robot/operator

Weak Possibilities

• Incorrect test procedure

Nonmatrix Possibilities

• Incorrect design revision