Issue: Extra Welds
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
Other Possibilities
- Incorrect design revision
