Issue: Extra Welds

Additional welds on a workpiece compared to current workpiece design.


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


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

Weak Possibilities

Other Possibilities

  • Incorrect design revision

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