Cause: Damaged Part or Fastener

The weld is not correctly made due to the use of a flawed workpiece.

Description 

The weld is not properly made due to the workpiece not meeting specifications (examples: twisted, bent, scratched, torn, surface quality, surface coating, etc.).

Detection 

Detection evidence may include:

• Cracks & holes
• Expulsion/burn through
• Inconsistent weld quality
• Mislocated edge weld
• Non-round or undersized weld
• Poor Class A appearance
• Sheet metal distortion
• Part inspection

Significance 

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

Quality: Welding process may be correct but flawed workpieces result in nonconforming assemblies.