Jim’s Cover Pass: 3 simple steps to enhance weld quality

There are simple steps that job shops can use to fight complacency in an effort to improve weld quality. Getty Images

Q: My company is in the process of restructuring our welding department. Our goal is to enhance weld quality and productivity as we move into the new year. Where would be a good place for us to start?

A: Many companies reach a plateau with welding quality because they become complacent and rely on processes simply because, as they put it, “that is how we have always done it.” To avoid this, look at reviewing or installing three items into the production process before you implement any new ideas.

First, does your company use work instructions? This is a document that follows the job order throughout the production process. It includes material acquisition, the required number of parts, processes involved, along with inspection stops and details at each step. Including a signoff with a date and time stamp at each step helps production flow analysis through the manufacturing process.

Along with these work instructions, you should include the print or package of prints that correspond with each operation. This may be as simple as one print for a single part, or it may include a series of detailed assembly drawings. The work instructions would then identify and reference specific details. For example, Print No. 14302, Reference Weld A should be completed and inspected before Welds B, C, D, and E.

Finally, add a qualified welding procedure specification (WPS) to the shop packet for each welding process. This will identify the essential variables and procedure limits. Many weld projects will require several WPSs throughout the manufacturing process or assembly. Your welding technicians should understand the WPS and be qualified to produce the required weldments.

Everything that your company manufactures and/or welds should include:

1. A detailed set of work instructions.
2. Corresponding prints.
3. Qualified WPSs for every required weld available to the technicians.

Installing and using these three documents will improve quality control procedures. As a result, your production quality will increase and your employees will have a better understanding of the company’s expectations.