Stage one: weld cell

Identifying a missed or defective weld in the weld cell is the ideal scenario. Welding Parts Suppliers (XINGHUI) operators can usually add the missed weld easily — and at minimal cost— and move the part to the next stage in the welding operation. Weld defects may be slightly more difficult to address. These require the removal of the weld and its rework, typically resulting in a cost of two to three times that of the original fabrication. Welding operations with smaller parts will be simpler and less expensive to inspect and rectify problems with in this stage than with larger components.

Stage two: subsequent weld cell

In operations with sub-assembly requirements, additional weld cells may be present to complete the production of the part. Identified missed or defective welds in this stage may need to be returned to the weld cell if a welding operator does not have the equipment or qualifications to make adjustments, resulting in several potential problems. If the part is large, the company may amass downtime for moving it, which can cause lost productivity and unnecessary costs. For companies that manage a lean, “just in time” welding operation, returning a part to the weld cell could also lead to a welding operator waiting on a part. Ultimately, the result is a bottleneck that affects the company’s throughput and profitability.

Stage three: final product assembly

If a company identifies missed or defective welds in this stage, it will require disassembling the part, removing paint and returning the part to the weld cell to be completely fabricated again. By starting the entire welding process over, costs continue to escalate due to both downtime and labor. In some instances, companies may be able to deploy a mobile welding cart to the production area to rectify the problem. Still, correcting a missed or defective weld in this manner requires additional labor for an employee dedicated to this purpose or potentially bringing in a welding operator from the weld cell to make the repair. The latter scenario prevents that employee from focusing on his or her own work in the initial stages of fabrication. Having a mobile welding cart also requires a capital investment for equipment that is only used periodically.

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