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

Nonmatrix Possibilities

  • Incorrect design revision