Cost Consequences of Missed or Faulty Welds

Written by Posted On Monday, 07 October 2019 10:57

Any welding projects aim to construct standard products for clients and at the same time maintaining the necessary levels of productivity and managing costs. Faulty and missed welds can create an adverse impact on a welding project, which may lead to safety issues and significant loss of revenue for fixing. Any matter relating to welding projects must be detected before it causes disaster.

Early detection of missed and faulty welds

Missed or faulty welds can jeopardize the aim of any project. Furthermore, the consequences could be so devastating, depending on the size of the welding project. There are some questions to consider to avoid the issues of missed or faulty welds in every welding operations.

  1. 1. Does your organization have intricate parts that could lead to missed or faulty welds?
  2. 2. Do you make use of simple visual inspection to check if all welds are thoroughly done?
  3. 3. Are you visual inspection always accurate?
  4. 4. What could be the consequences if any part fails fr your client?

In some cases, missed or faulty welds could pose a severe threat and may lead to physical injuries. Note that the earlier a missed or faulty weld is detected, the lesser the cost to fix it and the danger it poses to the customer. However, if a bad weld goes undetected, the cost increases at every level of the welding operation.

Level one: Weld cell

Detecting a missed or faulty weld in the weld cell is the perfect plan. In this case, welding operators can quickly make a fix without much cost. Though weld faults may be stressful to address, it may involve a total removal of the welded part and then rework. This might cost up to 2 to 3 times the average cost of the welding operation. Welding projects with smaller parts are less expensive to examine and rectify at an early stage than in bigger projects.

Level two: Successive weld cell

Additional weld cells may be present in projects with sub-assembly requirements. When a faulty or missed weld is detected at this level of operation, the operator may need to return to the first level, which is the weld cell. However, if the operator does not have the required equipment to correct, it may lead to some issues. If the part is large, the company's work progress may slow down, leading to unnecessary costs and lost productivity.

Level three: Paint booth

The company may need to remove the painting after it is done if any fault is detected. After this, they will return it to the formal weld cell to rework the steps in the welding process. This can lead to more cost for labor, rework, and also for painting. For bigger projects, the cost of the painting could be very high.

Level four: Product assembly

When a fault is detected at this level, it will require disassembling the part, removing the paint and back to the weld cell to start the work all over again. This means the cost of the entire welding project is now doubled. This is because it requires additional labor and sometimes additional equipment to repair. To help prevent or avoid faulty and missed welds check out the necessary equipment on the welding pro to get your company covered.

Level five: Customer or distributor detection

A company could accrue more costs when a distributor or customer identifies a faulty weld. The company may have to remove the product and deliver a new one. The cost could be more expensive if the product is a heavy one. In this case, the company might need to sed a qualified operator to fix the faulty weld, which is more costly. The company's brand name or reputation could be at risk if a customer detects missed or faulty welds.

Level six: Liability claim

 In case of physical damage or property damage due to missed or faulty welds, the consequences may be devasting. A threat to one's safety could be severe, and the results might be grievous. The customer liability claim could create significant expenses at this level. Loss of business and profits and damage to the company's reputation could come alongside its costs.


Finding a solution

To avert and avoid missed and faulty welds, companies should implement an advanced welding information management system to spring into action when an operator welds outside an acceptable limit. This system can give instant prompting or automatically stop the welding gun until the problem is identified and fixed. Quality monitoring weld sequence and parameters can be gotten on Getting the necessary equipment and gadgets for welding projects will save a whole lot of lost and sensible for doing good business.

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Jhon Issac

I'm not a reguller writter, some time i love to write article and posted content on BuyerThink. I also love travelling some time. I've visited INDIA last time.

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