Statistical Process Control Application to Weld Process

A statistical weld process monitoring system is described, aiming to enhance weld process quality control through statistical process control (SPC) techniques. The objective of the study is to provide a comprehensive overview of how SPC tools, utilizing data collected during welding — including voltage, current, wire feed speed, gas flow rate, travel speed, and elapsed arc time — can be implemented to ensure high-quality weld outputs. The methodology involves computing the mean, standard deviation, and range of these parameters, which are then analyzed through control charts to visualize changes over time or across different welds. Tolerance charts are utilized to display the minimum and maximum parameter values for each weld, along with upper and lower control limits. Furthermore, the SPC system employs sequential analysis, enabling real-time monitoring and prompt identification of potential deviations from established quality standards. The development of an expert interpreter to manage the extensive statistical output generated by the SPC system is also discussed, emphasizing the importance of data interpretation in welding processes. This approach enhances the ability to maintain stringent quality assurance in both manual and automated welding applications.