MACHINE
1. PIPE LEAK, FLOW NOT PROPER
2. NOZZLE CAP DAMAGE
3. PART POSITION NOT FIX IN FIXTURE
4. VOLTAGE CURRENT FLUCTUATION
5. POOR QUALITY WELDING WIRE
6. WELDING FIXTURE CLAMP LOOSE
7. CONTACT TIP DAMAGE
8. PART POSITION
9. BLOCK HEIGHT UNEVEN
1.PIPE LENGTH SHORT/LONG
2.PIPE THICHNESS LESS/MORE
3. PIPE HERD/SOFT DUE TO CHEMICAL COMPOSITION
4.PIPE CUTTING NOT PROPER
5.BRACKET NOT AS PER DRAWING
6.PRESENCE OF OIL, DUST
7.TWIST CHILD PART
MATERIALS
METHOD
1. WELDING DONE WITHOUT FIXTURE
2. OVER WELDING, INCORRECT POSITIONING
3. NO WORK INSTRUCTION AVAILABLE
4. LOT OF WELDING AT ONE PLACE
5.OVER HEATING IN THE POWDER COATING PROCESS
6. POWER FAILURE DURING WELDING
7. NOT FOLLOWING STANDERED OPERATING PROCEDURE
BURR ON
EDGES
1.PHYSICALLY POOR, ILL
2.LACK OF INTREST
3.PRODUCT AWARNESS, LESS SKILL CONFIDANCE
4.CHANGING IN WELDING PARAMETERS
46
5.EXTERNAL DISTRACTION
6.PART MISSING
7.POOR JUDGEMENT, STRESS, FATIGUE
8.CARELESS OPERATOR
MAN
Cause Effect

MACHINE METHOD

1. PIPE LEAK, FLOW NOT PROPER 1. WELDING DONE WITHOUT FIXTURE

2. NOZZLE CAP DAMAGE 2. OVER WELDING, INCORRECT POSITIONING
3. PART POSITION NOT FIX IN FIXTURE 3. NO WORK INSTRUCTION AVAILABLE
4. VOLTAGE CURRENT FLUCTUATION 4. LOT OF WELDING AT ONE PLACE
5. POOR QUALITY WELDING WIRE 5.OVER HEATING IN THE POWDER COATING PROCESS
6. WELDING FIXTURE CLAMP LOOSE 6. POWER FAILURE DURING WELDING
7. CONTACT TIP DAMAGE 7. NOT FOLLOWING STANDERED OPERATING PROCEDURE
8. WIRE FEED NOT SMOOTH
47
WELD
SPATTER
1.POOR QUALITY WELDING WIRE 1.PHYSICALLY POOR, ILL
2.PIPE CUTTING NOT PROPER 2.LACK OF INTREST
3.PRESENCE OF OIL, DUST 3.PRODUCT AWARNESS, LESS SKILL CONFIDANCE
4. PIPE HERD/SOFT DUE TO CHEMICAL COMPOSITION 4.CHANGING IN WELDING PARAMETERS
5.EXTERNAL DISTRACTION
6.PART MISSING
7.POOR JUDGEMENT, STRESS, FATIGUE
8.CARELESS OPERATOR
9.NO FIXED POSITION
MATERIALS MAN
MACHINE METHOD

1. WIRE SPEED,WIRE FEED 1. WELDING DONE WITHOUT FIXTURE

2. NOZZLE CAP DAMAGE 2. OVER WELDING, INCORRECT POSITIONING
3. IMPROPER GAS FLOW 3. NO WORK INSTRUCTION AVAILABLE
4. VOLTAGE CURRENT FLUCTUATION 4. LOT OF WELDING AT ONE PLACE
5. BURR ON EDGES 5.OVER HEATING IN THE POWDER COATING PROCESS
6. WELDING FIXTURE CLAMP LOOSE 6. POWER FAILURE DURING WELDING
7. CLENING CLAMPING 7. NOT FOLLOWING STANDERED OPERATING PROCEDURE
8. PART POSITION

BLOW
HOLES
1.PIPE LENGTH SHORT/LONG 1.PHYSICALLY POOR, ILL
48
2.PIPE THICHNESS LESS/MORE 2.LACK OF INTREST
3. PIPE HERD/SOFT DUE TO CHEMICAL COMPOSITION 3.PRODUCT AWARNESS, LESS SKILL CONFIDANCE
4.PIPE CUTTING NOT PROPER 4.CHANGING IN WELDING PARAMETERS
5.BRACKET NOT AS PER DRAWING 5.EXTERNAL DISTRACTION
6.PRESENCE OF OIL, DUST 6.PART MISSING
7.TWIST CHILD PART 7.POOR JUDGEMENT, STRESS, FATIGUE
8.CARELESS OPERATOR

MATERIALS MAN