Press Panel &{ Nut, Mig ,Spot, Stud welding } Defects occurs during operation

S no {Press Panel defects} Nut welding Defects MIG Welding Defects Spot Welding Defects. Stud Welding defects.
1 Reciept Inspection of Raw Material 6. Restrike Operation Nut weding Fail MIG Welding broken Spot welding fail / Weak Stud welding failure
Appearance : Crack,thinning & necking Nut miss Sheet burn at mig welding area Double Part welded Shud welding position shift
Rust,dust,scratch mark,sheet tear Reverse Nut welded Weld Bead Miss Extra Spot welded
off,dent, damage etc Double part Weld puncture
Material as per Spec/ drg. Wrinkles/ Waviness Nut on wrong side Weld Bead Shift Child Part shift Stud Half weld
Sheet thickness , grade , coated/non Nut welded on wrong hole Weld Bead Short Child part miss
coated & HRC/CRC Overlaping/sheet folding Stud Miss
Dent ,Scratch mark Nut welding shift Weld Bead Exccess Spot miss Spatter on Stud threads
2 Blanking & Piercing Operation Operation by pass Nut Thread burn Under cut Spot Shift Spatter on Stud root
Wrong, grade/spec material used I D mark miss Nut thread Damage Excess spatter Spot Undulation Wrong Spec stud welded
Extra Nut welded Welding strength less Child Part welded in wrong
Trim burr/ hole burr Tool mark orientation Stud Thread damage
Child part welded on opposite
Nut Thread Miss Over welding
Blank short surface Stud alingment NG
Dent , Scratches & cut mark Oversize nut welded Deformation in part profile Wrong child part welded Weld burr or flash at root
under size nut weled Pin Hole/Blow hole Spot Burr/Spot Flash Stud length excess
7. Hole Punching Nut Half weld Penetration less Half Spot Stud length short
3 Draw Operation Hole burr Spatter in Nut threads Spot Burn Stud thread miss
Crack,thinning & necking dent deformation Used Nut Welded Spatter inside part stud thread burn
Double part Hole miss Spot Puncture
Wrinkles/Waviness Hole oversize
Overlaping/sheet folding Hole undersize
Dent ,Scratch mark Hole shift
Tool mark Slug jam
Profile NG Datum hole punch in last
Deformation Ovelty
Score mark Operation by pass
Trim short Part mix-up {WIP+FG}

8. Final Inspection
4 Bending/Forming Operation Appearance :

Crack,thinning & necking Burr,crack,sharp edge,rust, hole

miss,operation miss, dent damaged,flange
short,wrinkles,folding,
thinning,waviness,tool marks etc
Double part Dimension :
Wrinkles/Waviness Gap & trim as per spec.
Overlaping/sheet folding
Dent ,Scratch mark 9. Packing :
Tool mark Packing should be as per spec.
Profile NG No damage during transit.
Operation by pass

5 Trimming operation
Trim burr, Sharp edge
Flange mismatch at segment area
Flange short
Operation by pass
 Press Panel &{ Nut, Mig ,Spot, Stud welding } Defects occurs during operation
S no {Press Panel defects} Nut welding Defects MIG Welding Defects Spot Welding Defects. Stud Welding defects.
1 Reciept Inspection of Raw Material 6. Restrike Operation Nut weding Fail i) Nut Strength Within Spec MIG Welding broken 1.No Mig Welding Broken Spot welding fail / Weak 1.Spot Strength Within Spec Stud welding failure
Appearance : Crack,thinning & necking i) No Crack/V Crack. Nut miss ii) No Nut Missing Sheet burn at mig welding area 2.No Over Penetration/ Sheet Punc Double Part welded 2.No Spot Miss Shud welding position shift

Rust,dust,scratch mark,sheet tear
off,dent, damage etc
Material as per Spec/ drg.
Sheet thickness , grade , coated/non
coated & HRC/CRC
2 Blanking & Piercing Operation
Wrong, grade/spec material used
Trim burr/ hole burr
Blank short
Dent , Scratches & cut mark
3 Draw Operation
Crack,thinning & necking
Double part
Wrinkles/Waviness
Overlaping/sheet folding
Dent ,Scratch mark
Tool mark
Profile NG
Deformation
Trim short
4 Bending/Forming Operation
Raw Material required as per spec. Sheet Reverse Nut welded iii) No Reverse Nut Welded Weld Bead Miss 3.No Welding Bead Miss Extra Spot welded 3.No Extra Spot
Thickness OK,Material strength & chemical
Composition within spec.
No Appurtenance Defect.
(No Rust,No dust,No scratches marks,No dent
& No tape or paper stick.) Double part ii) Thinning Within Spec/ No Necking Weld puncture
Wrinkles/ Waviness iii) No Part Twist/ Rocking/ Waviness/ Fl Nut on wrong side iv) No nut welded on wrong side. Weld Bead Shift 4.No Welding Shift Child Part shift 4.No Spot Shift Stud Half weld
Nut welded on wrong hole v) No nut welded on wrong hole. Weld Bead Short 5.No Welding Bead Short Child part miss 5.No Spot Puncher
Overlaping/sheet folding iv) No Scratch Mark/Tool mark / Dent Stud Miss
Dent ,Scratch mark v) Bending height within specification. Nut welding shift vi) No Nut welding Position Shift Weld Bead Exccess 6.No under Cut Spot miss 6.No Spot Undulation Spatter on Stud threads
Operation by pass vi) No Component Shift/Bending Shift Nut Thread burn vii) No Nut Thread Burn/Damage Under cut 7.No Excess Spatter Spot Shift 7.No Spot Burrs/ Flash Allowed Spatter on Stud root
i) No Trim Burr I D mark miss vii) No Wrinkle/Sheet folding Nut thread Damage viii) No Extra nut welded Excess spatter 8.Proper Welding Bead/Over Weldi Spot Undulation 8.No Child Part Miss. Wrong Spec stud welded
Child Part welded in wrong
Extra Nut welded ix) No nut thread miss Welding strength less 9.Deformation in Part 9.No Child Part Shift
ii) No Blank/Trim Short Tool mark viii) No ID Mark Miss orientation Stud Thread damage
Child part welded on opposite
Nut Thread Miss x) Nut Size Within Specification. Over welding 10.No Blow Hole/Pin Hole 10.No Half Spot
iii) No Blank/Trim Excess ix) ID mark Readable/No Damage/No Digit m surface Stud alingment NG
iv)No Scratch Mark/Tool mark / Dent/Cut Oversize nut welded xi) No Half nut weld Deformation in part profile 11.No Less Penetration/Less streng Wrong child part welded 11.No Spot Burn
mark x) No Operation Missing Weld burr or flash at root
v) Material Grade & Thickness As per under size nut weled xii) No Spatter in nut thread Pin Hole/Blow hole 12.No Press Operation Miss. Spot Burr/Spot Flash 12.No Spatter inside Part
Specification
vi) No Hole Missing Nut Half weld xiii) No Used nut welded Penetration less 13.No Rod Shift Half Spot 13.Child Part
vii) No Operation Missing Spatter in Nut threads 14.No Child Part Shift Spot Burn Orientation as per Drawing
Used Nut Welded 14.No Child Part Miss Spatter inside part 14.No Child Part welded on opposite surface.
Spot Puncture 15.No Double Child Part Welded.
16.No Wrong Child Part Welded.
17.No Press Operation Miss Part Welded
7. Hole Punching Stud length short
Hole burr a) In Plant : Stud thread miss
i) No Crack/V Crack. dent deformation i) No Hole/Slot Burr. stud thread burn
ii) Thinning Within Spec/ No Necking Hole miss ii) No Dent Deformation
iii) No Part Twist/ Rocking/ Waviness/ Flatne Hole oversize iii) No Hole/Slot Miss
iv) No Scratch Mark/Tool mark / Dent Hole undersize iv) Hole/Slot Size Within Specification
v) Draw height within specification. Hole shift v) No Hole/Slot Shift.
vi) No Component Shift/Draw Shift Datum hole punch in last vi) No Ovality
vii) No Wrinkle/Sheet folding Ovelty vii) No Operation Missing
viii) Material Grade & Thickness As per Specific Operation by pass
ix) No Operation Missing Part mix-up {WIP+FG}
8. Final Inspection
Appearance :

Crack,thinning & necking i) No Crack/V Crack. Burr,crack,sharp edge,rust, hole

miss,operation miss, dent damaged,flange
short,wrinkles,folding,
thinning,waviness,tool marks etc No Defect Out flow from Final Inspection
Double part ii) Thinning Within Spec/ No Necking Dimension :
Wrinkles/Waviness iii) No Part Twist/ Rocking/ Waviness/ Flatne Gap & trim as per spec.
Overlaping/sheet folding iv) No Scratch Mark/Tool mark / Dent
Dent ,Scratch mark v) Forming height within specification. 9. Packing :
Tool mark vi) No Component Shift/Flange Shift Packing should be as per spec. i) No Dusty or Rusty part
Profile NG vii) No Wrinkle/Sheet folding No damage during transit. ii) nvoice Qty vs Bin Qty Vs Tag Qty Should Be match.
Operation by pass viii) No Operation Missing iii) Part should be keep in approved packaging Std.

5 Trimming operation
Trim burr, Sharp edge i) No Trim Burr
Flange mismatch at segment area ii) No Trim Short
Flange short iii) No Trim Excess
Operation by pass iv)No Scratch Mark/Tool mark / Dent/Cut mark
v)No Operation Missing