Spot Welding

Defect Data Bank

MARUTI SUZUKI INDIA LIMITED

Quality Assurance Business Vertical
 Contents

• Salient features

• Types of Defects - Spot Welding

• Defects Causes
 Contents

• Salient features

• Types of Defects - Spot Welding

• Defects Causes
Salient features :

1. Defect Data bank summarizes all spot welding defects and

their Possible Causes

2. This Document can used as :

I. Reference document to conduct PFMEA
II. Training module

3. Reference :
I. MSIL Line Defects : 2018-19, 2019-20 & 2020-21
II. MSIL Suppliers : JBML , Bellsonica , Caparo &
Nagata
 Contents

• Salient features

• Types of Defects - Spot Welding

• Defects Causes
Type of Defects in Spot Welding
S. No Type of Defects in Data Bank

1 Spot welding fail / Weak

2 Double Part welded

3 Extra Spot welded

4 Child Part shift

5 Child part miss

6 Child part welded on opposite surface

7 Spot miss

8 Spot Shift

9 Spot Undulation

10 Child Part welded in wrong orientation

11 Wrong child part welded

12 Spot Burr/Spot Flash

13 Spot Puncture

14 Half Spot

15 Spot Burn

16 Spatter inside part

 Contents

• Salient features

• Types of Defects - Spot Welding

• Defects Causes
1. Spot welding fail / Weak
S No Cause Sub Cause
Parameter Control

Process Parameters not as per Specification

(Weld current , weld time or other Para. out of Spec.)

1 Wrong Program used for Welding

(Single impulse welding Program used on Double Impulse designated Spot)

Fluctuation of Current during welding/Power failure

(If Robot does not stop due to current Fluctuation)

Non-Standard Electrode Tip Used for Welding

(Not as per the Specification or Requirement of Gun manufacturer)

Non-Standard Cutter Used for Tip Dressing

(Not as per the Specification or requirement of Electrode Tip)

Tip Dressing Frequency less

(Tip Dressing done after more spots than defined based on Trial/Inadequate Trial)

Tip Dressing By-Pass

Tip Dressing

(Leading to Mushrooming /Carbon Deposition etc.)

2 Malfunctioning of Cutter
(Chip Deposit on Cutter , Inadequate Tip dressing like Deformation of Tip Shape ,
Inadequate Removal of Carbon from Tip)
Tip Shape Deformation
(Leading to Spot Shape not as per spec like Tip Dressing not proper (round) due to lack
of Skill of Man Power)
Tip Replacement Frequency not adequate
(Max. Wear Out limit should be ~6mm , Set value >6mm)

Worn Out Tip Being used

Tip Calibration NG
(If Tip has not been cut as per required limit but the calibration Plate shows Ok , then
the NG Dressed Tip will be used Spotting)
1. Spot welding fail / Weak
S No Cause Sub Cause

Electrode Tip Temp High

(Water circulation Less in welding gun)

Electrode Tip Temp high

(Cooling Water temperature high: Inadequate Capacity of Cooling Tower)
Welding Gun Related

Electrode Tip Temp High

(Non Standard Tip Design may lead to Water not reaching adequately to the Tip)

3 Electrode Force Less

(Due to less Air Pressure , Less Force Feed in the program)

Malfunction of Timer of Gun

Current Leakage due to Shunt Malfunction

Shunting of Welding Gun with Jig

Mix-up of Different Materials

Material Related

(Coated and Non-Coated Material : Parameters of Non Coated used Coated or Mix
up of Parts of different Tensile Strength)

4
Rust/Oil/Dust contamination on welding surface

Gap Between Parts

(Inadequate Current Flow due to Gap)
2. Double Part welded
S No Cause Sub Cause

Part with less sheet thickness Stick during Stacking

Material Related

Part Stick due to oil between Parts

1
Magnetic Separator Not available
Magnetic Separator not working Properly
(Less Strength of Separator : Inadequate Design leading to part not getting
separated)
Welding Jigs Sheet Thickness

Sheet Thickness Logic Not available

(To identify Double part or Part Miss)
Logic

2 Sheet Thickness Logic Malfunctioning

(Either the Tolerance considered is High, part thickness is less ~.6mm , Accuracy of
Gun is not adequate)

Sheet Thickness Logic by-pass

In case the Child part while welding becomes Blind
& Fixtures

(There is Possibility if Manpower is not adequately Trained)

3
Double part Welded during Fastener Welding
(Like during Nut welding)

3. Extra Spot
S No Cause Sub Cause

1 Programming Robot Program NG

(If Wrong variant selection , Variant with more Spot got Selected)

2 Material Variant Mix-up

(variant with More Spot mixed with Less Spots)
4. Child Part Shift
S NO Cause Sub Cause

PY Sensor Not available

(Inadequate PFMEA and Possibility of Shift not Installed)
Poya Yoke

PY Sensor Not Working

1 (PY Installed to Detect and Avoid Part Shift is not working)

PY Sensor Malfunctioning
(PY Installed to Detect and Avoid Part Shift is not robust)

Resting Pad Worn Out

(Resting part Worn out leads to Play in the Welding Jig and Thus Shifting)

Resting block Shift

(Resting Block Shifting like wrong Shim Adjustment)

Part Locating Pin Height less

Welding Jig Fixture

(May lead to part sitting on Pin or not adequate location as per locating Pin)

Locating Pin Miss/Loose

2 (locating pin Miss or Loose leads to inadequate Location of Child Part)

Locating pins worn out

(Worn out Pin gives provision for Play)

Rough Locator Not available

(Inadequate PFMEA : Rough locator to avoid Shifting not available)

Rough Locator Worn Out or Loose

(As worn out Locator/loose provides possibility of Shifting)
S NO Cause Sub Cause

Clamping inadequate less/Play in Clamp

(may lead to movement of Part and not keep child part at desired location)
Clamps

Inadequate Clamping of Part

3 (No possibility of the Large Pin/Clamp generally in cases like Child part under
Main Panel , Possibility of Gun Hitting)

Incomplete Stroke of Cylinder /Reed Switch

(Part does not get to required Position)
Parts Accuracy

Gap between resting myler and part (Leads to Play)

4
Part Matching Inadequate
(Main Panel may Lead to shifting of Small child Part during matching)

5. Child Part Miss

S No Cause Sub Cause

PY of Child part Not Available

PY of that child part Not Working/By-Pass

Poya-Yoke

PY Sensor malfunctioning
1 (Non Robust PY , can’t confirm Child part Presence /Absence with repeatability)

PY Sensor location inadequate

(Like Locating Pin Type sensor/PY Loose with Play may sense Main Panel/Pin
etc. instead of the Child part)

PY permanently high/on (spatter on PY sensors)

S No Cause Sub Cause
Inadequate PLC Linkage with PY
Programming (In PLC not linked to PY , then even in case of Child Part Miss , Robot and Jig
will Function)
2
Sheet Thickness Logic Not Working/By-Pass/Not
Available/Inadequate
(Sheet thickness logic to detect Part miss)

Part Fallen Down during clamping

Process Flow

(In Case the PY for Part Presence is on Clamp , so when the child part is mounted
on Clamp and PY signals JIG and Robot to function , But during Clamping if the
3 Part falls down then possibility of part miss is Generated)

Process flow not adhered

(Interlinkage which confirms the single piece flow of Material Maybe by-passed)
Related
Materi

4 Material Handling Inadequate

al

(May lead to Operation Miss or mix up of FG and WIP Parts)

6. Child Part Welded on opposite surface

S No Cause Sub Cause
Poka – Yoke & Sensors

PY Sensor Not Working/By Pass

(Sensor Provided to avoid the Child Part Loading on wrong surface Not
Working/By-Pass)

1 PY Sensor malfunctioning
(Sensor Provided to avoid Part Welding on wrong Surface Malfunction)

PY Sensor not Provided

(Inadequate PFMEA of Part and Fool Proofing to avoid welding on wrong surface
not provided)
Related

Inadequate PFMEA of Part

Jig

3 (Rough Guide/Mechanical PY not available To Avoid Welding on Wrong Surface)

7. Spot Miss
S NO Cause
Programming & Sub Cause

Wrong Variant Selection

(Variant With Less Spots being Run instead of Defined Spots)
Teaching

Wrong Program Selection :Modification in Program

Parts Produced in Weld off condition and Outflow

Weld Off

2 In case the Water flow decreases and Logic Indicates :

Weld Off and At same time spot is being Welded
(Logic Indicates : Weld Off and At same time spot is being Welded)
Related
System

3 Robot Run Manually for Cycle Completion

(During Break Down and Part without all shots might be produced)

Variant Mix-up
(Wrong Variant with lesser spots mix-up due to material Handling)
Material

4
In case of Excess Oil, Dust etc. & Alarm doesn't come
Operation

Operation Miss
Miss

5 (Operation By-Pass like offline Manual Spot Welding, Re Spotting Operation or

Other Operation)
8. Spot Shift
S No Cause Sub Cause
Programm

Teaching
ing &

1 Robot Program NG : wrong teaching/Variant mix-up

(during teaching , wrong teaching leading to Shifting of spot)
Welding

Electrode Alignment inadequate

Gun

2 Gun Fouling
(Gun hitting and may lead to minor shifting of Spot position)

Locating pins wear out

Jig & Fixtures

(Leading to Play in Part and Hence spot shift)

Jig Modification inadequate
3 (Like Spot template and May lead to wrong position of Spot)
No Adequate Jig/ Gauge available for Positioning of
part or due to untrained manpower
(Like manual Shop Welding on SSW etc.)

9. Spot Undulation
S No Cause Sub Cause
Electrode Alignment inadequate
Gun & Spot welding Gun Angle NG
1
Electrode
High gun pressure
( Leading to Excess Pressure on spot or hitting of Gun on Part)

2 Tip Dressing Tip Dressing not as per the requirement

3 Parts Accuracy Part Matching NG

10. Child Part Welded in Wrong Orientation
S No Cause Sub Cause

PY Sensor Not Working/By Pass

Poya Yoke & Sensors

(Sensor Provided to detect the Wrong orientation Child Part Loading Not Working/By-
Pass)

1 PY Sensor malfunctioning
(Sensor Provided to avoid the Wrong Child Part Loading Malfunction)

PY Sensor not Provided

(Inadequate PFMEA of Part and Fool Proofing to avoid Wrong orientation not
provided)
Teaching

Inadequate PLC Linkage with Part Clamping Sequence

2 program inadequate/wrong/Not Provided
(Wrong Overlapping of Part)

No Provision to avoid Wrong Orientation

Welding Jigs & Fixtures

(Inadequate PFMEA/Jig Design Rough Locator Not Provided in welding jig/fixture to

avoid Wrong Orientation)

Mix up of Similar Child Parts may lead to Wrong

3
Orientation part
(If Failure mode not considered during PFMEA)

Guide Block Shape Inadequate

(Not restricting the Possibility of Wrong Orientation of Child Part)
11. Wrong Child Part Welded
S No Causes Sub Causes

PY Sensor Not available

Poka – Yoke & Sensors

(Due to inadequate PFMEA : PY to avoid or sense wrong/similar child part is

not available)

1 PY Sensor Not Working/By Pass

(PY to avoid or sense wrong/similar child part is By-Pass)

PY Sensor malfunctioning
(PY to avoid or sense wrong/similar child part is Malfunctioning)

Guide block design inadequate

(Inadequate jig Design i.e Design can not avoid welding of similar child part )
Jig & Fixtures

Rough Locator not available in welding jig/fixture

2 (Rough Locator to avoid Wrong Child part/Similar Child Part is not being
welded)

Other : Inadequate PFMEA study

(Possibility of Similar part is not being considered during PFMEA)

Material Handling of Child Part

Material

(Mix-up of Child Part or variant as whole)

3
Wrong variant Selection
(Wrong Variant Selection can lead to wrong Child part Welded)
12. Spot Burr/Spot Flash :
S No Causes Sub Causes

1 Process Parameters High Current parameter used

Electrode Alignment inadequate

2 Gun & Electrode Spot welding Gun Angle inadequate

High gun pressure

3 Tip Dressing Tip Dressing inadequate

(Leading to Tip shape inadequate)

4 Part Accuracy Part Matching inadequate

(Gap Between Parts)

13. Spot Puncture

S No Causes Sub Causes
1 Process Parameters High Current
2 Gun & Electrode Electrode Force More/Less
3 Tip Dressing Tip Dressing NG
4 Part Accuracy Part Matching NG(Gap Between Parts)
5 Others Rusty/Oily part
14. Half Spot
S No Causes Sub Causes

1 Teaching Inadequate teaching

(Spot Shift during Teaching /Spot on Flange)

Electrode Alignment inadequate

2 Gun & Electrode
Spot welding Gun Angle NG

3 Tip Dressing Tip Dressing inadequate

(Face of Tip dressed in Taper)
Flange Short/Part Shift

4 Part Accuracy Damaged Part Loaded in welding jig

Part Matching NG

15. Spot Burn

S No Causes Sub Causes
1 Process Parameters High Current
Electrode Alignment NG
2 Gun & Electrode spot welding Gun Angle NG
High gun pressure
3 Tip Dressing Tip Dressing NG
4 Teaching Double spot at same location
5 Part Accuracy Part Matching inadequate
16. Spatter Inside Parts
S No Causes Sub Causes

High Current in process parameters

(Leading to Spatter)
1 Process Parameters
Variation in process parameters
(Leading to Spatter)

Spot welding Gun Angle NG

2 Gun & Electrode Spot Welding Gun Electrode Alignment NG

Inadequate gun pressure

3 Tip Dressing Tip Dressing inadequate

4 Part Accuracy Gap between Parts

5 Jigs & Fixtures No Covering Available

(Box type area/Matching Area/Fastener welding or other areas)

Oil, rust, dirt present on parts.

6 Others
In case there are Spatters and Likes of
Fastners etc. are without Covering
Thank You