Weld quality control system — implementation case study

Computer-aided weld quality control for an automotive chassis manufacturer

The production quality control system we built answered our client's need to simplify the weld inspection procedure required by the standards in force at their factory. Developed to order, the software is a comprehensive solution with a high degree of task automation. It reduced the work of inspection-station staff to the essentials – verifying the correctness of welds in the chassis components produced at the plant and entering the relevant information into the quality-control system. The solution consists of two closely integrated modules: the first runs the inspector's workstation, the second is a tool for managing the quality-control process.

The inspection application is operated entirely with a wireless barcode scanner. The operator logs in by scanning their individual ID from an employee card, then enters the number of the part being inspected, indicates the type of any detected defect, and saves the data – all through commands encoded in barcodes printed on dedicated sheets. This maximised comfort and safety in the demanding conditions of a welding hall.

The inspection procedure runs by displaying, on an industrial panel PC, an image of the part being inspected with all assessed welds marked. The operator checks each joint – if a fault occurs, they scan the barcode matching the defect type from the sheet, and it is automatically logged by the system, with no additional steps required. The system uses wireless barcode scanners built for harsh environments. The Motorola Solutions DS-3578-DPM model carries an IP65 rating, so it can be used reliably on the shop floor without risk of easy damage.

The second module manages the quality-control process. It gives full insight into a register of every action taking place on this section of the production line. Each defect detected by staff is stored in a database that can be browsed from within the system or exported to Microsoft Excel. The reports generated by the management software allow precise analysis of all errors and rapid root-cause investigation.

The quality-control system deployed at our client's plant brought far-reaching simplification of the whole process. The software supporting the final production stage increased the effectiveness of verifying the correctness of the chassis components produced. The process was significantly accelerated and the risk of errors minimised. The benefits are clear not only to management but also to line operators, who received an intuitive tool that genuinely makes their work easier.

Our client is an international manufacturer of structural components used in cars of many popular brands. The industrial system prepared by HDF was created for the operations of their Polish production plant.

Read more about our quality control system.

Screenshots of our software

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