6.

ROOT CAUSE ANALYSIS

6.1 WHAT IS BRAINSTORMING?
Brainstorming can be a very successful to map out problems and search for viable
solutions. However, managing a brainstorm sessions is the number one way to
make or break the session. In this article you will get to know the dos and donts of
managing a brainstorm session.
6.2 OVERALL CAUSES OF WELDING DEFECTS IN 4 Ms
DUE TO MACHINE
1. Improper feeding of liner (welding wire).
2. Bend in the wire
3. Variation in Gas flow rate.
4. Due to nozzle dust.
5. Delay in feeding wire.
6. Oil leakage in clamp that holds the web.
7. Gas mixture composition in cylinder (rare).
8. Mismatch of wire feed and gas supply during welding.

DUE TO MATERIAL
1. Due to presence of oil on the surfaces of either rim or web.
2. Improper planishing on web or rim.
3. Surface defect on rim.

DUE TO MAN
1. Calibration of material
2. Lack of Hourly parameters inspection.
3. Fatigue error
DUE TO METHOD
1. Increase the speed of the welding , to reduce the welding time and increase
the production
6.3 FACTORS RESPONSIBLE FOR DEFECTS
Factors responsible for Pin blow hole and blow holes are
1)
2)
3)
4)
5)
6)
7)

Variation in gas composition.

Irregular supply of gas.
Inclusion of foreign bodies.
Presence of oil in the rim or web.
Leakage of lubricating oil on to the weld area.
Moisture content in the gas that is being supplied.
Humidity of the atmosphere.

Factors responsible for Start weld

1) Delay in fusion.
2) Insufficient starting voltage.
3) Providing excessive Dwell time.
Factors responsible for Intermittent Weld
1)
2)
3)
4)
5)

Irregular wire feeding.

Fluctuation in voltage.
Error in transformer.
Dust in liner.
Dust in contact tip.

Factors responsible for Incomplete weld

1) Completion of weld wire in midway of welding operation.
2) Stucking of welding wire

6.4 CAUSE AND EFFECT RELATION-SHIP DIAGRAM

MATERIA

MAN
Calibration
of material

Due to
Presence of oil
in rim or web

Lack of Hourly
Inspection
Parameter
Fatigue Error

Improper Feeding
of welding wire
Due to Nozzle
Dust
Oil leakage
in the
Clamp

Improper
Planishing of
rim or web
Surface defect
on rim or web

Age
Factor

Variation
in gas flow
rate
Delay in
Increasing
Feeding
speed of weld
wire

Mismatch of gas
supply and wire feed
during welding

MACHI

METHOD

7. SUGGESTIONS AND COUNTER MEASURES

Weld
Defec
ts

To overcome some of the problems that encounter the weld defect we have some
suggestion.
Ring sensor is being installed for governing the availability of welding wire. This
ring senses the presence of wire in it at alarms when wire doesnt pass through its
passage. By providing this sensor we can lessen the incomplete weld defect jobs.
Till now, It is installed for only vital few machines. We propose to implement the
ring sensor to all other machines. This will also leads to reduce the defect rate

For cleaning the liner which is provided for the passage of weld wire a
provision can be attached before the feeder unit. A T-joint can be utilized before
joining to the feeder unit, such that the weld wire passes through this joint with a

third passage open for the inlet of pressurized air along with thinner. A small spray
gun can be used for accomplishing this process. The thinner sprayed here should be
cleaned before entering into the feeder unit thus we can provide an asbestos
cleaning ring before we pass it through feeder unit.

For cleaning the liner after the feeder unit that is in order to clean the liner
placed in the torch, we can inculcate an inlet passage for supplying pressurized air
in the gas inlet pipe. Here we cannot use thinner for cleaning the liner because it
might account for a defect in the weld area. We need an alternate supply of air and
gas so we use a solenoid valve to do this operation. This provision also cleans the
nozzle from inside and also cleans the rim holding clamp.