The primary goal of welding procedure specifications (WPSs) is to guarantee weld quality and consistency. By giving welders detailed instructions for depositing weld metal on specific joints, high-quality results are achievable. However, there’s a critical catch: welding procedures must be well-written and properly implemented. A poorly developed or executed welding procedure can be as detrimental, or even worse, than having no welding procedures at all, significantly impacting both product quality and shop productivity.

Welding procedures form the bedrock of any robust welding quality management system and adherence to welding quality standards. So, why do so many fabrication shops fall short when it comes to welding procedure conformance during audits? As experienced welding engineers, welding supervisors, and welding inspectors, we’ve identified 10 common reasons why shops struggle with their WPSs compliance, leading to failed audits. These reasons are not listed in any particular order.

Common Pitfalls Leading to Failed WPS Audits

1. Absence of Welding Procedure Specifications: Surprisingly, a significant number of fabricators still operate without formally written WPSs, despite their critical role in quality assurance and code compliance. This is a fundamental audit failure point.
2. WPS Not Accessible at the Workstation: Often, welding procedure development occurs solely to meet a customer or code requirement. Copies are then filed away, never reaching the welders on the shop floor. This forces welders to guess optimal welding parameters, making compliance impossible for auditors to verify.
3. Poorly Developed Welding Procedure: A poorly written WPS can lead to genuine welding issues like excessive spatter, an inconsistent arc, cold lap, or burn-through. When welders are forced to deviate from the written welding procedure to achieve an acceptable weld, they are in direct violation even though they may be improving the quality of weld. 
4. Faulty or Miscalibrated Welding Equipment: Even with a meticulously written WPS detailing tight ranges for variables like amperage and voltage, malfunctioning or uncalibrated equipment can prevent welders from adhering to the procedure. For example, voltage drops not reflected on the machine’s display can lead to non-conforming welds and immediate audit findings.
5. Unrealistic Productivity Demands: Every fabrication shop aims for efficiency. A welding procedure inherently dictates the maximum weld metal deposition rate, which directly impacts welder productivity. If shop management pushes for speeds beyond what a WPS allows, welders are often compelled to make changes that violate welding parameters, creating an audit risk.  
6. Disregard for Procedure Based on “Experience”: Sometimes, experienced welders believe their personal methods are superior to the established welding procedure. While their intentions might be to improve the weld, deviating from a WPS is a direct non-conformance. Auditors look for strict adherence to procedures, especially those tied to codes like AWS D1.1 Structural Welding Code – Steel and other structural welding codes which have critical heat input requirements.
7. Complacency Due to Lack of Prior Failures: When new WPS documents are implemented, welders who have never experienced a weld failure using their own, often unapproved, methods may simply ignore the new procedures. This complacency is a ticking time bomb for an audit.
8. Lack of Management Enforcement: A very common issue is that WPS documents exist, but management hesitates to enforce them. This reluctance often stems from a heavy reliance on skilled welders or a fundamental lack of understanding of the welding process by leadership. Without clear enforcement, welding procedure conformance will inevitably suffer as they are seen by welders as merely a suggestion. 
9. Uncontrolled Changes to Essential Variables: Even if most WPS essential variables  (like wire feed speed, voltage, contact tip-to-work distance, travel and work angles) are followed, an unapproved change to an essential variable—such as weld progression (e.g., vertical down instead of vertical up)—constitutes a violation. Unless a separate WPS accounts for this, it will require WPS requalification according to the applicable code and impacts welder qualification.
10. Mismatch Between WPS and Equipment Capabilities: If a WPS specifies parameters (e.g., a certain current with a specific wire and CTWD) that the available welding equipment simply cannot achieve, the welder is forced to deviate. This highlights a critical oversight in the welding procedure development process or equipment maintenance that an auditor will quickly identify.

In many cases, it takes an external audit, the loss of a major contract, or even a catastrophic weld failure for management to fully grasp the importance of developing sound welding procedures and implementing them effectively throughout their shop. Don’t wait for such a costly event. Proactively review your welding procedures, if any, and critically assess how well they are being followed (or not) in your shop today. This proactive approach is key to weld troubleshooting and maintaining high weld quality.

Enhance Your Shop’s Welding Performance & Audit Readiness!

This post has highlighted critical aspects of welding procedures and weld quality that directly impact audit success. We aim to explain complex welding engineering concepts for all welding professionals, from welders and welding supervisors to design engineers and business owners.

Looking to refine your welding procedure development processes, ensure welding procedure conformance, or even master weld troubleshooting to avoid audit failures? We offer advanced guides and specialized resources unparalleled in the industry.

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