| Peer-Reviewed

Quality Requirements and Conformity of Welded Products in the Manufacturing Chain in Welding Network

Received: 2 October 2015    Accepted: 15 October 2015    Published: 30 October 2015
Views:       Downloads:
Abstract

The objective of this study is to examine the manufacturing and conformity of welded products and the significance of co-operation of different functions to welding quality. This study focuses on costs arising from nonconformity from the manufacturing perspective. It briefly discusses unnecessary costs, claim costs and warranty costs in the production chain. It furthermore takes an overview of challenges in welding manufacturing in the engineering field with empirical research in the industry and shows that failures and defects are identifiable and known in companies but very rarely the root cause of imperfections is investigated. The requirements from manufacturing go unrecognized at the many levels of organisation. One of the main obstacles to improving welding functions is the lack of co-operation and knowledge of the demands on welding. This can cause continuous nonconformity in products and in welding manufacturing. The observations have been collected from welding networks in engineering workshops where GMAW welding is a commonly used process. The results provide a framework for future research to define the importance of actions of different functions to the quality and costs of manufacturing.

Published in International Journal of Mechanical Engineering and Applications (Volume 3, Issue 6)
DOI 10.11648/j.ijmea.20150306.12
Page(s) 109-119
Creative Commons

This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited.

Copyright

Copyright © The Author(s), 2024. Published by Science Publishing Group

Keywords

Welding Manufacturing, Welding Network, Product Conformity, Welding Quality, ISO 3834, Welding Production

References
[1] X. Tang and H. Yun, Data model for quality in product lifecycle, Computers in industry, 59 (2–3), 2008, pp. 167–179. doi: 10.1016/j.compind. 2007. 06. 011.
[2] D.N.P. Murthy and K.R. Kumar, Total product quality, International Journal of Production Economics, vol. 67 (3), 2000, pp. 253–267. doi: 10.1016/S0925-5273(00)00026-8.
[3] J. Freiesleben, J, Proposing a new approach to discussing economic effects of design quality, International Journal of Production Economics, vol. 124 (2), 2010, pp. 348–359. doi: 10.1016/j.ijpe.2009.11.030.
[4] ISO 9000:2005. Quality management systems. Fundamentals and vocabulary, International Organization for Standardization.
[5] P. Kah and J. Martikainen, Current trends in welding processes and materials: improve in effectiveness, Reviews on Advanced Materials Science, vol. 30, 2012, pp. 189–200.
[6] D.N. Shackleton, Reducing failure risk in welded components, Welding in the World, vol. 50 (9–10), 2006, pp. 92–97. doi: 10.1007/BF03263449.
[7] J. Váncza, L. Monostori, D. Lutters, S.R. Kumara, M. Tseng, P. Valckenaers and H. Van Brussel, Cooperative and responsive manufacturing enterprises, CIRP Annals - Manufacturing Technology, vol. 60 (2), 2011, pp. 797–820. doi: 10.1016/j.cirp.2011.05.009.
[8] V. Nosenzo, S. Tornincasa, E. Bonisoli and M. Brino, Open questions on Product lifecycle Management (PLM) with CAD/CAE integration, International Journal on Interactive Design and Manufacturing, vol. 8, 2014, pp. 91–107. doi: 10.1007/s12008-013-0184-1.
[9] F. Pan and R. Nagi, Multi-echelon supply chain network design in agile manufacturing, Omega, vol. 41 (6), 2013, pp. 969–983. doi: 10.1016/j.omega.2012.12.004.
[10] G. Xie, W. Yue, S. Wang and K.K. Lai, Quality investment and price decision in a risk-averse supply chain, European Journal of Operational Research, vol. 214 (2), 2011, pp. 403–410. doi: 10.1016/j.ejor.2011.04.036.
[11] W. Wang, R.D. Plante and J. Tang, Minimum cost allocation of quality improvement targets under supplier process disruption, European Journal of Operational Research, vol. 228 (2), 2013, pp. 388–396. doi: 10.1016/j.ejor.2013.01.048.
[12] R. Jiang and D.N.P. Murthy, Impact of quality variations on product reliability, Reliability Engineering and System Safety, vol. 94 (2), 2009, pp. 490–496. doi: 10.1016/j.ress.2008.05.009.
[13] J. Toivanen, J. Martikainen and P. Heilmann, From supply chain to welding network: A framework of the prospects of networks in welding, Mechanika, vol. 21 (2), 2015, pp. 154–160. doi: 10.5755/j01.mech.21.2.8463.
[14] D.K. Miller, Cost of Welding, Welding Design and Fabrication, vol. 3, 2004, pp. 32–37.
[15] W.C. LaPlante, How to Assure Quality in Outsourced Welded Products, Welding Journal, vol. 90 (10), 2011, pp. 42–46.
[16] F. Giudice, F. Ballisteri and G. Risitano, A Concurrent Design Method Based on DFMA-FEA Integrated Approach, Concurrent Engineering, vol. 17 (3), 2009, pp. 183–202. doi: 10.1177/1063293X09343337.
[17] T. Tomiyama, P. Gu, Y. Jin, D. Lutters, C. Kind and F. Kimura, Design methodologies: Industrial and educational applications, CIRP Annals - Manufacturing Technology, vol. 58, 2009, pp. 543–565. doi: 10.1016/j.cirp.2009.09.003.
[18] D. Dewhurst, Design First, Lean Second, Assembly, 2011, pp. 62–68.
[19] D. Hegland, DFMA Cuts Downstream Costs, Assembly, vol. 51 (6), 2008, 43–49.
[20] R. Dekkers, C.M. Chang and J. Kreutzfeldt, The interface between ‘‘product design and engineering’’ and manufacturing: A review of the literature and empirical evidence, International Journal of Production Economics, vol. 144 (1), 2013, pp. 316–333. doi: 10.1016/j.ijpe.2013.02.020.
[21] J.R. Barckhoff, Total Welding Management, American Welding Society, 2010, pp. 1–6, 15–36.
[22] L. Liu, F. Zhu, J. Chen, Y. Ma and Y. Tu, A quality control method for complex product selective assembly processes, International Journal of Production Research, vol. 51 (18), 2013, pp. 5437–5449. doi: 10.1080/00207543.2013.776187.
[23] ISO 3834:2005. Quality requirements for fusion welding of metallic materials - Part 1–5, International Organization for Standardization.
[24] A. Kazaz, M.T. Birgonul and S. Ulubeyli, Cost-based analysis of quality in developing countries: a case study of building projects, Building and Environment, vol. 40 (10), 2005, pp. 1356–1365. doi: 10.1016/j.buildenv.2004.11.010.
[25] G. Casalino, S.J. Hu and W. Hou, Deformation prediction and quality evaluation of the gas metal arc welding butt weld, Proceedings of the Institution of Mechanical Engineers, vol. 217 (11), 2003, pp. 1615–1622. doi: 10.1243/095440503771909999.
[26] ISO 5817:2014. Welding - Fusion-welded joints in steel, nickel, titanium and their alloys (beam welding excluded) – Quality levels for imperfections, International Organization for Standardization.
[27] ISO 13920:1996. Welding – General tolerances for welded constructions. Dimensions for lengths and angles. Shape and position, International Organization for Standardization.
[28] ISO 14341:2010. Welding consumables – Wire electrodes and weld deposits for gas shielded metal arc welding of non alloy and fine grain steels. Classification, International Organization for Standardization.
[29] ISO 14175:2008. Welding consumables – Gases and gas mixtures for fusion welding and allied processes, International Organization for Standardization.
[30] ISO 8501-3:2006. Preparation of steel substrates before application of paints and related products - Visual assessment of surface cleanliness. Part 3: Preparation grades of welds, edges and other areas with surface imperfections, International Organization for Standardization.
[31] SFS 8145:2001. Anticorrosive painting. Quality grades of mechanical surface preparations for blast cleaned or blast-cleaned and prefabrication primed steel substrates, Finnish Standards Association SFS.
[32] B. Li, X. Yang, Y. Hu and D. Zhang, Quality design of tolerance allocation for sheet metal assembly with resistance spot weld, International Journal of Production Research, vol. 47 (6), 2009, pp. 1695–1711. doi: 10.1080/00207540701644193.
[33] M-Y. Liao, Economic tolerance design for folded normal data, International Journal of Production Research, vol. 48 (14), 2010, pp. 4123–4137. doi: 10.1080/00207540902960307.
[34] N.V.R. Naidu, Mathematic model for quality cost optimization, Robotics and Computer-Integrated Manufacturing, vol. 24 (6), 2008, pp. 811–815. doi: 10.1016/j.rcim. 2008. 03. 018.
[35] EN 10210-2:2006. Hot finished structural hollow sections of non-alloy and fine grain steels - Part 2: Tolerances, dimensions and sectional properties, European Committee for Standardization.
[36] EN 10219-2:2006. Cold formed welded structural hollow sections of non-alloy and fine grain steels - Part 2: Tolerances, dimensions and sectional properties, European Committee for Standardization.
[37] ISO 10799-2:2011. Cold-formed welded structural hollow sections of non-alloy and fine grain steels – Part 2: Dimensions and sectional properties, International Organization for Standardization.
[38] ISO 12633-2:2011 Hot-finished structural hollow sections of non-alloy and fine grain steels – Part 2: Dimensions and sectional properties, International Organization for Standardization.
[39] D.C. Li, Research on Quality Management of manufacturing Equipment Welding Technology, Applied Mechanics and Materials, vol. 192, 2012, pp. 415–419. doi: 10.4028/www.scientific.net/AMM.192.415.
[40] K.K. Castillo-Villar, N.R. Smith and J.L. Simonton, A model for supply chain design considering the cost of quality, Applied Mathematical Modelling, vol. 36 (12), 2012, pp. 5920–5935. doi: 10.1016/j.apm.2012.01.046.
[41] A.I. Pettersson and A. Segerstedt, Measuring supply chain cost, International Journal of Production Economics, vol. 143 (2), 2012, pp. 357–363. doi: 10.1016/j.ijpe.2012.03.012.
[42] D.H. Besterfield, Quality control, Prentice-Hall, Inc, 1994, pp. 405–406, 420–421.
[43] O. Staiculescu, A new vision of cost: an essential optimization tool for managerial accounting, Procedia - Social and Behavioral Sciences, vol. 62, 2012, pp. 1276–1280, May 2012 [World Conference on Business, Economics and Management (BEM-2012), Antalya, Turkey]. doi: 10.1016/j.sbspro. 2012. 09. 218.
[44] S. Kim and B. Nakhai, The dynamics of quality costs in continuous improvement, International Journal of Quality & Reliability Management, vol. 25 (8), 2008, 842–859. doi: 10.1108/02656710810898649.
[45] G. Giakatis, T. Enkawa and K. Washitani, Hidden quality costs and the distinction between quality cost and quality loss, Total Quality Management, vol. 12 (2), 2001, pp. 179–190. doi: 10.1080/09544120120011406.
[46] J. Vörös, The dynamics of price, quality and productivity improvement decisions, European Journal of Operational research, vol. 170 (3), 2006, pp. 809–823. doi: 10.1016/j.ejor.2004.08.001.
[47] P.G. Maropoulos, Z. Yao, H.D. Bradley and K.Y.G. Paramor, An integrated design and planning environment for welding Part 1. Product modeling, Journal of Materials Processing Technology, vol. 107 (1–3), 2000, pp. 3–8. doi: 10.1016/S0924-0136(00)00708-1.
[48] D.N.P. Murthy and I. Djamaludin, I, New product warranty: A literature review, International Journal of Production Economics, vol. 79 (3), 2002, pp. 231–260. doi: 10.1016/S0925-5273(02)00153-6.
[49] C. Hicks, O. Heidrich, T. McGovern and T. Donnelly, A functional model of supply chains and waste, International Journal of Production Economics, vol. 89 (2), 2004, pp. 165–174. doi: 10.1016/S0925-5273(03)00045-8.
[50] M. Shafiee and S. Chukova, Maintenance models in warranty: A literature review, European Journal of Operational Research, vol. 229 (3), 2013, pp. 561–572. doi: 10.1016/j.ejor.2013.01.017.
[51] M.R. Karim and K. Suzuki. Analysis of warranty claim data: a literature review, International Journal of Quality & Reliability Management, vol. 22 (7), 2005, pp. 667–686. doi: 10.1108/02656710510610820.
Cite This Article
  • APA Style

    Jenni Toivanen, Paul Kah, Jukka Martikainen. (2015). Quality Requirements and Conformity of Welded Products in the Manufacturing Chain in Welding Network. International Journal of Mechanical Engineering and Applications, 3(6), 109-119. https://doi.org/10.11648/j.ijmea.20150306.12

    Copy | Download

    ACS Style

    Jenni Toivanen; Paul Kah; Jukka Martikainen. Quality Requirements and Conformity of Welded Products in the Manufacturing Chain in Welding Network. Int. J. Mech. Eng. Appl. 2015, 3(6), 109-119. doi: 10.11648/j.ijmea.20150306.12

    Copy | Download

    AMA Style

    Jenni Toivanen, Paul Kah, Jukka Martikainen. Quality Requirements and Conformity of Welded Products in the Manufacturing Chain in Welding Network. Int J Mech Eng Appl. 2015;3(6):109-119. doi: 10.11648/j.ijmea.20150306.12

    Copy | Download

  • @article{10.11648/j.ijmea.20150306.12,
      author = {Jenni Toivanen and Paul Kah and Jukka Martikainen},
      title = {Quality Requirements and Conformity of Welded Products in the Manufacturing Chain in Welding Network},
      journal = {International Journal of Mechanical Engineering and Applications},
      volume = {3},
      number = {6},
      pages = {109-119},
      doi = {10.11648/j.ijmea.20150306.12},
      url = {https://doi.org/10.11648/j.ijmea.20150306.12},
      eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ijmea.20150306.12},
      abstract = {The objective of this study is to examine the manufacturing and conformity of welded products and the significance of co-operation of different functions to welding quality. This study focuses on costs arising from nonconformity from the manufacturing perspective. It briefly discusses unnecessary costs, claim costs and warranty costs in the production chain. It furthermore takes an overview of challenges in welding manufacturing in the engineering field with empirical research in the industry and shows that failures and defects are identifiable and known in companies but very rarely the root cause of imperfections is investigated. The requirements from manufacturing go unrecognized at the many levels of organisation. One of the main obstacles to improving welding functions is the lack of co-operation and knowledge of the demands on welding. This can cause continuous nonconformity in products and in welding manufacturing. The observations have been collected from welding networks in engineering workshops where GMAW welding is a commonly used process. The results provide a framework for future research to define the importance of actions of different functions to the quality and costs of manufacturing.},
     year = {2015}
    }
    

    Copy | Download

  • TY  - JOUR
    T1  - Quality Requirements and Conformity of Welded Products in the Manufacturing Chain in Welding Network
    AU  - Jenni Toivanen
    AU  - Paul Kah
    AU  - Jukka Martikainen
    Y1  - 2015/10/30
    PY  - 2015
    N1  - https://doi.org/10.11648/j.ijmea.20150306.12
    DO  - 10.11648/j.ijmea.20150306.12
    T2  - International Journal of Mechanical Engineering and Applications
    JF  - International Journal of Mechanical Engineering and Applications
    JO  - International Journal of Mechanical Engineering and Applications
    SP  - 109
    EP  - 119
    PB  - Science Publishing Group
    SN  - 2330-0248
    UR  - https://doi.org/10.11648/j.ijmea.20150306.12
    AB  - The objective of this study is to examine the manufacturing and conformity of welded products and the significance of co-operation of different functions to welding quality. This study focuses on costs arising from nonconformity from the manufacturing perspective. It briefly discusses unnecessary costs, claim costs and warranty costs in the production chain. It furthermore takes an overview of challenges in welding manufacturing in the engineering field with empirical research in the industry and shows that failures and defects are identifiable and known in companies but very rarely the root cause of imperfections is investigated. The requirements from manufacturing go unrecognized at the many levels of organisation. One of the main obstacles to improving welding functions is the lack of co-operation and knowledge of the demands on welding. This can cause continuous nonconformity in products and in welding manufacturing. The observations have been collected from welding networks in engineering workshops where GMAW welding is a commonly used process. The results provide a framework for future research to define the importance of actions of different functions to the quality and costs of manufacturing.
    VL  - 3
    IS  - 6
    ER  - 

    Copy | Download

Author Information
  • Laboratory of Welding Technology, Lappeenranta University of Technology, Lappeenranta, Finland

  • Laboratory of Welding Technology, Lappeenranta University of Technology, Lappeenranta, Finland

  • Laboratory of Welding Technology, Lappeenranta University of Technology, Lappeenranta, Finland

  • Sections