Are You Ready for a Welding Quality Audit? 12 Checks for Welding Procedures, Material Traceability and Inspection Compliance

1. The WPS Available at the Shop Floor Is Outdated
The Welding Procedure Specification (WPS) defines the applicable welding instructions and parameters. An auditor may identify a concern when production personnel use an outdated revision, an uncontrolled printout, or a WPS that does not cover the welding activity being performed.
Manufacturers should verify that:
∙The current approved WPS is available at the point of use.
∙The applicable WPQR reference is identified.
∙Production parameters remain within the specified limits.
∙Changes are reviewed and authorised.
∙Obsolete revisions are withdrawn from use.
The WPS should reflect the qualified procedure and the applicable production requirements.

2. The WPQR Does Not Cover the Actual Production Conditions
A Welding Procedure Qualification Record (WPQR) demonstrates qualification under defined conditions and within a permitted range. Problems may arise when the production material, thickness, joint type, welding position, filler material, or process falls outside the applicable qualification range. Before an audit, manufacturers should compare actual production conditions with the WPQR and
the associated WPS. The assessment must follow the applicable standard and edition. Similarity between two welding
applications does not automatically establish that the same qualification covers both.

3. Welder or Welding Operator Qualifications Are Not Current or Applicable
Personnel qualifications must be appropriate to the work assigned. An auditor may examine whether the applicable qualification covers the welding process, product or material type, position, and other relevant variables. Continuity or validity requirements should also be checked where applicable. For mechanised and automatic welding, manufacturers should determine the applicable qualification requirements for welding operators and weld setters. A qualification register should identify the person, qualification scope, relevant dates, and any required continuity or renewal evidence.

4. Material Identification Is Lost During Production
Material traceability can become difficult when plates, pipes, sections, or other components are cut into smaller pieces and identification is not transferred correctly.
Potential warning signs include:
∙Missing material identification.
∙Material grades that do not match the drawing or purchase specification.
∙Incomplete links between material certificates and production items.
∙Unclear identification of material batches.
∙Records that cannot be connected to the finished product.
Manufacturers should establish traceability arrangements appropriate to the product, technical
requirements, and contract.
Where traceability is required, the material identification should remain reliable through cutting,
fabrication, welding, inspection, and final release.

5. Welding Consumables Are Not Properly Controlled
Incorrect consumable selection or unsuitable storage and handling can affect welding quality. During an audit, the manufacturer may need to demonstrate how consumables are received, identified, stored, issued, and handled. Depending on the consumable and applicable requirements, controls may include storage conditions, moisture protection, drying or rebaking instructions, batch identification, and shelf-life management. The selected consumable should correspond to the applicable WPS and production specification.

6. Welding Parameters Are Not Consistent With the Approved WPS
A WPS may be available, but production records can still show parameters outside its limits. Relevant variables may include current, voltage, wire-feed speed, travel speed, shielding gas, preheat, and interpass temperature, depending on the welding process and procedure. Manufacturers should establish how parameters are set, monitored, and recorded when required. If a deviation occurs, it should be evaluated according to the applicable technical requirements and  the manufacturer’s nonconformity process. A deviation should not simply be ignored because the completed weld looks acceptable.

7. Welding Coordination Responsibilities Are Unclear
Manufacturers should establish appropriate welding coordination arrangements according to their applicable requirements. Audit concerns can arise when responsibilities for WPS control, production monitoring, technical decisions, personnel qualification, and nonconformity evaluation are not clearly assigned.
The organisation should identify:
∙Who is responsible for welding coordination.
∙The authority assigned to that role.
∙How relevant technical decisions are reviewed.
∙How production deviations are escalated.
∙How applicable qualification and documentation requirements are monitored.
The required level of welding coordination depends on the relevant standard, product scope, and
contractual requirements.

8. Inspection Records Do Not Match Actual Production
Inspection documentation should accurately reflect the inspections performed. An auditor may identify a discrepancy if an inspection report refers to the wrong component, an incorrect drawing revision, an unidentified weld, or a test that cannot be linked to the production item. Manufacturers should verify that inspection and testing records contain the information needed to establish the status of the product. Depending on the requirements, records may include visual testing, dimensional inspection, non- destructive testing, repair verification, and final inspection.
Inspection methods and acceptance criteria should be defined by the applicable specification rather than selected retrospectively.

9. Welding Repairs Are Not Properly Documented
Weld repairs should be controlled rather than treated as informal production adjustments. Where required, the manufacturer should record the defect, its location, the repair method, the responsible personnel, and the results of reinspection. Repeated defects should be analysed to determine whether corrective action is needed. An audit may identify weaknesses when repaired welds cannot be traced to their original inspection results or when reinspection evidence is missing. A structured repair process helps establish that nonconforming work has been evaluated and corrected in accordance with applicable requirements.

10. Calibration and Equipment Maintenance Records Are Incomplete
Welding and inspection equipment may require calibration, verification, maintenance, or functional checks according to its intended use and applicable requirements. Examples include welding power sources, temperature-measuring instruments, dimensional
measuring equipment, and inspection instruments. Manufacturers should maintain relevant identification, status, due dates, and records. If equipment is found to be outside its required calibration or verification status, the organisation
should evaluate whether previous measurements or product acceptance decisions may have been affected. The appropriate response depends on the equipment, the nature of the issue, and the applicable quality arrangements.

11. Nonconformities Are Closed Without Verifying Effectiveness
An audit finding should not be considered fully addressed merely because a procedure has been revised or an employee has been informed. The organisation should identify the underlying cause, implement appropriate corrective action, and
determine whether the action has been effective. For example, repeated use of an outdated WPS may indicate a document-control weakness rather than an isolated operator error. Manufacturers should retain evidence of the problem, cause analysis, corrective action, and effectiveness review in accordance with the applicable management system.

12. Certification Scope and Customer Requirements Are Confused
A certification may cover a defined organisation, location, product scope, or manufacturing activity. It should not automatically be treated as approval for every customer or product. Railway OEMs and other major customers may have additional supplier qualification, drawing, inspection, traceability, or product-specific requirements.

Before accepting an order, manufacturers should confirm:
∙The applicable certification scope.
∙The product and manufacturing requirements.
∙Customer-specific technical specifications.
∙Required inspection and documentation.
∙Any separate supplier registration or approval.
∙The status and validity of relevant certificates.