WELDER QUALIFICATION
AUDIT & COMPLIANCE GAPS
HOW TO STAY COMPLIANT
Welder Shortage: How Unqualified Welders Can Create Audit Risks in 2026
By First Welding Certification Technical Editorial Team
6 Min Read
01 Sep 2026
Table Of Contents
- Why a Welder Shortage Can Become a Compliance Risk
- Can an Unqualified Welder Perform Production Welding?
- What to Check Before Assigning a Welder
- How ISO 9606 and EN 15085 Fit Into the Problem
- Why WPS and WPQR Still Matter During a Welder Shortage
- What Manufacturers Can Do During a Welder Shortage
- Frequently Asked Questions
WELDER SHORTAGE: AUDIT RISK AT A GLANCE
The safety relevance of the welded component determines the certification level.
QUALIFICATION
Verify:
- Welding process
- Material
- Position
- Qualification range
PRODUCTION
Verify:
- Applicable WPS
- Correct assignment
- Welding parameters
- Production requirements
RECORDS
Maintain:
- Qualification records
- Continuity records
- WPS / WPQR
- Traceability
Why a Welder Shortage Can Become a Compliance Risk
A production order is due, but two qualified welders are unavailable. The remaining welders are already working overtime, and production needs another person on the welding line.
This is where the welder shortage becomes more than a recruitment problem.
As discussed in our article on the [global welder shortage], manufacturers are facing increasing pressure to maintain production while retaining appropriately qualified welding personnel.
When production teams respond by moving personnel between jobs, increasing overtime or assigning welding work to someone based only on experience, the risk can move directly into welding quality and audit readiness.
The important question is not simply:
“Can this person weld?”
It is:
“Is this person qualified for the welding work being performed?”
Can an Unqualified Welder Perform Production Welding?
Experience and qualification are different.
Even if a welder has worked for many years, he will need a particular qualification to perform that welding task. ISO 9606-1 provides for qualification through test condition and range of qualification, and not in such a way that one qualification covers all welding activities.
When assigning production tasks, the manufacturer needs to ensure that the qualification covers the welding process/material/position/range of application in question.
Therefore, for those manufacturers who are faced with a problem of lack of qualified people, ISO 9606 welder qualification is an important component of maintaining qualification coverage.
But the qualification alone does not constitute the whole of the control system. There must be an agreement between the qualification of the person and the production task.
What to Check Before Assigning a Welder
| Check | What to Verify |
|---|---|
| Qualification | Is the qualification current? |
| Welding process | Does it cover the process being used? |
| Material | Is the material within the qualified range? |
| Position | Is the required welding position covered? |
| WPS | Is the applicable welding procedure available? |
| Records | Can qualification and continuity records be demonstrated? |
This verification process becomes even more important when there is a pressure to deliver the products.
Another difference that needs to be understood is the one between a regular welder and a welding operator. When mechanized or automated welding is used, then the personnel qualifications may become different. We have discussed ISO 9606-1 vs ISO 14732 welder and welding operator qualification in detail in another article.
How ISO 9606 and EN 15085 Fit Into the Problem
Where ISO 9606-1 relates to the qualification of welders, EN 15085 sets requirements related to welding manufacturers dealing with railway vehicle construction and components.
A personnel qualification is only one of many requirements for EN 15085 manufacturer. Qualified personnel operate in a broader scheme related to welding coordination, procedures, inspection, traceability, and documentation.
It results in the following chain:
Qualified personnel -> Approved welding procedure -> Controlled production -> Inspection -> Traceability of records
In case the welder shortage affects any link in the chain mentioned above, it becomes difficult for the manufacturer to prove that production was done in accordance with the necessary control.
Therefore, EN 15085 certification becomes especially important for railway manufacturers to check the sufficiency of their personnel, procedures, and production controls.
Why WPS and WPQR Still Matter During a Welder Shortage
The qualifications of a welder do not eliminate the requirement for a controlled welding process.
The welding task has to be carried out according to the applicable WPS, along with the qualification of the procedure when necessary. In cases where people are moved around during a shortage, it is important for the manufacturer to check both aspects:
Is the person qualified?
Is the procedure right for the task?
That is why the WPS and WPQR can be reviewed along with personnel qualification regarding production readiness.
There should never be a shortage of welders that leads to a production team considering a person’s experience as an alternative to controlled welding processes.
What Manufacturers Can Do During a Welder Shortage
The situation of having no personnel to perform welding duties doesn’t necessarily need to become a compliance issue for the last minute. Here are some practical measures that manufacturers can undertake:
1. Maintain existing qualification coverage
Maintain an inventory of the number of welders, the welding process, material, position and qualification of each person.
2. Locate potential gaps
Identify the areas of production that are dependent on just one or two qualified persons.
3. Focus on qualification
If there is a need for additional persons, locate the actual production requirement and find the way of qualification.
4. Train additional qualified persons
Having more qualified personnel will lessen the dependence on just a few welders making production less susceptible to absence or changeover of staff.
5. Re-assess production controls
The qualification records, WPS, WPQR, inspection requirements and traceability must stay under control regardless of the production schedules.
If the manufacturer uses welding qualification framework, ISO 3834 welding quality requirements can also be taken into account when assessing personnel competence and welding production control process.
Frequently Asked Questions
How could a shortage of welders impact welding conformance?
A shortage could lead to overtime, reassignment and use of temporary personnel. Where qualification scope, procedure and record control is not adequately established, such situations could increase nonconformities.
Can an experienced, but unqualified welder carry out production welding?
Being experienced does not qualify a welder to perform any particular production welding activity. It is important to verify the qualification requirements and scope of production.
What are the potential risks of using an unqualified welder?
Some of the potential risks include qualification deficiency, problems with weld quality, rework, traceability difficulties and audit challenges.
What should manufacturers consider when assigning a welder?
Some of the considerations include qualification status of the welder, welding process, material used, position and applicability of the qualification range and requirements, WPS and production records.
Is there requirement for qualified welders under EN 15085?
EN 15085 has requirements that relate to qualified welders and welding operators in controlled railway welding production. The requirements that apply are dependent on the manufacturing company’s scope and welding activities.
How can manufacturers deal with a shortage of qualified welders?
Manufacturers can develop an understanding of their qualification coverage, identification of gaps, additional qualifications prioritization and cross-training.
Conclusion
A welder shortage becomes an audit risk when production pressure causes manufacturers to lose control over who performs which welding work.
The practical response is not simply to increase headcount. Manufacturers should match personnel qualifications to actual production requirements, maintain appropriate records and ensure that welding procedures and quality controls remain effective.
Where qualification gaps exist, establishing the appropriate ISO 9606 welder or welding operator qualification route before production begins can reduce the risk of avoidable compliance problems.
Ensure Your Welders Meet Qualification Requirements
Lack of welders may cause qualification gaps if production staff has to be reallocated fast. First Welding Certification Pvt Ltd offers certification services to manufacturers looking to keep qualified welding staff and satisfy welding requirements.
Before assigning production welding, make sure that the qualification, welding process, material, position, and applicable range of each welder are in line with the work performed.
Make sure your welding staff is qualified before production starts.