Modern quality management believes that achieving specified product quality targets requires controlling and adjusting factors that affect process quality at every production step. Process quality must be achieved through operational quality and various management methods. Therefore, in quality management, operational quality must ensure process quality, which in turn ensures product quality. Therefore, achieving quality goals requires establishing an effective and user-friendly quality management system within the management system and applying this system throughout the entire manufacturing process.
1. Personnel-The Welding Operator Factor.
Different welding methods rely to varying degrees on the operator. For manual arc welding, the welder's skill and meticulous work attitude are crucial to ensuring weld quality. For various types of semi-automatic welding, the welder also controls the arc's movement along the weld joint. Welding quality can be directly impacted if the welder exhibits a lack of quality awareness, performs carelessly, fails to adhere to welding procedures, or possesses poor skills and unskilled techniques. The control measures for welding personnel are as follows:
(1) Strengthen the quality awareness education of welders on "quality first, user first, and the next process is also the user", improve the welders' sense of responsibility and meticulous work style, and establish a quality responsibility system.
(2) Conduct job training for welders regularly, master the process regulations in theory, and improve their operating skills in practice.
(3) Require welders to strictly implement the welding process regulations during the production process, strengthen self-inspection of the welding process and inspection by full-time inspectors.
(4) Seriously implement the welder examination system, insist on welders holding certificates before taking up their posts, and establish welder technical files. For the production of important or large welded structures, welders need to be considered more carefully. For example, the length of welder training, production experience, current technical status, age, length of service, physical strength, eyesight, attention, etc. should all be included in the assessment scope.
2. Mechanical - welding equipment factors. The performance stability and reliability of various welding equipment directly affect the welding quality. The more complex the equipment structure and the higher the degree of mechanization and automation, the greater the dependence of welding quality on it. Therefore, such equipment is required to have better performance and stability. Welding equipment must be inspected and tested before use, and a regular inspection system should be implemented for all types of welding equipment in service. In the welding quality assurance system, in order to ensure the quality of the welding process, the following points should be achieved for welding machinery and equipment:
(1) Regularly maintain, service and repair welding equipment, and conduct a trial run for important welding structures before production.
(2) Regularly calibrate various instruments on welding equipment, such as ammeters, voltmeters, gas flow meters, etc., to ensure accurate measurement during the production process.
(3) Establish a technical archive of welding equipment status to provide ideas for analyzing and solving problems that arise.
(4) Establish a responsibility system for welding equipment users to ensure the timeliness and continuity of equipment maintenance. In addition, full attention should be paid to the use conditions of welding equipment, such as requirements for water, electricity, environment, etc., the adjustability of welding equipment, the space required for operation, error adjustment, etc., to ensure the normal use of welding equipment.
3. Materials - Welding raw material factors. The raw materials used in welding production include base metal, welding materials (welding rods, welding wires, flux, shielding gas), etc. The quality of these materials is the basis and prerequisite for ensuring the quality of welding products. To ensure welding quality, the quality inspection of raw materials is crucial. In the early stage of production, that is, before feeding, the materials need to be sealed to stabilize production and stabilize the quality of welding products. In the welding quality management system, the quality control of welding raw materials mainly includes the following measures:
(1) Strengthen the factory acceptance and inspection of welding raw materials, and re-inspect their physical and chemical indicators and mechanical properties when necessary.
(2) Establish a strict welding raw material management system to prevent welding raw materials from being contaminated during storage.
(3) Implement a labeling operation system for welding raw materials during the production process to track and control the quality of welding raw materials.
(4) Select welding raw material suppliers and cooperative factories with high credibility and good product quality for ordering and processing, and fundamentally eliminate the occurrence of welding quality accidents. In short, the control of welding raw materials should be based on welding specifications and national standards, and their quality should be tracked and controlled in a timely manner, rather than just acceptance upon arrival at the factory while ignoring marking and inspection during the production process.
