A resistance weld tip mushrooms as it works. The contact face grows, current density falls, and the nugget gets smaller while every setting on the controller stays exactly where it was. This is the classic silent quality failure in body shops: the machine reports a good weld, the schedule was followed, and the joint is undersized.
The steps ChatterFix schedules for this PM. Every step is a checkable item on the work order — a technician can speak their way through it without touching a keyboard.
A resistance weld tip mushrooms as it works. The contact face grows, current density falls, and the nugget gets smaller while every setting on the controller stays exactly where it was. This is the classic silent quality failure in body shops: the machine reports a good weld, the schedule was followed, and the joint is undersized.
Undersized nuggets ship. They are invisible without destructive or ultrasonic testing, and they concentrate in whatever the tip was doing just before the change was due — which means the bad welds cluster in a window nobody can identify after the fact. Recall exposure on a structural joint is the reason this PM is counted in welds rather than days.
Weld count, always. Five thousand welds is a reasonable starting point for mild steel; coated and high-strength materials erode caps much faster and often run well under half that. The weekly calendar leg exists only so a low-volume cell still gets looked at.
This procedure — and every other PM for your industry — is already built into ChatterFix. Pick your industry and it lands on the right equipment, on the right interval, in about three minutes.