7 Critical WPS Mistakes That Cost Companies Thousands – Here’s How to Fix Them

In industries where welding plays a vital role, a Welding Procedure Specification (WPS) serves as the foundation for quality, safety, and compliance. Despite its importance, many companies overlook key details, leading to costly rework, project delays, or even safety hazards. Below, we highlight seven critical WPS mistakes that can drain resources and explain how to avoid them.

1. Poorly Defined Welding Parameters

A common mistake is failing to clearly specify essential variables such as voltage, current, travel speed, or filler material. When welders don’t have precise guidance, inconsistencies occur, increasing the risk of defects.

Fix: Ensure your WPS includes detailed, practical ranges for all parameters, and verify them through qualification tests.

2. Neglecting Preheat and Post-Weld Heat Treatment

Skipping or inaccurately recording preheat or post-weld heat treatment requirements often results in cracking or reduced durability of welds. This is especially critical in high-strength steels.

Fix: Document exact temperature requirements and enforce strict monitoring during welding operations.

3. Using Outdated or Unqualified Procedures

Some companies continue to rely on outdated WPS documents or use procedures that haven’t been formally qualified. This not only jeopardizes weld integrity but can also lead to failed audits.

Fix: Regularly review and update all WPS documents in line with the latest codes and standards. Ensure each procedure is supported by a valid PQR (Procedure Qualification Record).

4. Inadequate Welder Training and Awareness

Even the best WPS is useless if welders are not trained to follow it correctly. Many errors stem from welders not understanding or even seeing the WPS.

Fix: Provide clear training sessions, toolbox talks, and easy-to-read WPS copies at the job site. Encourage welders to raise questions before work begins.

5. Lack of Integration with Quality Control

Sometimes, the WPS is developed in isolation without aligning it with Welding Inspection requirements. This gap often leads to overlooked defects and higher rejection rates.

Fix: Involve your quality control team when drafting and qualifying the WPS to ensure inspections align with procedural requirements.

6. Ignoring Environmental Factors

Factors like humidity, wind speed, and ambient temperature directly affect weld quality, yet they are often ignored in the WPS. Outdoor welding, for instance, can easily lead to porosity if precautions are not listed.

Fix: Include environmental considerations and protective measures in your WPS, such as windshields, controlled environments, or consumable storage guidelines.

7. Overlooking Documentation and Traceability

Failure to properly control and distribute the WPS across projects can result in welders working with the wrong revision or missing critical updates.

Fix: Implement a robust document control system to track revisions and ensure only the latest WPS is available at the job site.

Final Thoughts

A well-prepared Welding Procedure is more than just paperwork—it is a safeguard against costly rework, safety incidents, and compliance failures. By avoiding these seven critical mistakes and implementing proper controls, companies can save thousands while ensuring their welding operations meet the highest standards of quality and reliability.