Bhuiyan, Reyan Hridoy and Khan, Sumaya Mahajabin and Aesha, Umme Habiba and Ayan, Yeasir Arafat (2025) Data-Driven Optimization of Resistance Spot Welding Processes for Advanced Manufacturing Quality and Industrial Reliability. American Journal of Engineering , Mechanics and Architecture (2993-2637), 3 (5). ISSN 2993-2637

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Abstract

Production changes can be challenging to ensure consistent production quality and operating conditions. The study is aimed at exploring the potential of an approach based on data to support process assessment and optimization through the application of resistance spot welding. 4,186 measurements from 495 welds and 13 variables (pressure, welding time, electrode angle, force, current, material thickness, pull strength, nugget diameter, Good, Bad, Explode) were analyzed using a quantitative exploratory analysis in R. Variation, quality, and defect patterns were explored using Boxplots, Scatter plots, Category comparisons, and a correlation heatmap. Welding time was identified as a factor that affected the pull strength and nugget diameter, and the categories showed variations with the time conditions. The results indicated unusual readings on the sensors, as well as repeated readings, which need to be interpreted carefully. Based on these results, the paper proposes a framework that links data preparation, process analysis, quality evaluation, and operating decisions. The framework is designed to help identify promising conditions, not a proven optimum. The findings show potential pathways for reducing waste and costs and minimizing production delays that merit investigation in practice, as they connect settings to quality outcomes. Recommendations need to be controlled, validated, and have better data quality before they are applied in production.

Item Type:	Article
Uncontrolled Keywords:	Production, Quality, Operating Condition, Process, Optimization, Data
Subjects:	H Social Sciences
Depositing User:	admin eprints
Date Deposited:	10 Oct 2026 05:01
Last Modified:	10 Oct 2026 05:01
URI:	http://eprints.umsida.ac.id/id/eprint/17170

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