What about your test coupons? I'm assuming you guys are running a bead on tube (BOT) to "coupon in" before beginning production for the day, and then you "coupon out" at the end of the shift (at least that was the drill when I was doing high-purity orbital welding) Are these test coupons of the same material thickness as your production materials? What I'm getting at is that my first guess would be your program isn't accounting for different material thicknesses encountered during production.