Key fault examples: resistance checks, blowhole recovery, C-factor deviations, high/low current, tip dress faults, excessive adhesive squeeze-out, mislocated laser brazing seams, wire feed issues, remote welding cooling system failures, cover lens integrity. Optimize KUKA-based welding and joining systems using deep understanding of robot position, speed, motion profiles, and process dynamics to diagnose and correct issues such as expulsion, arcing, stick-out, tip wear, cooling inefficiencies, contamination, and inconsistent nugget formation, size, and location.