This presentation provides practical guidance on how to increase the consistency of production flash welding operations, and drastically reduce the power requirements to operate the machine. Manufacturers performing production resistance flash welding are often plagued with inconsistent flashing performance, which leads to inconsistent upset repeatability and inconsistent welds. They also routinely encounter huge energy spikes from momentary shorting of the parts being welded and from the welding transformer being driven into saturation by irregular and unbalanced current patterns at the primary of the transformer. These phenomena cause severe flicker on the power lines, often resulting in the need to install very expensive dedicated high current feeds to satisfy local power company regulations. Learn how to control the flash welding process in a way that improves the flashing capability of the machine, prevent severe power surges from occurring, and control and monitor the upset repeatability of the machine.