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The paper summarises work which has been carried out to establish the sensitivity of the Alcan AVT weld-bonding system to manufacturing process variability. The robustness of the joint-line to factors such as panel fit-up, bondline thickness, adhesive fillet size and missing adhesive is discussed and their effects demonstrated. Manufacturing factors, such as pretreatment damage during part forming and the cure-cycle window for the adhesive, are considered and their effects on performance are indicated. Finally the effect of a series of manufacturing shortfalls and environmental factors have been put together in one experiment and the resulting strength and fatigue performance of bonded joints has been established.