The use of human resources in Gas Metal Arc Welding (GMAW) can cause defects, such as lack of penetration and uneven moldings due to the long distance between the blowpipe nozzle to the workpiece. The purpose of this study is to develop the distance monitoring applications, angle, and speed between nozzle and workpiece for GMAW by using an ultrasonic detection sensor system. The distance monitoring tool between the nozzle and workpiece for GMAW was developed based on the ADDIE model. Respondent included two experts of wiring and electronics, three experts of software and quality, and two experts in the mechanical field, selected by using purposive sampling methods. Monitoring tool developed using Arduino Uno programming technology. Besides, high-quality electronic components such as Ultrasonic HCSR04 and MPU6050 Gyroscopes are used. Based on the analysis, the whole application of distance monitoring, angle, and speed between the nozzle and workpiece for the GMAW can work well and suitable for GMAW with excellent ergonomic features that are easy to maintain and used. The study results will provide benefits in the welding industry as it can reduce defects in GMAW, and thus saving the cost of welding errors.
