A method for manufacturing a projection weld connection between at least two parts of a workpiece, where the workpiece remains blemish free, comprising automated real-time verification of the quality of the individual weld, without use of destructive testing by analysis of data from a force sensor is disclosed. Measurements of the quality of each weld can be calculated, and real-time measurements and calculations can be used to verification of the structural integrity of the projection in the workpiece before the welding current is applied in order to avoid further damage to the workpiece. The method may be implemented in a system comprising, among other features, a displacement sensor.