The gas metal are (GMA) welding is one of the most widely-used processes in metal joining process that involves the melting and solidification of the joined materials. To solve this problem, we have carried out the sequential experiment based on a Taguchi method and identified the various problems that result from the robotic GMA welding process to characterize the GMA welding process and establish guidelines for the most effective joint design. Also using multiple regression analysis with the help of a standard statistical package program, SPSS, on an IBM-compatible PC, three empirical models (linear, interaction, quadratic model) have been developed for off-line control which studies the influence of welding parameters on bead width and compares their influences on the bead width to check which process parameter is most affecting. These models developed have been employed for the prediction of optimal welding parameters and assisted in the generation of process control algorithms.