Over the past few years, several extensions of the traditional control charts have been proposed to adapt to the fuzziness inevitably existing in practical manufacturing processes. This paper proposed a fuzzy u chart to monitor the nonconformity of industrial products. A thorough evaluation of manufacturing conditions was also developed with certain categorization rules which can classify the process into four consequences, including in-control, rather in-control, rather out-of-control and out-of-control. With an empirical study of monitoring the weld discontinuities, our proposed approach can efficiently provide more sufficient and justified classification results in contrast with the traditional online processes monitoring methods.