A virtual welding system comprising: a logic processor based subsystem operable to execute coded instructions for generating an interactive welding environment that emulates welding activity on a virtual weld joint defined by at least one of a welding coupon (175, 180) and a sample part; a virtual sequence controller operatively connected to the logic processor based subsystem for implementing a virtual sequence, the virtual sequence containing validation checks on parameters like part placement, travel speed, welding duration, average amperage and/or other welding variables; displaying means operatively connected to the logic processor based subsystem for visually depicting the interactive welding environment including the virtual weld joint; an input device for performing virtual welding activity on the virtual weld joint in real time; and a spatial tracker comprising one or more sensors adapted to track movement of the input device in real time for communicating data about the movement of the input device to the logic processor based subsystem; wherein the virtual sequencer is used by an operator before a weld sequencer is used to produce real assemblies by repeating the same welding sequence; wherein the virtual sequence includes a plurality of operations to be performed in order, each operation intended to achieve a particular state, wherein at least one of the operations is a manual operation to be performed by the user, wherein a manual operation is one of providing user information, retrieving a part, providing part information, placing a part, securing a part, and providing assembly information, wherein the virtual sequencer and the weld sequencer direct and/or monitor the welding operations; and wherein during real welding the weld sequencer uses the same welding sequence with the same requirements as the virtual sequence for successful completing a real assembly. a logic processor based subsystem operable to execute coded instructions for generating an interactive welding environment that emulates welding activity on a virtual weld joint defined by at least one of a welding coupon (175, 180) and a sample part; a virtual sequence controller operatively connected to the logic processor based subsystem for implementing a virtual sequence, the virtual sequence containing validation checks on parameters like part placement, travel speed, welding duration, average amperage and/or other welding variables; displaying means operatively connected to the logic processor based subsystem for visually depicting the interactive welding environment including the virtual weld joint; an input device for performing virtual welding activity on the virtual weld joint in real time; and a spatial tracker comprising one or more sensors adapted to track movement of the input device in real time for communicating data about the movement of the input device to the logic processor based subsystem; wherein the virtual sequencer is used by an operator before a weld sequencer is used to produce real assemblies by repeating the same welding sequence; wherein the virtual sequence includes a plurality of operations to be performed in order, each operation intended to achieve a particular state, wherein at least one of the operations is a manual operation to be performed by the user, wherein a manual operation is one of providing user information, retrieving a part, providing part information, placing a part, securing a part, and providing assembly information, wherein the virtual sequencer and the weld sequencer direct and/or monitor the welding operations; and wherein during real welding the weld sequencer uses the same welding sequence with the same requirements as the virtual sequence for successful completing a real assembly. wherein the virtual sequence includes a plurality of operations to be performed in order, each operation intended to achieve a particular state, wherein at least one of the operations is a manual operation to be performed by the user, wherein a manual operation is one of providing user information, retrieving a part, providing part information, placing a part, securing a part, and providing assembly information, wherein the virtual sequencer and the weld sequencer direct and/or monitor the welding operations; and wherein during real welding the weld sequencer uses the same welding sequence with the same requirements as the virtual sequence for successful completing a real assembly.