Abstract: A welding wire consumption monitoring system includes a coupler mateable with a drive wheel of a welding wire feeder, a bracket attachable to the welding wire feeder, and a sensor mounted to the bracket and coupled to the coupler for detecting rotation of the drive wheel. The sensor is configured to generate one or more rotation signals and a controller is in communication with the sensor. The controller is configured to receive the one or more rotation signals, determine an available amount of wire based on the one or more rotation signals, compare the available amount of wire to a threshold amount of wire, and execute a corresponding response strategy.