The purpose of the production and quality-assurance modules is to provide efficient digital tools for in-process traceability, documentation and verification of welded structures.
These calculators and supporting applications help maintain technology discipline, record production parameters, and meet qualification and traceability requirements.
By using the modules, production processes become more transparent, auditable and aligned with applicable standards, supporting the manufacture of quality products with appropriate documentation.
The system's interconnected modules follow the complete welding-documentation process: from preparation of a preliminary welding procedure specification, through procedure qualification and material testing, to the approved WPS. Personnel and equipment-management modules provide traceable records for employees, qualifications, test equipment and production machinery.
WPS Manager
Module for creating and registering preliminary and approved welding procedure specifications
WPS Manager is a continuously developed, easy-to-use document editor and register that supports preparation and management of welding-technology documentation through three main functions.
Fast preparation of preliminary welding procedure specifications
With built-in calculator and library modules, such as the base-material and welding-consumable databases, users can prepare preliminary procedure specifications quickly and efficiently.
Base materials can be selected from the Base Material Library or from data in the user's own ClientDB database. Welding consumables can likewise be loaded from the central Welding Material Library data set or from the company's own consumable register.
The document can manage, among other information:
- basic technology data;
- the welding processes used;
- base materials and welding consumables;
- joint design and weld geometry;
- welding sequence and welding position;
- process-specific welding parameters;
- preheating and interpass temperatures;
- post-weld heat treatment;
- shielding gases, fluxes and other process consumables;
- notes and supplementary data belonging to the document.
Tracking the WPS qualification workflow
Connected with WPQR Manager, the system provides tracking of WPS qualification status, supporting auditability and quality-management compliance.
A pWPS prepared in WPS Manager can be linked to its corresponding WPQR document. When the qualification process begins, the preliminary welding procedure specification can be locked so that the underlying technology data cannot be changed without control while testing is in progress.
Based on a successfully completed and approved WPQR, the related pWPS can become a final, approved WPS document.
Document storage and access
The software supports structured storage, search and reloading of pWPS and WPS documents in the user's ClientDB database.
Document state, identifier and relationships are traceable, making it clear whether a given WPS is preliminary, under qualification, approved, locked or withdrawn.
WPS Manager is developed with the requirements of the MSZ EN ISO 15609 series in mind. In addition to functions for common steel materials, the system is continuously expanded to support further material groups and welding processes.
WPQR Manager
Module for managing welding-procedure qualification workflows and documentation
WPQR Manager creates the link between the preliminary welding procedure specification, the actual qualification weld and the resulting material-test results.
A WPQR is not created as an isolated document. It is linked to the originating pWPS, the base materials and welding consumables used, technology parameters recorded during the qualification weld, heat-treatment data and the tests registered in M-Test Manager.
Linking pWPS and WPQR
A WPQR can be created from an existing pWPS or WPS document. Related technology data can be reused when preparing the qualification record, so the same information does not have to be entered repeatedly in separate systems.
When the qualification process is started, the linked pWPS can be locked. This ensures that the fundamental data of the technology being tested cannot change without control during the qualification weld and material tests.
Managing qualification-weld data
The actual conditions of the qualification weld can be recorded in the module, including:
- the welding processes used;
- base materials and welding consumables;
- test-piece dimensions;
- joint design;
- welding position;
- current, voltage and travel-speed data;
- heat input;
- preheating and interpass temperature;
- any post-weld heat treatment;
- notes important for production and testing.
Test results and approval
Tests recorded in M-Test Manager can be assigned directly to the WPQR document. The system summarizes the state of related tests and indicates if any test is incomplete, non-conforming or not yet closed.
The WPQR can be approved only when all required tests are available, none is incomplete and every test taken into account has been completed with an acceptable result.
After approval, the WPQR, its related tests and the associated WPS documents are placed in a protected state. This helps preserve the integrity of the data on which the qualification is based.
Qualification ranges
WPQR Manager supports review of the ranges covered by the qualification. The document can manage validity data related to material groups, thicknesses, diameters, welding processes, positions and other essential variables.
With Document Template Manager, several types of standardized WPQR records can be produced according to the qualification standard and document type used.
M-Test Manager
Material-test report management and documentation module
M-Test Manager is a continuously developed module for creating, organizing and traceably storing reports from industrial material tests.
The purpose of the module is to provide a user-friendly system that enables fast, standardized documentation of tests and digital traceability of the complete material-testing process.
Tests can be assigned directly to the related WPQR document. This allows procedure qualification and the test results on which the qualification is based to form a single traceable documentation chain.
Destructive tests
The module supports management of data from, among others, the following destructive tests:
- tensile testing;
- bend testing;
- Charpy impact testing;
- hardness testing;
- macroscopic examination;
- additional specimen and measurement data related to the document type.
For each test, specimen data, measured values, requirements, limit values and conformity results can be recorded.
Non-destructive tests
Depending on the supported document types, the register can include, among others:
- visual testing;
- radiographic testing;
- ultrasonic testing;
- magnetic-particle testing;
- penetrant testing.
Test states and conformity
The module separately manages tests that are in progress, incomplete, conforming and non-conforming. Measured results, limit values and the aggregated conformity state can be evaluated together.
WPQR Manager can use the current state of the tests directly when checking whether the qualification document may be approved.
Reports and document storage
Reports can be created using customizable templates, automatically generated data tables and printable reports, supporting quality-assurance requirements and auditability.
Document Template Manager can provide separate document templates for several test types, so different tests do not have to use a single general report format.
Employee Manager
Register of employees, qualifications and professional authorizations
For welding and quality-assurance tasks, it matters not only who is assigned to a job, but also whether that person holds the required valid qualifications.
Employee Manager handles employee master data, qualifications, certificates and authorizations in a shared register. It makes it quick to review which employees can be assigned to a specific task and which documents are approaching expiry.
Employee data
The module can manage, among other information:
- employee identification and contact data;
- job position and organizational role;
- employment and active status;
- notes related to work activities;
- documents belonging to the employee.
Qualifications and authorizations
Welder qualifications, professional qualifications, certificates and other authorizations can be assigned to employees. The system records their validity periods and helps identify documents that have expired or will expire soon.
Personnel data remains in the company's own ClientDB environment and, when needed, can be used in WPS, WPQR and qualification-check workflows.
Employee Manager for Lab
Management of laboratory competencies and test authorizations
A material-test result can be considered properly documented only if the test was performed by an authorized person, using suitable equipment and a valid procedure.
Employee Manager for Lab registers laboratory employees' testing competencies, qualifications and equipment-use permissions.
Testing competencies
For each test type, the module can define which employee:
- is authorized to perform the given test;
- is authorized to evaluate the results;
- holds a valid personal qualification;
- may use the equipment required for the test;
- requires renewal or further training.
Together with M-Test Manager and Inventory Manager for Lab data, EMPL provides the personnel side of laboratory traceability.
Inventory Manager
Complete lifecycle register for production tools and equipment
Inventory Manager is more than a simple inventory list. From acquisition and commissioning through maintenance and repairs to current condition, it makes it possible to track machines, tools and equipment used in production.
The module can register, among other information:
- the equipment's unique identification data;
- manufacturer, type and serial number;
- technical characteristics;
- site and current storage location;
- the employee responsible for the equipment;
- current technical and usability state;
- maintenance, repairs and inspections;
- related documents and notes;
- the next maintenance tasks due.
The module not only simplifies inventory management but also helps prevent equipment with an expired inspection or unsuitable condition from being used in production.
In the future, Welding Cost Calculator may also use Inventory Manager inventory and equipment data to check production resources and missing quantities.
Inventory Manager for Lab
Calibration and usability control for measuring and test equipment
For laboratory measuring equipment, merely having the device available is not sufficient. The validity of calibration or verification, the condition of the equipment, its measurement range and its suitability for the relevant test must also be demonstrated.
Inventory Manager for Lab manages these data in a shared, traceable register.
The module can record, among other information:
- identification data for the measuring or test device;
- manufacturer, type and serial number;
- measurement range and accuracy characteristics;
- calibration or verification status;
- date of the last and next inspection;
- calibration certificates;
- equipment usability state;
- storage location and responsible person;
- laboratory employees authorized to use the equipment.
The module indicates approaching expiry dates and helps verify that suitable equipment with a valid inspection is available for a given test.
Together with M-Test Manager and Employee Manager for Lab, Inventory Manager for Lab provides the equipment side of traceability for the testing process.
