HOW TO INTEGRATE PQR, WPS AND WPQ MANUALLY AT PROJECT LAUNCH ?

23 April 2020

IMPORT YOUR DATA INTO SIRFULL™ WELDING

Procedure Qualification Record (PQR), Welder Performance Qualification (WPQ) and Welding Procedure Specification (WPQ) are the starting data of the very first user of SIRFULL™ Welding.

 

These documents contain the essential information for the company’s welding quality management: area of validity, materials used, welding processes, qualification of welders, thicknesses, diameters, assembly diagram, intensity, etc.

 

 

Therefore, these 3 documents will have to be digitalized in the solution. For the purpose of simplification, we deliberately ignore in this article the non-destructive testing reports, material certificates, etc., because the logic that will follow also applies to them.

 

THE PROBLEM is that at the beginning, all these documents are either: paper, PDF, EXCEL, WORD or all 4 at the same time.

 

Regarding this issue, and before starting a SIRFULL™ Welding project, ALL our customers have asked us this question:

 

PART 1 – HOW DO I INTEGRATE MY PQR, WPQ AND WPQ ( MANUALLY OR AUTOMATICALLY)?

 

 

Preliminary note: You can use the optional SIRFULL data recovery service. Nevertheless, you have the possibility to do it yourself, via the different techniques that will be discussed below.

 

The most critical requirement in this phase of digitizing the welding data is indeed TIME.

Imagine copying manually, line by line, all your PQR in the application seems time-consuming and frightening!

 

NO WORRIES, we are going to introduce – YOU future users of SIRFULL™ Weldingthe options for importing your welding data.

 

Option 1 – Excel import, known as “mass” (semi-automatic method)

 

SIRFULL™ Welding supports the import of Excel files. Magic, would you say? This argument alone may lead you to believe that a simple “copy/paste” of your Excel files into the software interface is enough to import your data. However, the copy/paste of non-homogeneous Excel files, in this case, does not exist (yet).

 

Indeed, whether with SIRFULL™ Welding or any other software, you must edit your Excel files in a format that the destination solution knows. This is also called “mapping”. That’s why we talk about semi-automatic method. To map, it is necessary to put the data from your Excel files into “new clean Excel files”.

 

Thus, SIRFULL™ Welding gives you access to compatible import templates for your PQR, WPS, WPQ, etc….

– Advantage: faster than manual retyping

– Constraint: the number of fields in a DMOS or QMOS is high, and by association, so is the error rate. Indeed, the slightest character error can lead to an import failure. The sum of time lost on import errors can – in the worst case – be higher than the time that could have been spent on manual import.

 

Option 2 – “Accelerated” manual import

 

The manual import consists of copying field by field your welding documents into the application forms. Please note that in the majority of cases, data entry is assisted and accelerated by automatic systems.

 

Manual import is worth considering, when :

 

few documents need to be imported (we consider “few” between 15-20 documents).

 

– too many “technical names” such as grades, materials, filler metals, etc., are not present in the technical libraries of the solution.

 

Note on technical and normative libraries: Indeed, you should know that the application SIRFULL™ Welding natively proposes a very extensive normative and technical library (example of references: 500 welding gas references, 600 grades, 500 commercial and standardised names of filler metals etc.). Sometimes these libraries are not sufficient – despite everything – to cover all possible cases. In such cases, it is necessary to reference these names in the libraries of the solution beforehand. In this case, manual import is then preferred or via the realization of several mass imports, but in this case it amounts to consuming the same amount of time as the manual import.

 

– you give up mass import because too much time is spent correcting character errors.

 

– you do not have your welding documents in EXCEL format

 

To sum up: the more complex your documents to be imported are, the more manual import will be considered.

 

 

Part 2 – How long does it take to manually import my data?

 

 

Before asking this question, you must first know “what” to import exactly. In reality, no matter what happens, you don’t need to manually re-import “everything” into SIRFULL™ Welding.

Indeed, the application has an engine for creating WPS from a reference PQR. In other words, a real time-saving machine!

 

Here’s how it works:

 

1. Re-enter a PQR ;

2. Designate this PQR as a reference for given WPS;

3. SIRFULL™ Welding automatically copies all PQR information into your new WPS;

4. Adjust the parameters (angles, thicknesses…) necessary to your needs in the newly created WPS.

 

Therefore, retyping your PQR is the only time – with a few small exceptions – when you do ” purely ” manual import.

 

In addition, SIRFULL™ Welding offers many other tools to get rid of “useless” re-entries:

 

– pass duplicator,

– PQR/WPQ/WPQ duplicator,

– assembly and pass drawings available in the application (more than 500),

– Numerous automation algorithms.

 

In the end, a PQR takes on average between 5 -10 min to regain, sometimes less. For example, 30 documents to be imported would take less than a day.

 

 

Notes on areas of validity: since this interpretation depends on your expertise, we do not consider the import of these as pure manual retyping. Nevertheless, SIRFULL is currently working on the creation of an automatic validity domain generator for PQR and WPQ. The latter should break down this time-consuming barrier.

 

3 – Conclusion

 

  1. The import of your welding data can be done in mass via EXCEL, but under certain format and “mapping” requirements.
  2. Manual re-entry is greatly facilitated by numerous automatisms, including an automatic WPS generator from a reference PQR and other means of automatic entry (fields linked to technical and regulatory libraries, schematics, metals, etc.). It is recommended when the effort/time ratio is lower than that of the EXCEL mass import.
  3. If these 2 options do not suit you, SIRFULL proposes as an option a data recovery service to all its new customers.

 

Last but not least: remember that the transfer of your welding documents/data will take place ONLY ONCE at the start of your project SIRFULL™ Welding.

 


To go further:

 

SIRFULL™ Welding offers many functionalities and applications dedicated to the management of the welding activity; we invite you to discover them on our site.

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About SIRFULL

Sirfull is a software vendor with a strong industrial culture and French know-how, which develops solutions that enable its customers to anticipate changes in their market.

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