Kemppi’s ArcQuality convinces Outotec

2nd April 2013
Posted By : ES Admin
Kemppi’s ArcQuality convinces Outotec
Outotec has installed an ArcQuality Welding Quality Management System from Finnish welding equipment manufacturer Kemppi Oy for its welding operations in their Turula engineering workshop. Outotec is also planning to expand the use of ArcQuality to its other workshops. Plant Director, Ilkka Hiltunen says that quality control for welding is a key part of the workshop’s activities. “It is easier to improve the quality when production is in one’s own hands. ArcQuality is a modern, up-to-date way of ensuring quality control.”
Outotec’s Production Development Manager, Kari Koistinen points out that quality and productivity go hand in hand. According to Koistinen, high welding quality is achieved by making sure that the company employs excellent quality-control processes. He said: “The manufacturer has to provide the client with the quality required and one needs to be able to prove the quality of the product to both the client and the quality assessment organisation.”

From the very beginning, Outotec Turula has invested in the latest available technology for its production processes. The company has a 21,000m2 production facility along with an area for pre-treatment. The Turula workshop has around 70 x MIG/MAG, TIG and MMA power sources. The ArcQuality system provides a sound way to verify welding quality creating a clear competitive advantage for Outotec.

Hiltunen gives the system unequivocal praise: ‘It can’t get any better than this. Previously, there were cases in which the client required data on who welded what and when. Now, the system collects all the required information automatically.’

Koistinen added: “ArcQuality is a highly suitable tool for the management staff, since it enables immediate intervention when there are noticeable deviations from the norm.” Koistinen, a seasoned metal-workshop man, knows what he is talking about, having served the company for 30 years.

Welding co-ordinator Rauno Kakkola is also impressed by ArcQuality. He notes that welding can only be performed by a professional welder whose qualifications are constantly under scrutiny – in very few professions is the level of expertise evaluated every six months. He says: “ArcQuality helps in this respect. The system lets us know, well in advance, about the need to refresh welders’ qualifications.” In addition to monitoring the welding – he is responsible for the Company’s subcontractors, plus his expertise is also utilised at other Outotec sites.

Setting the Standard

ArcQuality places new demands on welders and may bring about new training. Kakkola observes that, in the past, systematic mistakes may have been made without the welder even realising it. Now any errors can be eliminated right away and the same applies for mistakes in welding procedure specifications.

Kakkola believes that ArcQuality should become a mainstay of welding schools and that it also affects how management operate, because real-time reports are now readily available. “Management must make sure that welding procedure specifications are available. At first, the system requires guidance and training. It is used to make everyone’s work transparent and employees should not feel that there is extra pressure on them because of this.” Koistinen stresses.

Wanted: A Proactive Attitude

Implementing the system requires an active approach from the company deploying it, not just its supplier. Kakkola emphasises that the principles of the system must be taught to each welder individually and the smart reader device must become a personal work tool for every welder. Hiltunen addeed, “We must explain to the welders why we are using the system in the first place.”
ArcQuality is provided as a cloud service via a secure server, which gains nods of approval from the Outotec trio: now the system is accessible from anywhere, and it doesn’t place a burden on the company’s own network. Also, with this quick and nimble service, the updates and new features can be put to good use right away.

ArcQuality in brief

The Kemppi Arc System 2.0 module ArcQuality links together the two most important elements of welding production: quality and productivity. With the ArcQuality service, it is easy to make sure that the entire welding process is carried out in accordance with the welding procedure specifications. At the same time, monitoring by this service ensures that the welders are qualified to perform the tasks they are assigned. Possible deviations are reported automatically and in real time. The system can also be used in preparation for maintenance operations and the smart reader – the core of the system – compiles quality data even for weld-specific traceability, if need be.

ArcQuality benefits
• Monitors compliance with the WPS
• Ensures that the welders hold valid qualifications
• Creates non-conformance reports
• Automates data collection
• Reduces rework costs
• Supports the welding, quality-control, and management personnel
• Reports the arc and non-arc time
• Includes a welding-fleet management tool
• Anticipates service needs and records the service history
• Can be used in MIG/MAG and TIG welding alike
• Allows Web-based reporting
• Utilises WLAN technology

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