I think I understand your questions.
As far as D1.1
A welder qualified in in all positions for a given thickness and a given process. Is qualified in all those positions and for all materials covered in the code (within the thickness range he qualified to)
Procedure qualifications are based on material and filler groups in D1.1. Welder performance qualifications extend to all material groups covered in the code.
So if the procedure has been qualified for your material. And you choose a process, posiiton and thickness that your welder his already qualified to do.. You should not need additional welder performance qualification testing to go into production.