Mechanical Fabrication Department s Support of B-Factory Operations

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1 Mechanical Fabrication Department s Support of B-Factory Operations Presentation by Karen Fant 4/26/06 1

2 MFD featured because: Department provides a broad range of services Accelerator Systems Division one of our largest customers Significant overlap with LCLS related work Years of experience with manufacture, installation, repair and maintenance of accelerator vacuum and magnet systems 4/26/06 2

3 MFD Services Department provides wide range of consulting and fabrication processes within 8 shops. Staff size typically 70-75, consisting of engineers, physicist, chemists, science & engineering associates, technicians, machinists, welders and administrative staff. 4/26/06 3

4 Machine Shop CNC & Conventional mill and lathe machining CNC wire & sinker EDM Ceramic and surface grinding Cutting & polishing plastics WG bending 4/26/06 4

5 Structural Fabrication Sheet metal Welding services for structural assemblies & ultra-high vacuum including electron beam welding 4/26/06 5

6 Metal Finishing Chemical cleaning includes degreasing and cleaning for ultra-high vacuum Electroplating for brazing and vacuum applications including gold, silver, copper, indium, rhodium, electroless and sulfamate nickel, anodizing and chromate conversion for aluminum Alumina and glass bead blasting 4/26/06 6

7 Precision Assembly Hydrogen brazing Ultra high vacuum assemblies Helium leak detection Soldering and torch brazing Heat treatment Coil Winding Magnet Assembly Hydrostatic testing Hi-Pot testing insulation of electrical equipment 4/26/06 7

8 Vacuum Assembly Clean room assembly, welding and bake out of simple to very complex vacuum components and instrumentation Performing glow discharge cleaning, sputter coating, outgassing measurements and residual gas analysis Component testing (valves, pumps, gauges, etc) Component fabrication consulting Boroscope capabilities 4/26/06 8

9 Accelerator Operations Support Provides mechanical and vacuum installation, trouble shooting, repair and maintenance of accelerator systems 4/26/06 9

10 Plans and manages jobs within the department. Services include job input, routing, tracking, scheduling, cost estimation and summaries, material ordering, in process storage Production Control 4/26/06 10

11 Requesting Work MFD Job Input Standard Form Walk-in Form ARTEMIS (Accelerator Remedy Trouble Entry and Maintenance Information System) Web based tracking system Down Time Planning Schedules 4/26/06 11

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14 Setting Priorities Managed FIFO System for Shop Work Meetings 8:00 Operations Review 8:15 Maintenance Meeting MFD Job Status-internal & with customers Weekly to daily as required Flag jobs with firm deadline status or schedule risk Vacuum (MFD supervisors, AD Physicists, Engineers & Area Managers) Accelerator Planning & AIP Reviews ROD and Down Time Planning 4/26/06 14

15 Tracking Progress Manufacturing database schedule Every job is planned and estimated Schedule is loaded by personnel or work center Weekly customer reports Monthly progress reports Custom Project or Spreadsheet 4/26/06 15

16 Manufacturing Database Schedule 4/26/06 16

17 Weekly Customer Report 4/26/06 17

18 Vacuum Bake Station Schedule 4/26/06 18

19 Resource Management Personnel Plan early and often Scope planned projects with duration estimates and approximate head count Hire additional personnel as required Core staff are permanent employees with fixed term and contract added as required Will hire temporary staff in FY06 to support PEP II and LCLS Overtime when necessary Long shifts, second shifts, weekends Send work to outside vendors Extend time or scale back projects when necessary Equipment Identify requirements early: leak detectors, dewars, material handling devices, vehicles Perform maintenance and repair Procure or lease additional equipment 4/26/06 19

20 Safety Aspects ISMS Safety integrated in all planning and implementation processes Personnel Training Procedures ELP, Lift Plans, EWP Authorization Department Safety Officers Involved in planning Field presence Supervision Safety meetings Daily shift project Tailgate at work site 4/26/06 20

21 Priority Conflict Resolution Start with: Understand Laboratory priorities Planning and allocating resources Frequent communication and adjusting as necessary Priority Hierarchy (or how things get moved to the front of the line) Safety related item needing immediate attention. A currently operating physics program (e.g. PEP II, SPEAR 3) interrupted, waiting for completion of this work. Project identified as high priority by SLAC management (e.g. LCLS) needs work done immediately for the project to proceed. Component holds up a large body of other work on a project. Only some jobs can have Top Priority, but no job has zero priority Within Single Group or Between Multiple Groups Identify issues as early as possible Resolve at lowest level and escalate as necessary 4/26/06 21

22 Example: IR2 Vacuum Problem In March MFD performed installation work to replace bellows and Q2 chamber 9-10 MFD assembly technicians worked 2 weeks (>700 hours) Happened at same time LCLS increased work input Small decrease in percentage of jobs delivered on time, since this work moved to the front of the queue 4/26/06 22

23 Conclusion MFD has systems in place to accept work, set priorities and track progress Change is expected, we know how to remain flexible and adapt Schedule and resource conflicts do occur, but have methods to resolve them Questions? 4/26/06 23