Parts Tracking as a Basis for Quality Management

Transcription

1 Parts Tracking as a Basis for Quality Management Lars Hagge Deutsches Elektronen-Synchrotron, DESY XFEL WP40 1 st Accelerator Consortium Meeting DESY, April 17, 2012

2 2 Quality Management Parts Tracking Concepts Examples from WP71, WP03/09 and WP04 Summary

3 Why all the Effort? Motivation and Requirements Parts 1 tracking and documentation is a foundation for: Quality assurance & control (QA/QC): Parts must pass acceptance tests when received (and at intermediate fabrication steps). Test results must be reliably & orderly recorded, signed-off & processed. Legal regulations (in certain areas, e.g. PED): Compliance requires that parts are uniquely identified and their complete history is tracked throughout the entire lifespan of the XFEL. Compliance is mandatory for receiving and keeping the permit of operating the XFEL. Operation, Maintenance and Upgrades (OMU): Many OMU activities need access to complete and up-to-date documentation of the facility, which has to be captured now, during installation and commissioning, and has to be continued as the facility evolves. Objective: Provide procedures for reliably gathering, recording, processing & archiving the complete mandatory fabrication information. DESY EDMS shall act as the central collaboration & documentation platform. 1 Part is a generic term for component, equipment, device, etc. 3

4 Quality Management 4 Quality Management is about meeting the requirements QM activities asked for at XFEL include: Defining and assigning roles and responsibilities Managing resources and infrastructure Organizing and monitoring purchasing and production, and handling non-conformities Controlling documents, data and records HOW to organize Quality Management - Project planning - Parts Tracking in Design, Fabrication, Installation - Monitoring and Reviewing of WHAT? - Deliverables

5 Parts Documentation Concept The documentation of any deliverable, aka part comprises: 5 Fabrication Installation, Operation, Fabrication Documentation Assembly Drawings Process Instructions Safety Analysis Quality Mgt. Plan Test Cases Manuals Fabrication Documentation for that type of part: Define how the part shall be realized (aka manufacturing dossier). Inventory (Physical) Documentation Inspection Sheets Conformity Certificates Shipping Records Installation Records Usage Records Full History Inventory Documentation for that particular individual physical part: Keep track and record the history of each physical part.

6 Has Instance Example: Parts & Documents Vacuum Pump Purchased Physical Vacuum Pump #12345 Purchased Physical Vacuum Pump #12349 Fabrication Part type of part Physical Part Document Has Description Has Template Has Description Has Description particular individual (serialized) part describes selected aspects of part Contract with Vendor Warranty Statement Installation Manual [Empty] Acceptance Test Record [Empty] Installation Record Acceptance Test Record VP Installation Record VP-12345/1 Inspection Record VP Year 1 Inspection Record VP Year 2 Acceptance Test Record VP Installation Record VP-12349/1 Repair Record VP-12349/1 Inspection Record VP Year 1 Inspection Record VP Year 2 6

7 Complex Parts More complex components are hierarchically decomposed into smaller, better manageable parts, yielding the so-called product breakdown structure PBS. PBS level of detail depends on purpose: PBS for fabrication is called Manufacturing Bill of Materials, MBOM and shall contain all parts that occur in assembly, inspection, maintenance processes. 7

8 Example: MBOM of Preseries Undulator 8

9 Example: Fabrication Part Undulator Frame 9

10 Example: Physical Part Undulator Basis X003-N001 10

11 How to Define an MBOM: Reflect the Assembly Steps = Undulator Basis + Magnet Structure = Undulator = Undulator Frame Complete + Magnet Girder Top Magnet Girder Bottom Undulator Frame + Undulator Control System

12 Example: Cryomodule MBOM MBOM contains all parts which are relevant during fabrication, e. g. which need to be transported, assembled, changed, tested, certified, MBOM has ca. 400 parts iterative procedure within WPG1 to agree on names, assign responsibilities, link with docs, Part Name EDMS Reference Responsible Party Tracking Info Logistics Info Quality Inspection

13 Example: Part-Based Quality Assurance Define (Excel-Based) template for inspecting physical parts during fabrication Link inspection sheets (i. e. filled templates) with physical parts Let fabrication managers review and release inspection sheets Let suppliers provide completed inspection sheets Various easy upload tools avaialble

14 Example: Traceability of Nb-Sheet 14 Pack list for sending and receiving Nb sheets Link to Ingot Certificate & Result of scan Backlink to fabrication documentation: Specification and QC instructions Nb-Sheet serial number and metadata Optional label with data matrix code

15 More information: XFEL-Note on Parts Tracking & Documentation 15 Policies and Method for Parts Tracking & Documentation during Fabrication at the European XFEL Presented in XFEL project meeting and published on XFEL web pages. Or: Contact WP40

16 Summary Thinking in parts is an essential aspect of quality mgt. 16 HOW to organize Quality Management - Project planning - Parts Tracking in Design, Fabrication, Installation - Monitoring and Reviewing of WHAT? - Deliverables