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Field Period Assembly (FPA) Operations, Cost and schedule, staffing, and metrology utilization

Field Period Assembly (FPA) Operations, Cost and schedule, staffing, and metrology utilization. Mike Viola Field Period Assembly Manager 10 AM October 12, 2006. FPA Concerns and Risks. Heavy emphasis on Prototyping each activity Crack Work Crew and Support

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Field Period Assembly (FPA) Operations, Cost and schedule, staffing, and metrology utilization

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  1. Field Period Assembly (FPA) Operations, Cost and schedule, staffing, and metrology utilization Mike Viola Field Period Assembly Manager 10 AM October 12, 2006

  2. FPA Concerns and Risks Heavy emphasis on Prototyping each activity • Crack Work Crew and Support • Our best, highly effective and ingenious technicians assigned to perform first time tasks. More time allocated for first time. John Edwards 30 years experience (Master Support Technician), Mike Duco from Lockheed (simulations, manufacturing, coatings vibrations), Ed Bush 20+ Quality Assurance then NB Ion Sources. • Augmented as needed by Cryogenic operators and NB Technicians • Learning Curve (Time included in schedule) • Perform all tasks first with crack crew – Prove principles to mitigate risk!! And then Finalize Procedures • Train secondary support crew to perform bulk of work • Tooling • Crack Crew perform dry run of tooling • Metrology (Mike Duco with Steve Raftopoulos Support) • Leica Laser: 0.0005” accuracy • Romer arm: 0.005-0.010” accuracy (2 other Romer Arms available) NCSX Field Period Assy Peer Review

  3. FPA Metrology Issues • Equipment in house • Leica Laser: 0.0005” accuracy • Romer arm: 0.005” accuracy (2 other Romer Arms available) • Reach/Accessibility • Coils are easy to reach but need high accuracy • VVSA is hard to reach but localized activities can use lower accuracy equipment. • Repeatability • Datums strategically located to provide individual activity support • Need recommendation for datum locations to be used through final machine assembly • Expert support group being considered within Fabrication Division NCSX Field Period Assy Peer Review

  4. SAFETY • Documentation and ISM Work Plans • Manufacturing Facility Operation Plan (MFOP) covers overall facility conduct using ISM as its basis. • Activities Control Committee (ACC) independently reviews each station setup, operations, and plans before station is activated. NCSX Field Period Assy Peer Review

  5. FPA Process Definitions • FPA Manufacturing, Inspection, Test, Quality Assurance Plan (MIT/QA) • Input: • Dimensional Control Plan • FPA Assembly Sequence Plan • FPA Specification and Assembly Drawings • Output: • Individual procedures to perform tasks NCSX Field Period Assy Peer Review

  6. FPA Cost and Schedule • FPA Cost and Schedule • Station 1 $744K 6/30/06 – 1/17/08 • Station 2 $336K 10/5/06 – 1/31/08 • Station 3 $300K 7/31/07 – 4/7/08 • Station 4 $214K 10/4/07 – 6/3/08 • Station 5 $647K 9/14/07 – 7/11/08 • Total FPA Cost $2.241M NCSX Field Period Assy Peer Review

  7. Field Period Assembly Operations Very good agreement. VVSA1_MTM_FINAL_NUMBERS VVSA1_PPPL_BEST_FIT NCSX Field Period Assy Peer Review

  8. Field Period Assembly Operations Metrology is serving appropriate needs. VVSA2_MTM_FINAL_NUMBERS VVSA2_PPPL_BEST_FIT NCSX Field Period Assy Peer Review

  9. Field Period Assembly Operations Station 1 setup Portprefit NCSX Field Period Assy Peer Review

  10. Field Period Assembly Operations NCSX Field Period Assy Peer Review

  11. Field Period Assembly Operations • Station 1 Schedule (VVSA) • All three VVSA’s received 9/30/06 • All work performed on station 1 fixture (2 “rotisserie” stations) with Leica & 2 men augmented with 3 technicians if needed • Install VVSA external components (Diagnostic Coils, Cooling Tubes, Thermocouples) Laser or Romer • Tooling Checks and Metrology Training 5/15/06 – • FP#1 6/30/06 – 5/3/07 • FP#2 (VVSA #3) 9/30/06 – 8/31/07 • FP#3 (VVSA #2) 8/1/06 – 1/17/08 NCSX Field Period Assy Peer Review

  12. Field Period Assembly Operations • Station 2 Schedule (3 Coil preassembly) • Perform crude prefit – any gross interferences & Tooling checkout 10/30/06 – 6/19/07 • Perform prefit – shim and alignment • Align and Assembly Laser Tracker • Tooling checks 10/5/06 – 3/4/07 • FP#1 3/5/07 – 9/6/07 • FP#2 9/7/07 – 11/15/07 • FP#3 11/16/07 – 1/31/08 NCSX Field Period Assy Peer Review

  13. Field Period Assembly Operations • Station 3 Schedule (Coils onto VVSA) (Laser Tracker or Internal GPS) • Align and Assembly 2 coil three packs • Tooling checks 7/31/07 – 8/27/07 • FP#1 9/7/07– 10/4/07 • FP#2 11/16/07 – 12/10/07 • FP#3 2/1/08 – 2/21/08 • Align and Assembly Coils onto VVSA • Tooling checks 7/31/07 – 8/27/07 • FP#1 8/28/07– 11/7/07 • FP#2 11/8/07 – 1/16/08 • FP#3 1/17/08 – 4/7/08 NCSX Field Period Assy Peer Review

  14. Field Period Assembly Operations • Station 4 Schedule (TF Coils) Laser • Align and Assembly TF Coils • Tooling checks 10/4/07 – 11/14/07 • FP#1 11/15/07 – 1/15/08 • FP#2 1/16/08 – 2/19/08 • FP#3 2/20/08 – 6/3/08 NCSX Field Period Assy Peer Review

  15. Field Period Assembly Operations • Station 5 Final Assembly Schedule in NCSX Test Cell to enhance efficiency and reduce HP overhead (Weld ports, Install TF Coils, Leak Check, Final metrology) • Align and Assembly Laser Tracker and Laser on Target for port welding • Tooling checks 9/14/07 – 10/4/07 • FP#1 11/8/07 – 4/4/08 • FP#2 1/17/08 – 5/20/08 • FP#3 4/11/08 – 7/11/08 NCSX Field Period Assy Peer Review

  16. Field Period Assembly Operations • To Conclude • Assembly operations are considered conceptual and will be tested out prior to actual work is performed. • Our best technicians are assigned to these FPA tasks. • Reasonable time is allocated to perform FPA NCSX Field Period Assy Peer Review

  17. And if all else fails We found this guy NCSX Field Period Assy Peer Review

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