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PVC Module Production ( 2.5)

PVC Module Production ( 2.5). Minerba Betancourt , Jianming Bian , Tom Chase ,

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PVC Module Production ( 2.5)

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  1. PVC Module Production (2.5) MinerbaBetancourt, JianmingBian, Tom Chase, Dan Cronin-Hennessy, Ben DeYoung, James Geddes, Chris Kluge, Susan Lein, Tina Lorsung, Jarek Nowak, Greg Pawloski, Jim Parker, Nathaniel Pearson, Ron Poling, Nick Raddatz, Dominick Rocco, KanikaSachdev, Alex Smith, Brian Sherwood, Dick Wildberger, Robyn Woolands, Jan Zirnstein Ken Heller University of Minnesota May 8, 2012 + 170 undergraduates typically 15 hrs/wk (~ 240 is full staffing) Technician Accounting Engineer Physicist

  2. Manifold Parts Raceway holder Ken Heller WBS 2.5

  3. End Seal Parts Ken Heller WBS 2.5

  4. Module Production Status • All machines & QA –operating. • All molds & dies – completedand in production. • Parts – flowing in. • QA, process, & inventory software – operating • Asynchronous 2 to 1 operation – in production • Module production – ramping up • Management of students working part time (170 students working a minimum of 10 hrs/wk) – in operation • Module shipping – 4 planes (48 modules) to Ash River on schedule • Factory floor – filling up Slow ramp-up for first month - 123 good modules produced • Initial process adjustments to minimize • Fiber damage • Optical connector leaks • Outer seal leaks • Visual inspection flaws Ken Heller WBS 2.5

  5. Module Factory Stable 2 to 1 Production 2 to 1 operation Factory and annex are almost full 2 to 1 storage annex Peak 2 to 1 production rate 38/day (average needed 24/day) 3277 complete 2 to 1 (8.5 blocks = 29% of far detector) Failure rates overall Flatness – 0.7% End Cut – 0.7% Failure rates April Flatness – 0% (125 done) End Cut – 1.6 % (125 done) Slowing 2 to 1 production to put effort into module production Ken Heller WBS 2.5

  6. Scenes from the Factory Floor Production floor Production floor Gluing extrusions Stringing stations Ken Heller WBS 2.5

  7. Scenes from Production – Final Stages Stacking finished modules Painting Packing Closed fiber testing Ken Heller WBS 2.5

  8. Scenes from Production Pressure testing Sealing endplate Fly cutting Stringing Open fiber testing Ken Heller WBS 2.5

  9. Production Snap Shot One day production process 5/7/12 outer seal leak 2to1 flatness trim end trim end length snout string open fiber test open fiber test flycut optical connector leak open fiber test open fiber test Inner seal cover Inner seal end plate closed fiber test end plate squareness Inner seal leak outer seal paint closed fiber test final inspection stack pack ship In full production each step would have the 24 modules/day. A single module goes through all the steps in 6 days. Ken Heller WBS 2.5

  10. Production Progress 166 good modules Goal is 2% Goal is 120/wk Failures week 1 Fiber: 4 Final inspection: 1 Failures week 4 Fiber: 6 Optical connector: 1 Fly cut: 1 Failures week 2 Fiber: 12 Optical connector: 16 Failures week 5 Fiber: 2 Optical connector: 1 Failures week 3 Fiber: 13 Final inspection: 1 Ken Heller WBS 2.5

  11. Module Parts Received Plastic Part module units (12500) % Manifold Cover 388 (382 = 1 block) 3 End Plate 3372 27 Top Raceway 541 4 Bottom Raceway 536 4 Top Fiber Tray 9662 77 Generic Fiber Tray 2570 21 Bottom Fiber Tray 4464 36 Raceway Cover 3422 27 Raceway Support 3919 31 Snout Front 3300 26 Snout Back 3300 26 Manifold Side Seal 3919 31 End Plate Side Seal 3920 31 Optical Connector 12544 100 Fiber Ring 12891 100 External Center Seal 12500 100 Ken Heller WBS 2.5

  12. Redesign of Manifold Cover & ToolingAnalysis & Testing Ang Lee (Fermilab) FEA Measured material strength between 6400 & 5100 psi. New cover and clamp design - max stress between 1000 & 1400 psi. 10 mil gap Tight fit Ken Heller WBS 2.5

  13. Manifold Cover Strength Tests Ken Heller WBS 2.5

  14. Manifold Cover Ultrasound Scans Section 1 Section 2 No flaws observed in structure or strength of manifold covers Ken Heller WBS 2.5

  15. Vigilance is the Price of NOnA It’s all about QA/QC • Parts inspected when received • 2 to 1 • Flatness • Length • Squareness • Glue strength • Fiber • Continuous as strung • Open ended after stringing • After fly cutting • After sealing • Fly cut dimensions • Optical connector leak check • Inner seal leak check • Outer seal leak check • Final visual inspection, fiber test, dimension check • Glue strength • Chemical compatibility http://www.animal-photos.org/photo/2673.html Training 3 QA audits by Fermilab project staff Ken Heller WBS 2.5

  16. Cross section cuts to check glue flow Cross-section cut every 0.05” Snout Joints Optical connector Cross-section cut every 0.015” Ken Heller WBS 2.5

  17. Scintillator Interaction Testing Test all glue types and all parts Scintillator only Noise Run Alpha only counts Ratio of Compton to alpha to take out phototube variation Pulse height Ken Heller WBS 2.5

  18. Risks and Mitigation Have manufacturer pay attention to their QC and remake parts. Adequate parts are buffered so should not cost production time. Add weekend production if necessary. Parts do not meet specifications Project contingency held to cover up to a doubling of utility rates. Utility rates increase for factory Factory already has over 6 months of stored extrusions so should not cost production time if extrusion factory can make up the deliveries later. Extrusion delivery interrupted Factory stores several months of completed modules so should not cost production time if shipments can resume. Unable to ship completed modules Factory stores several months of completed modules so detector assembly can continue. Weekend production can make up the time. Module production interrupted Ken Heller WBS 2.5

  19. Module Shipping/Receiving Damage Visual inspection of modules at Ash River by module factory personnel found damaged fiber. 5 modules (21%) in stack 1 6 modules (25%) in stack 2 All good leaving factory Investigation plan Ship 1 stack of modules to Ash River and back to module factory Monitor shock and temperature Check for fiber damage Autopsy any damaged modules to determine location of damage Ken Heller WBS 2.5

  20. Looking Ahead Stringing Gluing seals & snouts Get to ~ 2% module failure rate (now at 7%) Ramp up to 24 modules/day (now at 12) – end of May Investigate and eliminate fiber damage in shipping Summer means easier management control fewer students (~70) working full time Expand staffing from 170 to ~210 students in Fall Production ramp up going well process improvements decrease defects rate increasing Unloading extrusions Ken Heller WBS 2.5

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