Philip G. Cutino, P.E.

1. Philip G. Cutino, P.E. Engineering 10 Presentation April 19, 2012 Chabot College, Hayward CA

2. Today’s Agenda • SLAC National Accelerator Laboratory • Linac Coherent Light Source (LCLS) • My role at SLAC over the years • The Mechanical Fabrication Department

3. Stanford Linear Accelerator Center • Location: Menlo Park, CA • Type: Multi-program Laboratory • Contract Operator: Stanford University • Website: www.slac.stanford.edu • Physical Assets: • 426 Acres • 145 Buildings • 1.8M GSF in Active Operational Buildings • Human Capital • Employees: 1,496 FTE as of 4/15/08 • Users, Visiting Scientists and Grad Students: 3036 Head Count

4. SLAC Mission • SLAC programs explore the ultimate structure and dynamics of matter and the properties of energy, space and time - at the smallest and largest scales, in the fastest processes and at the highest energies - through robust scientific programs, excellent accelerator based user facilities and valuable partnerships.

5. Research at SLAC • Accelerator Physics • Astrophysics and Cosmology • Elementary Particle Physics • Materials and Nanoscience • Molecular Environmental Science • Structural Biology • Ultrafast Science • http://www6.slac.stanford.edu/Research.aspx

6. Total Machine* : ~1750 meters of beam line 1242 Devices Injector: 28 meters of beam line & 95 devices Linac 1003 meters 708 devices LTU & Dump 408 meters 176 Devices *Electron Beam Line Only Does not include Photon Beam Lines LCLS

7. Linac Coherent Light Source • Ultrafast X-ray science • Directly observe the motions of atoms on ultrafast time scales • Investigate dynamics, bonding, heating and melting, at atomic and nanometer length scales • Create and observe extreme new conditions in atoms and materials • Imaging of nonperiodic molecules and nanostructured materials • World’s first X-ray free electron laser • Producing 100 femtosecond pulses of photons in the energy range 800-8,000 eV • 10^12 coherent X-ray photons/pulse • Potential for sub-femtosecond pulses • Lead nanoscale science revolution • Master control of energy-relevant complex systems • Lead the world in the investigation of dynamics of atomic transitions, chemical bonding, catalysis and heating

8. Links to More Information • http://www.slac.stanford.edu • http://lcls.slac.stanford.edu • http://www6.slac.stanford.edu/ExploringSLACScience.aspx • https://news.slac.stanford.edu/

9. Atypical career path • Mechanical Engineer • Register Professional Engineer in CA • Returned to school late in life • Diverse background . . . • ~25 years with the same employer • Four different jobs

10. My Roles at SLAC • Process Control Instrumentation Technician • Facilities Engineer • Accelerator Engineer • Mechanical Fabrication Department Head

11. Mechanical Fabrication Department Phil CutinoOctober 27, 2010

12. Mission and Vision • Mission • Provide specialized manufacturing and field support services necessary for the Lab to achieve it’s stated goals • Provide collaborative and quick turn around manufacturing • Provide services unique to the SLAC mission not available elsewhere • Vision • Partner with SLAC organizations to effectively deliver high quality manufacturing services in a safe and cost efficient manner supporting the scientific mission Mechanical Fabrication Department Page 12

13. Delivering SLAC’s Mission • Broad capability on site for specialized manufacturing services • High quality, consistency, capacity and unique accelerator research specific processes developed and delivered safely • Technical know how developed over many years • Highly trained & experienced staff available for changing needs of an experimental research user facility • Quick turn around and collaborative manufacturing • Metal Finishing • Documented processes developed specifically for accelerator research needs • Hydrogen Furnace Brazing • Vacuum Processing and Precision Assembly • Magnet fabrication, refurbishment and repair • Machining • Special capability such as ability to machine exotic & low-level radioactive materials • Field work includes installation, installation coordination, accelerator mechanical and vacuum system maintenance and operations Mechanical Fabrication Department Page 13

14. Organization • 85 Full time staff members • 6 Engineers • 12 Science & Engineering Associates • 67 technicians and trades • 9 supervisors • 12 matrixed out • Formal matrix agreements • 9 are temporary employees • Very experienced workforce • 16% have 10 to 20 years of service • 19% have 20 to 30 years of service • 9% have more than 30 years of service Mechanical Fabrication Department Page 14

15. Organization continued • Management (4) • Mgmt., Admin., ES&H support • Production Planning (6) • Job inputs, Estimating • Manufacturability Review • Machine Maintenance (4) • Field Operations (6) • Vacuum Shop (21) • Vacuum Processing • Precision Assembly • Braze Shop (7) • Precision Assembly • Machine Shop (12) • Metal Finishing (8) • Structural Fabrication Shop (7) • Magnet Coil Shop • Sheet Metal and Welding Shops Mechanical Fabrication Department Page 15

16. Core Competencies • Broad range of technical know-how necessary to support the scientific mission • Generally very high quality on site for ongoing and urgent operational needs as well as collaborative manufacturing • Manufacturing & Field Support Services • Seamless integration of production planning, machining, metal finishing, magnet fabrication, precision assembly, sheet metal forming, welding operations, quality assurance, vacuum processing with installation, maintenance and repair Mechanical Fabrication Department Page 16

17. Core Competencies continued Machine Shop Clean Machining for UHV Quick Turnaround Radioactive Materials DFM & Prototype Parts Mechanical Fabrication Department Page 17

18. Core Competencies continued Hydrogen Furnace Brazing And Heat Treating Mechanical Fabrication Department Page 18

19. Core Competencies continued Metal Finishing Plating and Cleaning for UHV Mechanical Fabrication Department Page 19

20. Core Competencies continued Mechanical and Vacuum Processing and Field Operations Precision Assembly Mechanical Fabrication Department Page 20

21. Performing Work • Customers have access to the manufacturing process • Scope and technical changes are routinely accommodated • Collaborative manufacturing is facilitated • Problems are solved quickly • Customer feedback is regularly provided • Cost and schedule estimates are provided as part of the job input process • Customers can check an online tool for real time updates • Scope and technical changes are not re-estimated unless requested by the customer • Regular planning meetings are held • There is a standing weekly meeting for all field work • Larger projects are coordinated in project specific meetings held weekly or as needed Mechanical Fabrication Department Page 21

22. Performing Work continued • Quality assurance is integrated and documented on travelers. • All machined parts are independently quality checked by MET unless the customer requests this step is to be skipped • Vacuum processing reports are recorded in traveler • Vacuum leak checking is provided in the shop on assemblies and in the field on systems • Manufacturing process is seamlessly integrated • Procurement of materials, machining, metal finishing, vacuum processing, precision assembly and installation can be procured from a single request • In process storage of components and assemblies is provided • Schedule updates are available to project managers • Schedule reporting is provided to customers or to integrated schedules as requested by customers • Change control is generally formal Mechanical Fabrication Department Page 22

23. Performing Work continued Collaborative Manufacturing Example: Wire Card for combination OTR / Wire Scanner Developed for KEK by Doug McCormick (SLAC) Resolution ~2 microns Technical Challenge: 10 micron Tungsten Wire Soldered to gold plated Macor substrate requiring high positional accuracy Mechanical Fabrication Department Page 23

24. Concluding Work • Estimate vs. Actual reports are provided for all jobs. • Actual costs are available online for future use in estimating. • Historical and real time data is searchable by part number, customer name and job number. • Performance reporting is facilitated using manufacturing software. • Performance reports are published monthly. • Scope changes are not typically re-estimated. • Scope changes affect performance. • Recently began tracking jobs with significant changes. • All Redline drawings are routed back to MED for updating. • An online feedback tool is available. Mechanical Fabrication Department Page 24

25. Questions and Answers Mechanical Fabrication Department Page 25