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Corrective and Preventive Maintenance at NSCL. Introduction to NSCL & MSU. Quality Management at NSCL. Outline. Tools used at NSCL for availability. Future. Questions. NSCL.

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Presentation Transcript
outline

Introduction to NSCL & MSU

Quality Management at NSCL

Outline

Tools used at NSCL for availability

Future

Questions

slide3

NSCL

National Superconducting Cyclotron Laboratory (NSCL) is a world leader in rare isotope research and nuclear science education

NSCL employees 454 Faculty,

Staff and Students

Located on the campus of

Michigan State University

Ranked as the #1 graduate program in nuclear physics

In the United States by U.S. News & World Report

michigan state university

The United States pioneer land-grant university, established in 1855

In 2010, MSU enrollment consisted of 47,131 students

from all 50 United States and 130 countries

Michigan State University

MSU has over 11,000 employees

Throughout the world, there are nearly

half a million MSU alumni

why is a robust maintenance program important
Why is a Robust Maintenance Program Important?

It allows a facility to do what it does best……….

It allows a facility to meet the demands of its funding agencies……….

It allows a facility to meet its operational goals……….

“Operate the laboratory reliably, efficiently and safely. Maintain high (>90%) level of availability and seek further gains in efficiency through improved procedures and automation of NSCL operations without compromising safety. Encourage the professional development of staff to raise the overall skill, performance, and knowledge bases within the laboratory.”

NSCL has a Quality Management System (QMS) to meet all of the above

nscl quality management system

NSCL Quality manual states:

“NSCL developed and implemented a Quality Management System in order to document the laboratory’s best operational practices, better satisfy the requirements and expectations of its users and improve the overall management of the laboratory”

NSCL Quality Management System

The Quality Management System of NSCL meets the requirements of the international standard ISO 9001. This system addresses the production and delivery of rare isotope beams

This manual describes the Quality Management System, delineates authorities, inter relationships and responsibilities of the personnel responsible for performing within the system.

nscl qms scope

The Scope of the NSCL Quality System is: All NSCL processes related to the production and delivery of rare isotope beams to the experiment

The quality manual outlines the policies, procedures and requirements of the Quality Management System. The system is structured to comply with the conditions set forth in the International Standard ISO 9001.

NSCL QMS Scope

nscl qms quality objectives

Rare isotope beams will be delivered within 24 hours of the scheduled time

NSCL QMS Quality Objectives

Rare isotope beams will be delivered with 90% availability

Availability(Total Time - Scheduled Off - Unscheduled Offexcl) / (Total Time - Scheduled Off)

tools

Logging & Reporting

Administrative

Document Handling

Tools

Inventory Management

Planning

Scheduling

Tools…the actual hand tools

logging and reporting

HourLog

Allows for both narrative and system status reporting

Logging and Reporting

Reliability statistics are derived from HourLog

Trouble Reports

Used to report a problem with a system or process and even a suggestion

Allows the trouble report to be tagged for various management systems

administrative

Reliability Committee

Trouble Reports are reviewed bi-weekly

Administrative

Committee can reopen a solved Trouble Report for further investigation

Repair Team

Meeting called by department head

All system experts are present

Actionable items generated

document handling

Document Handling

Alfresco document management

Workflow determined by users

Mechanical Design department design review approval

Revision control

inventory management

Inventory Management

Developed in-house, using IRMIS

IRMIS is a descriptive documentation

Tool *

Uses relational database and associated applications to comprehensively document the large and complex EPICS-based control systems *

Handheld Bar Code Scanners MC55

* An Overview of IRMIS, 4/19/2005 (http://www.aps.anl.gov/epics/irmis/Primer.pdf)

scheduling

Scheduling

Administration Schedule

~ 1 day resolution

Determined 3 months out

Operations has final review

Short Term Schedule

~ 1 hour resolution

Determined daily

STS Coordinator

maintenance planning

Maintenance Planning

Experimental schedule is determined 3 - 4 months in advance

Preventive maintenance is scheduled in between experimental periods

The maintenance group solicits tasks from other departments to add to the maintenance schedule

Microsoft Project 2008 is used to build the maintenance schedule

NSCL written software is used by the employees to get a list of their tasks

The same software is also used by the employees to report the status of their tasks back to the project leader

breakdown plans

Breakdown Plans

In order to reduce downtime during breakdown repairs lasting at least 24 hours, but less than 7 days, a breakdown response plan is proposed to better allocate resources, and use time more effectively. The scope of this document is to explain the process for using and creating canned breakdown response plans. The initial scope of the breakdown, and such considerations as duration and level of support by other departments should be determined by a repair team meeting.

tools the actual tools

Tools…the actual tools

Modified 5S method

5S is a system to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results *

Provides a basic set of tools to address an immediate need without wasting valuable time

Vault Tool Box

http://beyondlean.wordpress.com/2010/09/13/5s-in-the-office/

* Lean Manufacturing and the Environment, http://www.epa.gov/lean/thinking/fives.htm

operator structure

During experiments, all personnel rotate through shifts as operators

During maintenance, all personnel become part of the resource pool used during scheduled maintenance

Operator Structure

Operations/Maintenance

Operating Engineers

Maintenance Engineers

future

Future

Tighter Integration of tools

Written with common software