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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

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
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


Fpa metrology issues
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


Safety
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


Fpa process definitions
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


Fpa cost and schedule
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


Field period assembly operations
Field Period Assembly Operations

Very good agreement.

VVSA1_MTM_FINAL_NUMBERS

VVSA1_PPPL_BEST_FIT

NCSX Field Period Assy

Peer Review


Field period assembly operations1
Field Period Assembly Operations

Metrology is serving appropriate needs.

VVSA2_MTM_FINAL_NUMBERS

VVSA2_PPPL_BEST_FIT

NCSX Field Period Assy

Peer Review


Field period assembly operations2
Field Period Assembly Operations

Station 1 setup

Portprefit

NCSX Field Period Assy

Peer Review


Field period assembly operations3
Field Period Assembly Operations

NCSX Field Period Assy

Peer Review


Field period assembly operations4
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


Field period assembly operations5
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


Field period assembly operations6
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


Field period assembly operations7
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


Field period assembly operations8
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


Field period assembly operations9
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


And if all else fails
And if all else fails

We found this guy

NCSX Field Period Assy

Peer Review