ncsx field period assembly (fpa) operations, cost and schedule, staffing, and metrology utilization...

NCSXField Period Assembly (FPA)

Operations, Cost and schedule,

staffing, and metrology utilization

Mike Viola

Field Period Assembly Manager

NCSX FPA Peer ReviewOctober 11-12, 2006

PPPL

October 12, 2006 NCSX Field Period AssemblyPeer Review

M. Viola 2

NCSXFPA Concerns and Risks

Heavy emphasis on Prototyping each activity• Crack Work Crew and Support

– Our most 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 (Extra 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)


M. Viola 3

NCSXFPA Metrology Issues

• Available Equipment in house – Leica Laser: 0.0005” accuracy– Romer arm: 0.005-0.010” accuracy (2 other Romer Arms available)

• Reliability– Hardware/Software is ~80% reliable. – Have days of crashing and unpredictable operations.

• Combination of Windows, Verisurf, MasterCAM, Leica Power Inspect, ROMER…

• 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 – May need recommendation for datum locations to be used through final machine

assembly if datum shift or tolerance buildup is of concern• Expert support group being considered within Fabrication Division.


M. Viola 4

NCSX“SAFELY SAFELY SAFELY”

• 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.


M. Viola 5

NCSXFPA 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 then

revised to include developed improvements.


M. Viola 6

NCSXFPA 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


M. Viola 7

NCSX

FPA Metrology

VVSA1_MTM_FINAL_NUMBERS VVSA1_PPPL_BEST_FIT

Very good agreement.


M. Viola 8

NCSX

FPA Metrology

VVSA2_MTM_FINAL_NUMBERS VVSA2_PPPL_BEST_FIT

Metrology is serving appropriate needs.


M. Viola 9

NCSX

FPA Station 1 Active

Station 1 setup Port prefit


M. Viola 10

NCSX

FPA Schedule


M. Viola 11

NCSX

FPA Station 1

• Station 1 Schedule (VVSA)– All three VVSA’s received by 9/30/06– All work performed on station 1 fixture

(2 “rotisserie” stations) with Leica & 2 men augmented with 3 technicians when 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


M. Viola 12

NCSX

FPA Station 2

• 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


M. Viola 13

NCSX

FPA Station 3

• 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


M. Viola 14

NCSX

FPA Station 4

• 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


M. Viola 15

NCSX

FPA Station 5

• 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


M. Viola 16

NCSX

FPA Summary

• To Conclude– Our best technicians are assigned to these FPA tasks.– Some assembly operations are still somewhat conceptual and

will be tested out prior to actual work is performed.– Reasonable time is allocated to perform FPA including proof of

principle.

• Open Issues– I invite the review team to offer their concerns or provide advice.– Some activities are still quite conceptual– Datum transferability and tolerance buildup– Very limited machine serviceability


M. Viola 17

NCSXAnd if all else fails

We found this guy

ncsx field period assembly (fpa) operations, cost and schedule, staffing, and metrology utilization...

Documents

fitfpa station

station setup

total fpa cost

time tasks

assembly drawingsoutput

final machine assembly

schedulefpa cost

activitycrack work crew