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Corrective and PreventiveMaintenance at NSCL

OutlineIntroduction to NSCL & MSU

Quality Management at NSCL

Tools used at NSCL for availability

Future

Questions

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

Located on the campus of Michigan State University

NSCL employees 454 Faculty,Staff and Students

Ranked as the #1 graduate program in nuclear physics In the United States by U.S. News & World Report

Cyclotrons & Beam Lines

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

Michigan State University

MSU has over 11,000 employees

In 2010, MSU enrollment consisted of 47,131 students from all 50 United States and 130 countries

Throughout the world, there are nearly half a million MSU alumni

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……….

Why is a Robust Maintenance Program Important?

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

“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 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”

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 Quality Management System

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

Rare isotope beams will be delivered with 90% availability

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

NSCL QMS Quality Objectives

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

NSCL Availability

ToolsLogging & Reporting

Administrative

Document Handling

Inventory Management

Planning

Scheduling

Tools…the actual hand tools

Logging and ReportingHourLog

Trouble Reports

Allows for both narrative and system status reporting

Reliability statistics are derived from HourLog

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

AdministrativeReliability Committee

Repair Team

Trouble Reports are reviewed bi-weekly

Committee can reopen a solved Trouble Report for further investigation

Meeting called by department head

All system experts are present

Actionable items generated

Document HandlingAlfresco document management

Workflow determined by users

Mechanical Design department design review approval

Revision control

Inventory ManagementDeveloped in-house, using IRMIS

IRMIS is a descriptive documentationTool *

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)

SchedulingAdministration Schedule

Short Term Schedule

~ 1 hour resolution

~ 1 day resolution

Determined daily

Determined 3 months out

Operations has final review

STS Coordinator

Maintenance PlanningExperimental 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 PlansIn 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 toolsModified 5S method

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

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 *

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

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

Vault Tool Box

Tool Integration

Operator Structure

Operations/Maintenance

Maintenance Engineers

Operating Engineers

During experiments, all personnel rotate through shifts as operators

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

FutureTighter Integration of tools

Written with common software

Questions