NCSX

Field Period Assembly (FPA) Operations, Cost and schedule,

staffing, and metrology utilization

Mike ViolaField Period Assembly Manager

10 AM October 12, 2006

October 12, 2006 NCSX Field Period AssyPeer Review

M. Viola 2

NCSXFPA 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)

October 12, 2006 NCSX Field Period AssyPeer Review

M. Viola 3

NCSXFPA 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

October 12, 2006 NCSX Field Period AssyPeer Review

M. Viola 4

NCSXSAFETY

• 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.

October 12, 2006 NCSX Field Period AssyPeer Review

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

October 12, 2006 NCSX Field Period AssyPeer Review

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

October 12, 2006 NCSX Field Period AssyPeer Review

M. Viola 7

NCSXField Period Assembly Operations

VVSA1_MTM_FINAL_NUMBERS VVSA1_PPPL_BEST_FIT

Very good agreement.

October 12, 2006 NCSX Field Period AssyPeer Review

M. Viola 8

NCSXField Period Assembly Operations

VVSA2_MTM_FINAL_NUMBERS VVSA2_PPPL_BEST_FIT

Metrology is serving appropriate needs.

October 12, 2006 NCSX Field Period AssyPeer Review

M. Viola 9

NCSXField Period Assembly Operations

Station 1 setup Port prefit

October 12, 2006 NCSX Field Period AssyPeer Review

M. Viola 10

NCSXField Period Assembly Operations

October 12, 2006 NCSX Field Period AssyPeer Review

M. Viola 11

NCSXField 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

October 12, 2006 NCSX Field Period AssyPeer Review

M. Viola 12

NCSXField 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

October 12, 2006 NCSX Field Period AssyPeer Review

M. Viola 13

NCSXField 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

October 12, 2006 NCSX Field Period AssyPeer Review

M. Viola 14

NCSXField 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

October 12, 2006 NCSX Field Period AssyPeer Review

M. Viola 15

NCSXField 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

October 12, 2006 NCSX Field Period AssyPeer Review

M. Viola 16

NCSXField 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

October 12, 2006 NCSX Field Period AssyPeer Review

M. Viola 17

NCSXAnd if all else fails

We found this guy