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Mike Viola Field Period Assembly Manager

Field Period Assembly (FPA) Operations, Cost and schedule, staffing, and metrology utilization. Mike Viola Field Period Assembly Manager. NCSX FPA Peer Review October 11-12, 2006 PPPL. FPA Concerns and Risks. Heavy emphasis on Prototyping each activity Crack Work Crew and Support

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Mike Viola Field Period Assembly Manager

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  1. Field Period Assembly (FPA) Operations, Cost and schedule, staffing, and metrology utilization Mike Viola Field Period Assembly Manager NCSX FPA Peer Review October 11-12, 2006 PPPL

  2. FPA 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) NCSX Field Period Assembly Peer Review

  3. FPA 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. NCSX Field Period Assembly Peer Review

  4. “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. NCSX Field Period Assembly Peer Review

  5. 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 then revised to include developed improvements. NCSX Field Period Assembly Peer Review

  6. FPA Roll up Schedule NCSX Field Period Assembly Peer Review

  7. 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 Assembly Peer Review

  8. FPA Metrology Very good agreement. VVSA1_MTM_FINAL_NUMBERS VVSA1_PPPL_BEST_FIT NCSX Field Period Assembly Peer Review

  9. FPA Metrology Metrology is serving appropriate needs. VVSA2_MTM_FINAL_NUMBERS VVSA2_PPPL_BEST_FIT NCSX Field Period Assembly Peer Review

  10. FPA Station 1 Active Station 1 setup Portprefit NCSX Field Period Assembly Peer Review

  11. FPA Schedule NCSX Field Period Assembly Peer Review

  12. 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 NCSX Field Period Assembly Peer Review

  13. 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 NCSX Field Period Assembly Peer Review

  14. 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 NCSX Field Period Assembly Peer Review

  15. 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 NCSX Field Period Assembly Peer Review

  16. 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 NCSX Field Period Assembly Peer Review

  17. 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 NCSX Field Period Assembly Peer Review

  18. And if all else fails We found this guy NCSX Field Period Assembly Peer Review

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