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Production & Maintenance

Production & Maintenance. Steven J. Durand May 2006. Electronics Division Manufacturing Goals. Out-source board assemblies Build modules in-house as needed Ready the facility for manufacturing ESD protected facility Production success stories.

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Production & Maintenance

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  1. Production & Maintenance Steven J. Durand May 2006 Advisory Committee May 2006

  2. Electronics DivisionManufacturing Goals Out-source board assemblies Build modules in-house as needed Ready the facility for manufacturing ESD protected facility Production success stories Advisory Committee May 2006

  3. Outsource Circuit Cards- Board Vendor Provides: • Fully assembled boards/cables • Some assemblies tested • Flying probe tests – NRAO test fixtures • ESD packaged and labeled • Scheduled deliveries • Hazardous chemical handling Advisory Committee May 2006

  4. In-house Module Assembly Preparation • Trained staff • Same team that built the prototypes • Complete assembly drawings • New soldering stations • Test equipment & computers in place Advisory Committee May 2006

  5. Planning for Small Production Runs • Goal is to produce 28 identical antennas • Small quantity builds, 5-10 at a time • In-house module assembly and test • VLBA cable and small parts assembly Advisory Committee May 2006

  6. Inventory Control • New and old warehouse managed by Skip Lagoyda, Business Manager • Control of high dollar items • PeopleSoft software re-order mechanisms Advisory Committee May 2006

  7. CDL / EVLA Coordination Advisory Committee May 2006

  8. Attributes of In-house Module Assembly • Minimize module storage problems • Tight engineering control • Improve the design • Fast turn-around time • Distributed parts inventory Advisory Committee May 2006

  9. ESD Preparation • 12 ESD stations including floor mats • ESD totes and parts bins • ESD shoes and wrist straps • Humidity controlled facility Advisory Committee May 2006

  10. Trained staff Some components only available in lead-free. Can be used with ‘leaded’ solder. May require higher soldering temperatures, 20 to 30 degrees higher (Fahrenheit). Solder & Flux Compatibility, and Quality Issues Advisory Committee May 2006

  11. Mother Board Approach • More robust design • Easy to assemble Advisory Committee May 2006

  12. MIB Quality • 1400 MIBs required for the project • 34 in each antenna - in every type of module • Turn-key solution • Large quantity buys lowered price per board • 100% flying probe – 100% electrical test • 99% yield (last run of 100 boards) Advisory Committee May 2006

  13. Design for Manufacturability • 300 pin transponder • Easy assembly • 10GHz circuits Changed vendor to save $400K without a design change Advisory Committee May 2006

  14. Conclusion • Ready to maintain production schedule • Looking for cost savings • Utilized every NRAO asset • Manufactured for a 20 year life Advisory Committee May 2006

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