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DOE Review of the LCLS Project 24-26 October 2006

This review outlines the major areas of quality assurance in the LCLS project, including design reviews, procurement control, manufacturing processes, problem identification and corrective action, systems integration, and work authorization.

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DOE Review of the LCLS Project 24-26 October 2006

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  1. DOE Review of the LCLS Project24-26 October 2006 Quality Assurance Darren S. Marsh Stanford Linear Accelerator Center

  2. Outline • Major Areas of Quality Assurance • Quality Program Management and Support Planning • Design Reviews • Procurement and Subcontractor Control • Manufacturing, Inspection and Test Control • Problem Identification and Corrective Action • Systems Integration • Work Authorization • Summary

  3. Quality Assurance Program LCLS QA Program will be conducted in accordance with LCLS Quality Implementation Plan Lessons learned from other programs will be utilized The implementation relies upon the controlled application of plans, procedures, and requirements • Objectives • Clear, formal communications of specifications • Clear, formal definition of interfaces and responsibilities • Verification that specifications have been met

  4. Technical Specifications

  5. Technical Baseline – Design Definition Requirements Summary

  6. Requirement Documents Tracking • Requirement documents status reviewed at LCLS Management Meetings • Applicable requirements document updated based on CCB action or requirement change

  7. Design Review Program • Design reviews are essential to good engineering practice and are used as a quality assurance metric to ensure the successful construction of the LCLS. • ESD 1.1-324 establishes guidelines for design reviews conducted by the LCLS Subsystems. • It describes the material to be covered, the documentation requirement and the process for closure of all action items. • Reviews based upon the appropriate selection from the following reviews: • System Concept Review (SCR) • Preliminary Design Review (PDR) • Final Design Review (FDR) • Readiness Review (RR)

  8. Technical Design Reviews • >100 design reviews have taken place • ~50 design reviews have taken place in last six months

  9. Procurement & Subcontractor Control • PMD 1.1-013 establishes processes to ensure that suppliers provide items and services that meet requirements • Procured items and services must perform as specified and meet requirements • Suppliers are evaluated and selected based on specified criteria • Acceptance of procure items and services in accordance with specified methodology • Advance Procurement Plan key for critical procurements • ~50% of the technical procurements and subcontracts executed • No major issues to date

  10. Work Processes • Manufacturing, Assembly and Installation Activities • Work processes are planned and controlled • Activities are performed in accordance with prescribed instructions, procedures and drawings • Items are designed and changes controlled using sound engineering practices, analyses and configuration management • Inspection and Test • Items are inspected and tested to verify conformance to specified requirements

  11. Inventory Database Drawing # from SLAC document control Serial #, Barcode #, Alias name Optics name

  12. Problem Reporting • LCLS QA Report identifies major systems and components that do not meet established requirements • Conditions adverse to quality are identified, controlled and corrected to prevent recurrence, and reviewed for lessons learned • 11 QA Reports generated to date • Most visible QA issue relates to problems associated with BPM feedthroughs

  13. PMD 1.1-028 describes roles and responsibilities for integration and installation planning and coordination Quality Assurance activities Facilitate the early detection of problems Ensure adherence of products and activities to applicable standards and requirements Ensure peer reviews are conducted where appropriate Verify change documents are developed when identified and configuration management is maintained Systems Integration

  14. LCLS Work Authorization • PMD 1.1-026 provides guidance for affirming readiness of personnel to perform LCLS related work • Ensures that work will be done safety • SLAC standards and requirements are met • Work planning has been completed such that it will completed properly the first time • LCLS Quality Assurance Manager has approval authority when work is sufficiently complex or has sufficient programmatic importance • Completed Work Authorization Forms are archived in QA Sharepoint folder

  15. SLAC/LCLS ES&H Interface • Safety Oversight Committee (SOC) • Coordinates environment, safety and health review by CCs or SOs • Citizen Committees (CCs) • ALARA Committee • Earthquake Safety • Electrical Safety • Environmental Safety • Fire Protection Safety • Hazardous Experimental Equipment • Hoisting and Rigging Safety • Laser Safety • Non-Ionizing Radiation Safety • Radiation Safety • ES&H Division • Subject Matter Experts • Safety Officers (SOs) appointed by SLAC Director • SLAC ES&H Manual, Chapter 2 – Work Authorization, delineates process to obtain SOC/Citizen Committee/Safety Officer approval

  16. Summary • LCLS Quality Assurance Program well established • Quality Assurance processes are in place to plan, perform, assess, and improve work • Based on the development and maintenance of the integrated LCLS Total Management System • Performance Oriented • Infrastructure elements in place for successful integration/installation of system hardware • Need to maintain current level of teamwork and cohesiveness

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