LOI Backup Doc: Strips Production

1. LOI Backup Doc: Strips Production Feb Mtg 2012

2. Assembly • Basic model (barrel): • 6 mo. ramp, 2 years production • ~500 staves needed (inner + outer) • 1 stave/day (1 core, 2 bus tapes) • 24 modules • 48 hybrids • 2 EOS • 48 PPB, HCC if not integrated

3. Basic Model • Avoid single point bottlenecks • Certain critical capabilities to be duplicated • 2 stave core sites • 2 bus tape sites • 2 module attach sites • Front load industrial production aspects so inventory is on-hand and pre-tested • Many hybrid/module production/test sites • Identical fixtures, software, procedures, QA

4. Production Effort Model • Assy = mounting, gluing • Bond = wirebonding • Insp = metrology, probing • Test = electrical test and burn-in • Model is for barrel only, assume 0.5 year ramp, 2 years production, 6 mod, 4 hybrid sites, average 1 stave/day total. This determines all the other required rates • Total technician workforce = ~60 “shifts” • If peak rate needs to be higher add shifts rather than acquire additional capitol equipment? • Bottlenecks may be testing and burn-in rather than assembly steps • This does not include engineering, physicist oversight, armies of postdocs, students

5. Production Example • Wirebonding: 48 hybrid, 24 modules, 2 EOS, 1 stave / day • From prototype build and estimate: ~60technicians • 2 modules bonded/shift = 12 shifts • 12hybrids bonded/shift = 4shifts • 1/2 stave = 1 shift • +overflow • 6 module / 4 hybrid sites • Other calculations for assembly (2-3/site), inspection (2), test (3) • Large equipment required • Bonding machines • CMM • Glue dispensing systems • Assembly robot?, alignment systems (like SCT) • Temperature controlled chambers • HSIO systems