Assembly Organisation and Duration Cavities DIRTY TRIAL ASSEMBLY
Assembly Organisation and Duration
Cavities DIRTY TRIAL ASSEMBLY Large Parts Small Parts CM Cryostat parts STORAGE SMA 18 MANUFACTURE Work Site Organisation CERN-SITE CLEANING ISO 5 Baldaqun PREPARATION CLEANING SMALL PARTS ISO 7 UNLOADING ISO 5 CLEAN ROOM SM 18/SMA 18 AREA
Manpower and Assignment of Roles Role Assembly coordination Assembly workforce Clean-Room tech. Components preparation (outside clean-room) # FTE Identified person(s) Competency Remark 1 Y. Leclercq, L. Williams Eng 2 teams of 2 G. Barlow+ X 1, X 2+X 3 Mech Tech: Clean-room Trained and Cryo-module Trained 1 shift of 8 h/day 1 J. B. Deschamps, M. Souchet+FSU Mech Tech includes cleaning Quality Control Team Quality Manager 1 (part time) J. A. Bousquet Eng or tech eng Vacuum leak checks 1 (part time) Technician to be identified Vac Tech Survey alignment/checks 2 (part time) G. Kautzmann, C. Gayde Survey Tech 1 (part time) Technician to be identified Elec Tech Electr. Tests Assembly Support Team Assy follow-up and documentation 1 (part time) J. A. Bousquet Eng Storage and Logistics 1 (part time) J. B. Deschamps+FSU Tech Cryo-module Design & Integration 1 (part time) J. Dequaire Des eng, Des tech Tooling design 1 (part time) P. Minginette Des eng, Des tech Workshop support Dirty trial assembly Maintenance Team Clean-room Housekeeper Clean-room tooling Supporting Services on need TBD Wks Tech re-work components/tooling 1 (part time) TBD Mech Tech 1 (part time) TBD Tech 1 (part time) J. A. Bousquet+FSU Mech Tech Handling and transport 1 (part time) Tech SM 18/SMA 18 Cleaning 1 (part time) M. Malabaila's team Tech on need TBD Eng HSE safety
On-site Quality Assurance Should be independent of the production Tasks specific to the first assembly: Take ownership of the draft procedures Follow the work in progress Modify/update the procedure in work according to lessons learned Photographic support Text update support Feedback to worksite Take action to modify procedures to come that may be affected by current changes General Tasks: Keep a manufacturing/assembly file up to date as work progresses Manage results of QA tests including preventive/corrective actions on non-conformities
Estimates of Time Required • Recently, three people well informed about our project, did 3 independent estimates • Of these, one person considered the assembly in “production-line” terms where – All resources are in place meaning: • All parts immediately to hand • Procedures fully tested and validated • All tooling fully tested and validated • Clean-room assembly staff well trained and practiced • Unforeseen problems very largely ironed out of the process – This could also be called a well mastered “routine” activity. – Where we had already assembled a few cryo-modules of the same type – Where the total time required comes close to the sum of the times needed for the suite of component activities
“Routine Task” Time Required Procedure stage Time taken in days 1 Vacuum vessel assembly 3 2 Thermal shield and vessel assembly 3. 5 3 Chimney assembly 1. 5 4 Chimney on to the lifting frame 5 Top plate assembly 6 Upper thermal shield and He tank 7 Insertion of the chimney 2. 5 8 Installation of the support frame 4. 5 9 Installation of the solenoid 3 10 Installation of the cavities 5 11 Installation of the cavitiy auxiliaries 7 12 Cryomodule vessel closure 4 1 1. 5 2 38. 5 days total Approximately 8 weeks
Real Time required? • Our situation for the first cryo-module is quite different; • New activity at CERN, new people, new tooling, new draft procedures, new QA activities. • Equipment and tooling is now arriving on a just in time basis
What may we expect in reality? • A first prototype – Debugging on 1 st CM; will be better on 2 nd – Some Re-work on components, procedures • New activity, new clean-room, new tooling: – Running in phase may be long – Incomplete learning curve on 2 units (just debugging) • Missing resources: slow build-up of assy team: – Specific training is needed on CM assembly • New Clean-room: – Training is needed for productive clean-room work • Uninterrupted work depends on “continuous flawless coordination” around the assembly (inside and outside the clean-room) Reasonable? • …
- Slides: 8