**I**

**HEP Production Readiness Review:**

**Findings and Recommendations**

During a period of two days, the IHEP Production group led by Chunhua
Jiang presented to the review committee their plans for the CMS-EMU
Chamber production at IHEP. The review committee had a chance to visit
the production factory and address directly the vast majority of the
issues associated with the startup and operation of their production
facility. Based on the IHEP presentation and factory tour we were given,
we present our comments and recommendations subdivided into the
following categories:

-   Factory Setup

-   Tooling

-   Production Control & Travelers

-   Production Engineering & Coordination

-   Project Management

For each category, we present a brief paragraph describing the major
findings followed by the relevant committee recommendations.

######## Factory Setup

######### 

######### **[Findings]{.underline}**

The IHEP Factory has the major tooling in place, setup, and ready to
start chamber production. The sub-assemblies necessary for chamber
production have been clearly identified and proper tools are in place.
Secondary tooling was not visibly in place. In particular there was no
space identified or allocated for drying the panels, after hand
cleaning, and for storage of completed panels during interim stages
prior to the chamber assembly. There was also no space identified for
the HV training of multiple chambers or for chamber reworks. The plan
for the assembly of small sub-assemblies was not clear.

The factory personnel were identified and trained on the specific steps
of the chamber production. It was not clear however, that proper
cross-training has taken place to prevent production slow-down in the
event of key personnel absence. It also appeared that some of the
personnel who built the prototype chambers were not full time
contributors to the project.

The production flow plan showed only how chamber parts would flow in
order to attain maximum production rate, but did not show all the
tooling that was required and how all their tooling and the production
space is to be utilized. Hence no tooling or space utilization critical
path analysis could be realized.

> Production activities have been generally defined and sequenced.
> Estimates of activity duration are in place and a preliminary daily
> production schedule has been presented. It is the committee's opinion
> that the IHEP group is doing all the right steps to converge on a
> meaningful and obtainable production plan.
>
> **IHEP Response to PRR Recommendations**

######### **[Recommendations]{.underline}**

1.  ***Consider the various storage needs and issues for interim parts
    and assemblies (parts, panel, and chamber storage, etc.) and insure
    there is adequate space for parts and tooling during chamber
    production.***

> **Take the hall beside the fast site lab for general storage, like
> completed chambers, chamber parts**

2.  ***Allocate resources and some space for unavoidable panel and
    chamber rework***

***.***

> **Half of the preparation room 40SqM for this work should be enough**

3.  ***Cross-train the assembly personnel on as many aspects of the
    chamber production as possible.***

> **scheduled when the mass production starts**

4.  ***Develop a plan to complete the various subassemblies or parts
    preparations (ground foils, cathode connectors, resistors,
    capacitors, etc..) with available resources before they are needed
    in production.***

> **Responsible person and place (in meeting room) defined**

5.  ***Present an updated production flow plan that shows what tooling,
    manpower, and space is needed for each operation in the production
    process. This analysis is needed to insure that there are no
    critical path issues and that there is an adequacy of each
    available.***

**Done(see attach file Schedule.jpg)**

6.  ***Allocate some special space for High Voltage Test and Training
    away from the assembly area.***

> **in the east part of tension measurement room, NIM crates ready
> there**

7.  ***Develop a plan for safely transporting completed chambers to the
    FAST site facility such that the chambers are protected from the
    weather and damage.***

> **Special electrical car with hut and crane for transporting under
> investigation**

8.  ***Based on US experience (FNAL, UF, and UCLA), increase the number
    of physicists and engineers, not counting technicians, working full
    time on the CMS CSC project to a minimum of 5-7 by January, 2002, in
    order to insure adequate management, production, and testing
    support. In addition, there may be a need for more support provided
    by physicists and engineers, working part time on the CMS
    Project.***

> **try to get as many physicists to be involved by Jan. 2001**

######## Tooling

######### 

######### **[Findings]{.underline}**

All the major critical tooling for chamber production is setup and
functioning in place, and has been used for the assembly of two
prototypes. Some other small tools, production aids, carts, and other
secondary tooling useful for chamber production (wire positioning tools,
support/storage for finished panels, etc..) were not available on the
production floor at the time of the review but we were told that these
items have been made and exist.

######### **[Recommendations]{.underline}**

1.  ***In general, refine the production process to smoothen out
    critical path areas and insure there is an adequate amount of needed
    tooling in each area to sustain at least the ultimate production
    rate.***

> **done**

2.  ***Establish a production plan that would allow the production
    facility to operate above the expected peak capacity in case
    problems delays require the ability to catch up.***

> **done**

3.  ***Obtain additional equipment to measure atmospheric pressure,
    humidity, and temperature during leak rate tests.***

> **additional three Humidity and temperature digital meters,the
> atmospheric pressure meter delivered to CSC lab, there are 4set in
> total**

4.  ***Complete acquisition and preparations of all tools, jigs, and
    fixtures for the processing and assembly of parts and subassemblies
    (capacitors, resistors, foils, connectors, etc.)***

> **done**

5.  ***Develop a program for the routine testing and recalibration of
    all the required tools and measuring instruments to be used .***

> **allocate the workshop calibration center to do this every two months
> and when accidents happens, tenstion calibration is under
> investigating**

######## Production Control &Travelers

######### 

######### **[Findings]{.underline}**

In general, the IHEP group should be congratulated for adopting the
travelers scheme to insure control of the chamber production process.
They have chosen to use the English language Fermilab supplied ME 1/2
and ME 1/3 prototype chamber travelers as a basis for creating and
maintaining production chamber travelers. Fermilab will send current and
updates of the ME 234/2 travelers to IHEP and IHEP will have to insure
they update their travelers to be consistent in content and methodology
with Fermilab's ME 234/2 travelers. IHEP will maintain a master set of
Chinese interpretation traveler documents only as a reference for
personnel that have difficulty understanding the English version
travelers. Examination of the IHEP used travelers completed for the
prototype chambers showed several areas where the travelers were not
completely filled out and signed or where data entries of test
measurements were clearly outside of specification limits with no
follow-up action indicated or discrepancy report written. IHEP did not
have in place a system or procedure for dealing with discrepancies.

######### **[Recommendations]{.underline}**

1.  ***Insure that all Travelers are complete and up to date and
    consistent with FNAL reference travelers.***

> **the responsible person defined and is doing this**

2.  ***Establish proper lines of responsibility and authority for
    following traveler directions, document data entry, sign-off, and
    document close-out .***

> **the responsible person defined**

3.  ***Institute a post final assembly close-out check list to insure
    all instructions, steps, tests and measurements, and packaging
    requirements are met prior to closing a chamber up into its shipping
    box.***

> **done by defined responsible persons**

4.  ***Scan all Travelers and associated Discrepancy Reports and make
    them available on the Web, allowing an active dissemination of these
    documents.***

> **one page/chamber and Discrepancy report are planed to be done**

5.  ***Measure the panel strip positions and write them to a database
    available to the EMU Collaboration.***

> **wait for the database ready**

6.  ***Reference, in the IHEP travelers, the FNAL traveler version to
    which they are associated for cross-reference purposes.***

> **done**

7.  ***Establish a Quality Assurance Calibration Plan whereby all
    measuring and test instruments and equipment are re-measured on a
    periodic basis to insure they remain in calibration.***

> **Done**

8.  ***A Discrepancy Report (DR) plan needs to be established and
    implemented within the factory Quality Assurance group.***

> **the discrepancy form needed from FNAL for refrence**

9.  ***Create a plan to be followed for follow-up inspections of vendor
    made parts.***

> **done with the company**

######## Production Engineering & Coordination

######### 

######### **[Findings]{.underline}**

In general there is good engineering support for the production at IHEP
although some items such as customs issues, configuration control, and
document control require additional attention by both IHEP and Fermilab.

######### **[Recommendations]{.underline}**

1.  ***Insure that all drawings, travelers, and specifications are under
    "Configuration Control" meaning you are using only the latest
    official FNAL specified versions and/or revisions prior to beginning
    any part procurement or manufacturing process.***

> **Responsible person assigned**

2.  ***Drawings and specifications to be used in the manufacturing shops
    at IHEP should be converted as required to suit the vendor or
    machinist needs (metric units, european projection standards,
    etc.).***

> **We strongly ask to have the hard copy drawings with Metric units and
> the signature of the authors sent to IHEP so we could know it is the
> right version we get from Web**

3.  ***IHEP should follow the procedures to be distributed by N. Chester
    to insure the documents being used for production are those that are
    under Configuration Control.***

> **sure**

4.  ***Provide proper QA for parts not inspected by FNAL (Anode
    Protection Boards, SIPS, subassemblies and manufacture frame
    parts).***

> **will be done by special responsible persons**

5.  ***Separate the Final Assembled Chamber certification from the
    Integrated (FAST-SITE) Chamber Validation. Perform Final Assembled
    Chamber Certification after chambers are completely assembled BUT
    before being sent to the FAST SITE for electronics and cooling plate
    integration and final integrated chamber test validation.***

> **sure**

6.  ***Fully describe in a written document what packaging documentation
    must be provided by third parties (FNAL, US Universities) along with
    shipped goods to allow for the efficient clearance of these items
    through the Chinese Custom.***

**done by Mr.DENG of IHEP custom office to Oleg**

7.  ***Set up a computer assisted Inventory Control system to keep track
    of parts distribution and quantities on hand.***

> **Done(computer ready and defined person)**

8.  ***Develop a plan that can be implemented to control and protect
    in-process parts. Describe the space and tooling needed to provide
    for their safe keeping.***

> **at the parts preparition room and responsible person defined**

######## Project Management

######### 

######### **[Findings]{.underline}**

> The scope of the IHEP effort was clearly and accurately defined
> (manufacturing and handling of chamber parts and assembly of ME1/2 and
> ME1/3). With the exclusion of Project Cost Management, almost all of
> the major management areas have been addressed in a satisfactory way
> by the IHEP group. The management hierarchy was graphically shown and
> described and the management plan presented for the project seemed
> clear and adequate. However, some question about the exact duties and
> responsibilities of each of the management personnel appeared to
> exist.
>
> Of concern is the fact that funding for all the projected 12 needed
> technicians and associated physicists and engineers are not available
> at this time and that the people who are contributing to the project
> are all not necessarily scheduled to work on the project full time.
> Also, no inventory control person seemed to be assigned to manage the
> production flow and control of parts.
>
> No risk analysis and contingency plan was presented to the review
> committee should IHEP fall behind in its production schedule. There
> are risks associated with the production and integration of the
> chambers (none of the chambers to be assembled at IHEP have been
> integrated yet), risk associated with the shipment of chamber parts to
> IHEP , and risk associated with the timely shipment of chambers from
> IHEP to CERN.

***[Recommendations]{.underline}***

1.  ***Appoint an individual to act as "Inventory Control Coordinator
    (ICC)" responsible for the gathering up of chamber parts from
    inventory and bring them to the shop floor. This person should also
    maintain and control inventory part counts and flow using a computer
    assisted database or spreadsheet.***

> **Will be done**

2.  ***Consider placing all chamber (and integration) parts in dedicated
    bins or on shelves labeled with respective part numbers, and
    controlled by ICC.***

> **under doing**

3.  ***Identify the risks of the project. If and when they affect the
    CERN installation schedule, develop alternative plans with the
    agreement of the L1-L2-L3 Management in CMS.***

> **Main risk is from Material Shipping and the critical toolings like
> winding machine, tension measurement equipment, if key parts damaged,
> immediate help from US needed. We could not be responsible for the
> chamber parts shipping delay**

4.  ***Since no Risk Analysis has been presented to the Review
    Committee, it is strongly suggested that IHEP develop a Risk
    Analysis, assessing ALL the risks to the project and the potential
    for delays or failures to the various major production activities
    and operations, and present a contingency plan that shows how
    recovery may be accomplished. Where these risks could potentially
    affect the CERN installation schedule, deviant plans must be
    approved by L1, L2, and L3 CMS Management. Included should be the
    potential need for extra tooling and personnel to allow the
    production of more than 6 chambers per month.***

> **as above**

5.  ***Resolve remaining funding issues with IHEP and Project
    Management.***

**sure**

6.  ***Present a plan that clearly defines the rolls and
    responsibilities of all contributors, covering all operations of the
    chamber production effort. This plan should include the rolls of all
    physicists and engineers as well as technicians.***

> **will be done when all needed physicists confirm their joinning**

7.  ***Present a plan showing when the contributors mentioned in item #6
    above are to be brought into the project and the percentage of their
    time that that will be allocated to the CMS chamber assembly and
    testing and FAST site assembly and testing over the duration of the
    project.***

> **Will be done**