# Presentation: 885821

## Advanced Manufacturing FacilityPeer ReviewAugust 26 – 27, 2003Justification for a New Building

**Rich Stanek**

## Outline 

**Mission Statement for the Shops**
**Support of the Lab’s Mission **
**Historical Perspective and Present Status**
**Problems Facing the Machine Shops**
**Steps Being Taken to Improve the Situation**
**Why the New Building is Needed**
**Conclusion**

- R. Stanek

## Mission Statement for the Machine Shops

**The mission of the Fermilab Machine Shop is to provide a range of on-site machine shop and welding capabilities that meet the programmatic needs of the Lab, including:**
**Quick response for modification of existing components in support of accelerator and experiment operations**
**Machining of slightly radioactive materials under controlled conditions**
**Development of prototypes and proof of principle concepts involving close interaction with scientists and engineers**
**R&D associated with new or unique machining/welding technologies and processes as required for future projects**

- R. Stanek

## Supporting the Lab’s Mission

**Operation of the accelerator is 24/7.  On-site machine shops can react quickly to modify, repair or weld components for quick return to service **
- 	**(repair water, vacuum or cryogenic leaks, attach brackets and modify stands for beam components)**
**On-site machine shops can handle slightly radioactive materials (Class 1) and some types of hazardous materials under controlled conditions.  This eliminates the need for costly and sometimes risky transportation**
**	****(recent incident involving beam pipe)**
**The ability to refine or modify a component while it is being fabricated is invaluable, especially for situations involving design uncertainty**
**	****(flying wire vessels for Recycler, SCRF cavity prototypes, lithium lens...)**
**Direct communication with a machinist or welder is an excellent training ground for new engineers and scientists**
**	****(personal testimony as to the value of this interaction)**

- R. Stanek

## Supporting the Lab’s Mission (cont’d)

**On-site shops can serve as a back up to outside vendors when schedules are tight or when the parts come in and are not quite right and they can provide some flexibility when budgets are not yet available**
- 	**(Tevatron magnet stands, D0 fiber tracker connectors, CDF/COT parts...)**
**Welding capability must be present on-site in order to install equipment.  There are also many projects that require on-site machining due to the complexity of trying to transport components **
**On-site prototype activities help improve designs and aid in developing  accurate cost estimates for large production orders**
**	**
**On-site shops can undertake one of a kind, risky activities that otherwise would be cost prohibitive for a vendor**
**	****(CDF/Time of Flight welding template)**

- R. Stanek

## One Example of Machinists’ Contributions

- 															February 4, 2003
- TO:	Charles Matthews
- FROM:	Mike Foley
- 	BD/Mechanical Support Department
- RE:	Letter of Commendation for Joe Mueller and Gary Markiewicz
- Joe Mueller has been the primary machinist working on superconducting RF (SCRF) cavity fabrication for over a year.  Joe has done all the critical work, notably deep drawing niobium half cells for the Kaon Separator cavity development, and forming copper and niobium half cells for the 3rd Harmonic Tesla Injector.  The shape profile of the inner surface of these half cells is designed to electrically resonate at a precise frequency.  Thus, mechanical tolerances on the inner contour and the length of each half cell are strict.  It is the task of the machinist to devise a procedure to form and machine the half cells to satisfy these strict tolerances.  Joe has exceeded what both Dan Snee and I thought possible.  He just completed 22 copper 3rd Harmonic half cells.  Electrical measurements indicate these half cells were all within +/- 0.02% of the design frequency.  This was a remarkable achievement.
- Recently Gary Markiewicz has joined Joe on the SCRF cavity fabrication efforts.  Gary did the N/C programming and machining for the 3rd Harmonic end cell dies and turning fixture.  Gary has taken great interest in this work and is very productive.  Together Joe and Gary form an effective team.
- Joe and Gary are dedicated, methodical individuals who take pride in their work.  They are deserving of recognition for their contributions.

- R. Stanek

## History of the Fermilab Machine Shop

**The Fermilab Machine Shop was started in 1968 in a rented facility at an off-site location**
**Also in 1968, the Lab constructed eight very similar buildings to be used for laboratories, warehouses, etc.**
**One of those buildings (Lab 4) was designated as the Main Machine Shop**
**	****=> Never designed or optimized to be a machine shop**
**As time passed, the need arose for additional machine shop capabilities in the experimental areas and in Wilson Hall.  “Satellite” shops were set up to accommodate this need**

- R. Stanek

## How the Machine Shop Operates

**The Fermilab Machine Shop is organized to include the Main Shop (Lab 4), one large Satellite Shop (Wilson Hall), and five small Satellite Shops (IB4, Lab 8, Si-Det, MAB and MW9)  **
**The *****Main Shop***** is equipped to handle large fabrications, special welding requirements, EDM, CNC work, prototype development, long and short run jobs, and radioactive machining**
**Work taken to the Main Shop requires that a cost estimate be made and a signed Purchase Requisition (internal only) with appropriate budget code approval be produced**
**The *****Satellite Shops***** are situated in convenient locations around the site with an emphasis on putting the machining operation close to the fabrication work.  Typically, they handle smaller jobs both in size and duration; repairs, rework of existing components and prototype development**
**Work in the Satellite Shops is controlled by the local supervisor and requires only a budget code to charge time to**

- R. Stanek

## How the Machine Shop Operates (cont’d)

**The Machine Shop operates as a “cost neutral” organization in the Technical Division**
**Most operating expenses (direct salaries, consumables, tool bits, training, vacation and sick leave) are all covered by the “charge back rate” (currently $55/hour)**
- This charge back rate increases when the union salary scale increases or when the number of hours “sold” to projects decreases (lack of work, increased training time, sick leave or vacation)
- A recent survey of machine shop rates indicated we are comparable to rates charged by local vendors and very favorable compared to rates charged by other national laboratories
**Expenses not covered by this rate include cost of electricity and heating/cooling of the building (Lab budget), building repairs and new machine purchases (Tech Division budget)**
- Having shop functions spread out over several buildings _**increases the costs**_, particularly as the buildings and machines show their age

- R. Stanek

## Organization Chart

- R. Stanek

## Machine Shop Employment (Current)

**Total of 48 employees in the Machine Shop Department**
**Machinists – 26**
**Machinist Apprentices - 3**
**Welders - 9**
**Machine Shop Assistants - 3**
**Machine Repair Personnel- 2**
**Staff Supervisors (3 @ Main Shop, 1 @ Wilson Hall) - 4**
**Administrative Assistant – 1**
**Of the 26 machinists the distribution is as follows:**
**12  Main Shop**
**7    Wilson Hall Shop**
**7    Satellite Shops **

- R. Stanek

## Machine Shop Employment (Historical)

- R. Stanek

## Problems Facing the Machine Shop

**Where we are at now:**
**Overall budget for the Lab is tight**
- Low funding scenarios have reduced project budgets and forced project leaders to shop for the lowest cost alternatives for fabricating components
**Amount of work for the on-site shops has declined**
- A multi-faceted problem
*No new, “big” project for the Lab*
*Fermilab’s  Make or Buy Program has as its goal to ensure that goods and services are obtained in a best value/least overall cost manner *
*Outside vendors have been able to offer lower bids on jobs *
*Some projects have “industrialization” as one of their major objectives*
*Some projects require a “fixed price” bid for their part fabrication*
*New project leaders may not know the capabilities of our shops or appreciate the advantages and flexibility of doing a job “in-house”*
**Number of machinists has decreased**
- Since Sept 2000, the machine shop workforce has been reduced by 12 employees through normal attrition (resignations or voluntary retirement)
- On a positive note, we are supporting a Machinist Apprentice Program with three candidates currently enrolled

- R. Stanek

**Notes:**
Since Sept 2000, the machine shop workforce has been reduced by 7 employees through normal attrition (resignations or voluntary retirement).
This reduction is staff is consistent with the situation in the rest of the Lab.

## Problems Facing the Machine Shop (cont’d)

**Infrastructure problems**
- Old machines (WWII vintage) => higher maintenance costs, lower accuracy and fewer computer interfaces
- Type of machines needs to be better matched to projects => acquire machines tailored to the requirements and prototyping needs of our upcoming projects
- Aging building structures => crowded facilities, functions not centralized and high maintenance costs
- Competition for existing spaces (especially in satellite areas) => reuse existing buildings for new purposes
- The Village area is no longer the hub of construction activities.  The emphasis of this area is now housing and light assembly operations

- R. Stanek

## Site Map of Fermilab

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## Map of Village & Industrial Areas

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## Steps Being Taken to Improve the Situation(starting the process)

**Cost Control – Minimizing overhead charges whenever possible (reduced the number of management personnel by one) and regularly charting the “hours sold” percentage (areas that negatively affect hours sold are addressed).  Holding the line on new hires until new projects appear and work load calls for increases**
**Improve communication to projects by opening direct lines of communication and trying to get involvement from shop personnel early in the planning stages**
**Replace high maintenance and inefficient machines with new more accurate, modern and efficient equipment (whenever possible) **
**Doing Internal Assessments – Gathering data on the types of jobs coming into shops, performing customer satisfaction surveys and looking at variance reports for cost overruns  **

- R. Stanek

## Steps Being Taken to Improve the Situation(cont’d)

**Trying to make better use of the Internet by posting machine shop capabilities with pictures (for new engineers) and by finding a job scheduling and status program that allows people to see the status of their job**
**Shop Steering Committee (SSC) – Input from key personnel in the BD, PPD and the TD that helps to direct the future of the shops and keeps everyone informed of upcoming changes**
**Participated in the DOE Fabrication Facilities Peer Group Meeting (ORNL & LBL) – Representation from 10 National Labs from across the country**

- R. Stanek

## Problems with the Lab 4 Building

**Lab 4 has many problems, all of which have existed since it was first designated as the Main Machine Shop**
**Floor space is inadequate**
- Building is too narrow for proper machine spacing
- Aisles are not wide enough for forklift trucks
**Ceiling is too low for proper crane clearance**
**Crane capacity is inadequate and not continuous over the length of the building  **
**Lighting is poor**
**East end driveway ramp has a very steep incline **
**Attached offices (houses) do not provide adequate space for shop support functions**
**	****Over time some improvements have been made, however these problems still exist.  **_**Changes are very costly**_

- R. Stanek

## High Cost of Making Improvements(one example)

**There **_***was at one time***_**, a GPP Project entitled “Lab 4 Addition, which sought to make some improvements to the building.  **
**The scope included additions to the east and west ends of the building to increase the shop floor space and the construction of a 600 sq ft addition on the north side of the building to allow the washrooms to be repositioned and open up additional shop space**
**Project was divided into 5 phases to optimize the overall cost of the project and match the GPP funding profile**
**Estimated Total Project Cost ~ $1.4M ****(incl. EDIA, G&A, Cont.)**** **
**In October 2001, the Phase 1A (old washroom demolition and new construction) Title II construction package was released for bid with an estimated cost of $156K**
**Four bids ranging from $232K to $407K were received.  ****	****Attempts to reduce the costs were unsuccessful**
**	****Based on these results the *****AMF***** proposal was introduced**

- R. Stanek

## Floor Space is Inadequate

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## Ceiling is Too Low for Proper Crane Clearance

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## Crowded Aisles / East End Ramp

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## Machine Shop Operations

**Problems that affect the efficiency of operations:**
**Functionality of the shops (cut shop, sheet metal shop, machine repair, etc.) is spread out over several buildings  (all of which suffer from the same sorts of space constraints) ****=> Very inefficient with regards to work flow**
**Having multiple Satellite Shops increases the cost of operation with respect to additional supervision required and duplication of machinery (maintenance costs)**
**No staging area for incoming/outgoing materials**
**There is not enough floor space to add a Quality Control or a Temperature Controlled Precision Machining Area**
**Many machines are more than 50 years old (WWII vintage) and lack the advantages of new machines (precision, electronics, and lower maintenance costs)**
**As we invest in new machining technology, more space will be required as the foot print for new machines is larger**

- R. Stanek

## Staging Area / Machine Repair

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## Satellite Shops 

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## Possible New Equipment

**When budget permits, the shops will look at purchasing:**
**6 axis wire electrical discharge machine**
**Water jet machine**
**Rapid prototype machine**
**High precision CNC lathe**
**High precision CNC vertical mill**
**Laser machining and welding**
**Coordinate measuring machine**

- R. Stanek

## Conclusion	

**Fermilab needs a capable and efficient, on-site Machine Shop that provides services which complement those available from outside vendors**
**The present Machine Shop operations can be improved and made more efficient but only if the infrastructure allows for changes**
**The existing facility (Lab 4) has many operational problems and does not offer the flexibility to be transformed into the desired “shop of the future”**
***	***_***The Advanced Manufacturing Facility offers the right solution to the problem***_

- R. Stanek