# Presentation: 438972

## Advanced Manufacturing FacilityPeer ReviewAugust 26 – 27, 2003Existing Conditions & Data on Shop OperationsCharles Matthews

## Outline

**Number of Employees**
**Age of Workforce**
**How Shops are Organized**
**Type of Work Survey**
**Available Hours/Hours Sold by Month**
**Perspective**
**Examples of Work**
**Existing Conditions**
**Conclusion**

- Charles Matthews

## Current Number of Employees

**Machinists – 26**
**Classifications and number of people:**
**Instrument Machinist – 3**
**Instrument Maker – 4**
**CNC Machinist – 5**
**Working Foreman – 3**
**Machining Specialist – 1**
**CNC Capable Inst. Mach./Inst. Maker - 10**
**Weldors - 9**
**Machine Shop Assistants - 3**
**Operate Cut Shop**
**Operate Tool Crib**
**Lube Machines**

- Charles Matthews

## Current Number of Employees (cont’d)

**Machine Shop Assistants (cont’d) - 3**
**Rad wipes and rad surveys**
**Setup radiation machining areas**
**Control Waste**
**Apprentices - 3**
**Machine Repair - 2**
**Have mechanical and electrical expertise**
**Troubleshoot and repair shop equipment**
**Provide repair service to other Departments**
**Bargaining Unit - 43**
**Staff Supervision - 4**
**Office Support - 1**
**Total - 48**

- Charles Matthews

## Workforce

**Average Age**
**Machinist Age Average****	****	****   51**
**Average Years of Experience****	****29.5**
**Weldor Age Average****	****	****   48**
**MSA Age Average****	****	****   50**
**Apprentice Age Average****	****	****   32**
**Machine Repair Average****	****	****   51**
**Overall Group Age Average****	****   49**

- Charles Matthews

## How the Shops are Organized

**The Fermilab Machine Shops are comprised of one Main Shop (15), one large Satellite Shop (7), and five small Satellite Shops ranging from one to two Machinists in each shop.**
**Main Shop**
**The Main Machine Shop is equipped to handle large fabrications, special welding requirements, EDM, CNC machining and programming, prototype development, long and short run jobs, and perform radioactive machining.**

- Charles Matthews

## How the Shops are Organized (cont’d)

**Main Shop (cont’d)**
**Open to all Lab users at shop rate.  Nonusers at shop rate + G&A.**
**Broad mix of machinery.**
**Nine CNC machines.**
**Tighter quality control.**
- Calibrated measuring tools.
- Shop floor CMM.
- Contour projector.
**Capable of running a number of short and long run jobs concurrently.**
**Heavy jobs - up to 5 tons.  (Limit of the crane.)**
**Prototype development.**
**Rework.**
**Customer provides drawings or sketches.**
**Fast turnaround one to two weeks.**
**Flexible queue.**

- Charles Matthews

## How the Shops are Organized (cont’d)

**Satellite Shop**
**Staffed by one to seven man shops.**
**Satellite shops are located at convenient locations to satisfy the needs of the users.**
**The assignment of work and setting of priorities is the responsibility of the area supervisor.**
**The Machine Shop maintains administrative control of the machinist.**
**The machinist is embedded in the group and offers solutions to manufacturing problems.**
**Wilson Hall, IB4, Si-Det, MAB, Lab 8, and MW9.**
**Light production - short duration jobs.**
**Rework.**
**Small repairs.**
**Prototype development and manufacturing problems.**

- Charles Matthews

## How the Shops are Organized (cont’d)

**Satellite Machine Shops**
**We currently staff six satellite Machine Shops.**
**There are 14 Journeyman Machinists in these shops.**
**Shops are placed at convenient locations to satisfy the needs of the users.**
**They are under direct control of a particular department but the Machine Shop retains oversight management.**
**The department that the machinist is assigned to sets priorities.**
**Wilson Hall Machine Shop**
**Staffed with seven Journeyman Machinists.**
**Shop is designed to handle small to medium size jobs.**

- Charles Matthews

## How the Shops are Organized (cont’d)

**Wilson Hall Machine Shop**
**Equipment includes:**
- 2 CNC Vertical Mills, 1 CNC Lathe
- 1 CNC Wire EDM, 1 EDM Sinker
- 4 Bridgeport EZ-Trak Mills
- 2 Standard Bridgeport Mills
- 1 Horizontal Jig Mill, 6 Tool Room Lathes
- Misc. sawing, grinding, and sheet metal equipment
**Shop mainly provides fast turnaround support for the Beams Division.**
**Industrial Building 4 Machine Shop**
**Staffed with two Journeyman Machinists.**
**Shop is designed to handle small to medium size jobs.**

- Charles Matthews

## How the Shops are Organized (cont’d)

**Industrial Building 4 Machine Shop**
**Equipment includes:**
- 1 Bridgeport EZ-Trak Mill
- 2 Standard Bridgeport Mills
- 2 Horizontal Jig Mills, 3 Tool Room Lathes
- Misc. Sawing and grinding equipment
**Shop mainly provides fast turnaround support for the Technical Division.**
**Meson Assembly Building Machine Shop**
**Staffed with two Journeyman Machinists.**
**Shop is designed to handle small to medium size jobs.**
**Equipment includes:**
- 3 Standard Bridgeport Mills
- 2 Horizontal Jig Mills, 4 Tool Room Lathes
- Misc. sawing, grinding, and sheet metal equipment.

- Charles Matthews

## How the Shops are Organized (cont’d)

**Shop mainly provides fast turnaround support for the Mechanical Group  of the Particle Physics Division.**
**Meson West 9 Machine Shop**
**Staffed with two Journeyman Machinists.**
**Shop is designed to handle small to medium size jobs.**
**Equipment includes:**
- 1 Standard Bridgeport Mill
- 2 Tool Room Lathes
- Misc. sawing and grinding equipment
**Shop mainly provides fast turnaround support for the Cryogenic Group of the Beams Division.**
**Lab B Machine Shop**
**Staffed with two Journeyman Machinists.**
**Shop is designed to handle small to medium size jobs.**

- Charles Matthews

## How the Shops are Organized (cont’d)

**Equipment includes:**
- 2 Standard Bridgeport Mills
- 2 Tool Room Lathes
- Misc. sawing, grinding, and sheet metal equipment
**Shop mainly provides fast turnaround support for the Silicon Detector Group of the Particle Physics Division.**
**25A Blackhawk Machine Shop**
**Staffed with one Journeyman Machinist.**
**Shop is designed to handle small to medium size jobs.**
**Equipment includes:**
- 2 Standard Bridgeport Mills
- 3 Tool Room Lathes
- Misc. sawing and grinding equipment
**Shop mainly provides fast turnaround support for the Machine Development & Maintenance Group of the Particle Physics Division.**

- Charles Matthews

## Type of Work

**Performed monthly surveys to determine who uses the Village and Wilson Hall Shops and the type of work entering the shops.**
**Summary of June/July for the Village and Wilson Hall Shops**
- Total Number of Jobs for July ’03	      279
- Prototype Jobs			        15
- Production Jobs			      264
**Percent of Total Jobs by Division**
- Beams				     64%
- PPD				     13%
- Technical			     20%
- Misc.				       3%

- Charles Matthews

## Type of Work (cont’d)

- Charles Matthews

## Type of Work (cont’d)

- Charles Matthews

## Available Regular Working Hours/Month vs. RegularHours Sold FY03

- Charles Matthews

## Available Regular Working Hours/Month vs. RegularHours Sold FY03 (cont’d)

- Charles Matthews

## Perspective

**The Machine Shop has been deeply involved in the development and success of major components and systems since the inceptions of the Laboratory.**
**Linac Tanks**
**Booster Development**
**Conventional Magnet Component Parts**
**Cryostat Assemblies for Doubler **
**Linac Upgrade**
**Now we are, again, involved in another cutting edge project -  prototyping cavities for the Next Linear Collider Project.**

- Charles Matthews

## Flying Wire Can

- Charles Matthews

## Coining Half-Cell Blank

- Charles Matthews

## Assembled Cell

- Charles Matthews

## Stripline Flex Joint 2

- Charles Matthews

## Stripline Flex Joint 2

- Charles Matthews

## Inner Conductors

**Inner conductor of the accelerating cavity - node blocking capacitor - Mark II in the Booster Accelerator RF Systems.**

- Charles Matthews

## Copper Half-Cells

**Coining and machining of copper half-cells to be made into normal conducting accelerator cavities.**

- Charles Matthews

## Shell Coil Housing

**Outer framework for an air coil or focusing magnet made up of non-magnetic material.  This is a corrector magnet for low-energy electron beam coming from the A-0 photo injection electron source in the Linear Collider.**

- Charles Matthews

## Niobium Cell Assemblies

**Three cell & thirteen cell assemblies of SRF Separator Cavities used for the Kaon Separated beam in the superconducting RF Research & Development.**

- Charles Matthews

## Existing Conditions

**Several years ago a committee was formed within the Technical Division to evaluate space usage in the Village Machine Shop.**
**Several recommendations were offered by the committee:**
**Remove some seldom used machinery.**
**Remove Jib cranes that blocked the aisles.**
**Add an overhead crane to the west end of the building.**
**Remove the toilet facilities from the shop floor, add a new facility to one side of the existing building.**
**Add four bays on to the building.**
**Technical Division removed some machinery and the Weld Shop to another building.**

- Charles Matthews

## Existing Conditions (cont’d)

**Technical Division cleared the aisles.**
**Technical Division added the crane.**
**Technical Division investigated adding on an addition, discovered that the cost was too great.**
**Bids to add a 600 sq. ft. washroom ranged from $220,000.00 to approximately $400,00.00.**
**Adding the washroom and the addition would have alleviated more of the overcrowding.  It did not provide for any future growth.**

- Charles Matthews

## Conclusion

**The Machine Shop/Welding Department has been a vital asset to Fermilab.**
**The shops have a well trained and talented workforce.**
**The shops provide an Apprenticeship Training Program to bring talented young individuals into the trade.**
**The shops promote convenience, flexibility, and offer manufacturing consultation when requested.**
**The shops have used the available space in this facility as efficiently as possible.  Therefore, to continue to fulfill our mission and our vision for the future a new facility is greatly needed.**

- Charles Matthews