# Presentation: 800759

## EMU - CSC Production at FNAL

**Giorgio Apollinari**
**Fermilab**
**Oct.  5-6, 2001 -  FNAL**
**EMU Meeting**

## Outline

**Preparation/Procurement Plans**
**FNAL Activities for:**
- Prototypes & Tooling at Foreign Sites
- Production at Foreign Sites
**Cooling Plates Procurement **
**Other FNAL Activities**
**Configuration Releases**
**Parts Shipments**
**Production Tooling**
**FNAL Production Activities**
**Panel production**
**Chamber Production****	****	**

## Preparation Plans

**Preparation Plans**

**Prototyping Schedule**
**ME1/2 Assembled by Jan. ‘00**
**ME2/1 Assembled by May ‘00**
**ME3/1 Assembled by Jun. ‘00**
**ME1/3 Assembled by Nov ‘00****	**
**4 Pre-production ME234/2 by Jun ‘00.**
**ME4/1 Assembled by Jun ‘01**
**ALL PROTOTYPES COMPLETED**
**Tooling Schedule**
**FNAL Tooling **
**PNPI Tooling**
- Setup in PNPI
**IHEP Tooling**
- Setup in IHEP
**ALL TOOLING INSTALLED AND OPERATIONAL**

## Preparation Plans

**Production at PNPI **
**Production Readiness Review in June ’01.**
**No major showstopper, however many technical suggestions were provided:**
- Extra space
- Better production flow definition
**All Chamber parts, frame parts and *****un-cleaned***** panels for ME2/1 production were shipped by the beginning of Sept. In transit through Hamburg, arrived in St. Petersburg port on Sept. 26****th****.**

## Preparation Plans

**Production at IHEP**
**Production Readiness Review in July ’01 (N.Chester).**
**No major showstopper, however many technical suggestions were provided:**
- Manpower allocation
- Better production flow definition
**All Chamber parts, frame parts and 50% *****un-cleaned***** panels for ME1/2 production ready to be shipped. 50% of remaining panels to be cleaned. Shipment waiting for Custom paperwork.  **

## Cooling Plates

**Procurement of Cooling Plates**
**First ME234/2 Release (April 2001)**
- Budgetary quotes from 3 vendors
- Deal with lowest bidder: could not achieve the technical specs
**Major problem: keep flatness during the tube soldering process**
- Progress
**Converged with the lowest bidder on proper soldering process (end of Sept. 2001) **
**Identified additional possible vendors **
**ME234/2 Configuration Control (September 2001)**
- Produce 10 ME234/2 Cooling Plates at FNAL under schedule requirements
- Order at least one prototype from every vendor willing to quote on the balance of 140 cooling plates. Bids closing by mid October.
- No order placed before inspection of the prototype.
**Cooling Plates Prototypes**
- ME2/1 Produced
- Waiting for drawing release for ME3/1, ME4/1 and ME1/3.

## Cooling Plates

## Configuration Releases

**Chamber Configuration Release**
**Needed to allow PNPI/IHEP to finalize the chamber parts “procurement” (typically they still have to machine the frames) and allow them to go into chamber production. **
**Frame finalization intimately connected to Integration finalization (ex: ME1/2)**
- ME234/2 	CC in Spring 2000
- ME2/1		CC in Sep. 2001
- ME1/2		to be placed under 			CC shortly
**Integration Configuration Release**
**Needed to start parts procurement, mostly at FNAL and U. Wisc.**
- ME234/2	CC in August 2001
- ME1/2		to follow shortly
- ME2/1		to follow shortly

**	*****http://tdserver1.fnal.gov/project/uscmsemu/Configuration_Control_Documents/Released_Configurations/***

## Configuration Releases (cont.)

**Configuration Release Communication to Foreign Sites**
**Procedure in place to let foreign sites know about released Configuration **
- Initial released Configuration to be transmitted by CD.
- Foreign site responsible to update drawings in their possession if/when new Configurations are approved.
**Process (Travelers) Changes communication to Foreign Sites**
**Procedure in place to let foreign sites know about Assembly process changes at FNAL.**
- Initial released Configuration to be transmitted by CD.
- Foreign site responsible to *translate* and update travelers in their possession for their own purposes.

**	*****http://tdserver1.fnal.gov/project/uscmsemu/Released_Specifications/Chamber_Specifications/***

## Parts Shipment

**Completed instructions for parts shipped to Foreign Sites through FNAL, to be enforced by L3 Manager (A.K.) which obtained all agreements.**
**Major points:**
**Pre-packed boxes not opened at FNAL.**
**Full *****List of Parts***** attached on multiple sides of the box. **
**Unit Value & Weight.**
**Description of where the part is shipped to with reference on which chamber it is going to be used.**
**Etc....**
**CR still to be approved *****(almost ready to receive boxes, but not quite)***

***http://tdserver1.fnal.gov/project/uscmsemu/Released_Specifications/Chamber_Specifications/***

## Chamber Shipments

**New EU requirements on measures for NMWP (Non-Manufactured Wood Packing) materials allow three treatment options:**
**Heat Treatment**
**Fumigation**
**Chemical Pressure Impregnation**
**The shipping containers manufacturing company has recently obtained the certification from the ALSC (American Lumber Standard Committee).**
**Wood ~ 30% more expensive, ~5-15% increase in cost for shipping containers.**
**Option for 35 chambers at FAST Sites**
**Fumigation by Commercial Pest Control Company to kill Pine Wood Nematode**
**Remaking of ~35 Shipping Containers**
**Heat Treating the ~35 Shipping Containers**

## Production Tooling

**Cleaning Machine**
**Redesigned and fabricated almost from scratch**
- Not adequate deburring
- Falling apart (PVC construction)
**Substituted 8 polishing brushes with 2 deburring and 2 polishing brushes **
**Various *****ups-and-downs*****, presently in an *****ups***** stage (N.C.)**

**Before**

**Before**

**After**

## Production Tooling (cont.)

**MP9 Tooling**
**MP9 in steady-state production mode since ~ beginning of 2001**
**Analysis of tools usage**
- Daily, random visits to production floor recording particular tools usage
- Mostly biased to record an under-usage of tooling.
**Deficiencies/Bottlenecks  in**
**Anode Panel Brackets (used for assembly process and panel storage)**
- Extra being fabricated
**Chamber Assembly Area**
- Multifaceted problem
- Started addressing by increasing the number of HV testing units.

**Panel Assembly**

**Chamber **
**Assembly**

## FNAL Factories Status

**Panel Machining in full-speed production as of ~ Jan ‘00**
**Production goal for FY’00 obtained with the expected manpower.**
**In FY’01, the production rate is well above expectations with minimal additional manpower (3.2 FTE used vs. 2.5 FTE expected)**
**Completed machining of ME234/2 panels (FNAL Production)**
**Completed machining of ME2/1 & ME3/1 panels (66% of PNPI Production)**
**Completed machining of ME1/2 panels ( 50% of IHEP Production)**
**Starting machining of ME4/1 panels (completion expected by Dec. ’01)**
**Finish machining on ME1/3 panels (completion expected by Jun ’02) and spares**
**	****	****	****COMPLETED 70% of PANEL PRODUCTION**

## FNAL Factories Status

**Production**
**3 chambers ready, failing new leak rate spec**
**One chamber to be re-built (006) **
**Rate**
**3.25 Chamber/ month in FY01**
**4 chambers on a *****Good Month***
***2 *****chamber on a *****Bad Month***

**45 ME234/2 Production Chambers assembled (30%) **

## FNAL Factories Status

**Production Issues**
**Goal of increasing output to 4 Chambers/month on average in FY02 with baseline (7 techs) manpower in MP9.**
- ME234/2 Production completed by Nov. 2003.
**Goal to convince L2-L3 to augment the efficiency of manpower usage in MP9 by closing the program of visitors training and using the available funding to increase the trained assembly personnel.**
- With 8 techs in MP9 the production rate could probably increase to 4.5 Chambers/month by the time the full work-force is fully trained (~March ’02).
- ME234/2 Production would be completed by Aug. 2003.

## Chamber Production Experience

**New Lesson**
**One case of bad wire**
- Corona on 2 planes
- Gold flakes on wire
**No new case/additional problems with same batch spools reported since then. **

**Chamber Production Experience**

**Discrepancy Report (DR) summary (ME234/2-003 to *****016 027*****  051) **
**Average: *****5DR/Chamber (73 DRs)*****  *****3.8 DR/Chamber (105 DRs)***
**	****3.2 DR/Chamber (162 DRs)**
**Most DR: ME234/2-006 with 11 DRs**
**Least DR: Many Chambers with 0 DRs**
**Most Consistent Cause: Wire position**
**Most Dramatic/Scary Problem: RTV mixing/Flaking Wire**

## FNAL FY01 Milestones

- Canceled

## FNAL FY01 Milestones (2)

## Conclusion

**FNAL Factories**
**Activities proceeding according to plans.**
**Panel Production activities almost completed. **
**Some “catch-up” activities and technical specification changes have caused ~20% delays on Chamber Production activities.**
- No-cost remedies can still be implemented to retrieve some of the lost schedule.
**FNAL Shipment Activities**
**Chamber & Un-machined Frame Parts Shipments proceeding according to the new plans.**
- PNPI Shipment at destination
- IHEP Shipment almost ready.
**FAST Sites***** “Part Flow”***
- FNAL to act as *“expeditioner*”, waiting for PO approval.