# Presentation: 824597

## Advanced Manufacturing FacilityPeer ReviewAugust 26 – 27, 2003Wrap Up

**Rich Stanek**

## Goals of this Review - Reminder

***	***_***We would like to achieve the following:***_
**Inform and remind everyone of the role that the Machine Shop plays in support of the Lab’s mission ****(RS)**
**Characterize the present situation of the Shops ****(CM & RH)**
**Present the plan for how these deficiencies will be addressed with the construction of the *****AMF *****(RS)**
**Show two possible layouts for the new building ****(GVZ)**
**Demonstrate a strong justification for the construction project based on the SLI proposal and program documents ****(RS & JS)**
**Give a sense of where the Shops are headed and a vision for the future ****(RS & CM)**

- R. Stanek

## Charge to the Review Committee - Reminder

**	**_***Comment on these specific issues:***_
**Do the Machine Shops adequately meet the needs of the Laboratory?  Is the investment in a new facility and expansion of capabilities justified?**
**Does the construction of a new facility represent the best approach for solving the problems associated with the present conditions?**
**Does the plan and future vision for the machine shops characterize a reasonable approach to meeting the needs of the Laboratory in the future?**
**Do the proposed building layouts represent logical and correct usage of floor space?  Are the capabilities of the new facility well matched to the requirements, both now and in the future?**
**Is the proposal that will be submitted to the SLI Program Office sound?  Does it adequately represent the justification for the project?**

- R. Stanek

## What Has Been Presented

**Summary of existing conditions (work force, work load, types of machines, floor space) along with identified issues and areas that lead to inefficiency  **
**Many of the identified inefficiencies are characterized and quantified in the Draft SLI Proposal Document**
**Plan for improving the situation **
***AMF***** Building (two possible configurations)**
**Information on the SLI Program and the documents that we hope to submit as justification for the project**
**Plan for the future of the Shops **
**Involves much more than just a new building**
**Believe that once we improve the Shop efficiency, cost effectiveness and productivity and show scientists and engineers how much the Shops can add-value to their projects (help them do their science   => the funds for additional machine upgrades and improvements to expand the capabilities will be available**

- R. Stanek

## Discussion on $ Limits of SLI Program

**Assume the limit on a SLI project is $15M**
**At $350/sq ft this equates to ~42,800 sq ft**
**Assume Plan B (Linear Model) is preferred**
**High Bay = 34560 sq ft****	****Low Bay = 18432 sq ft**
**Scenario 1 – differential rates**
**Assume High Bay costs $350/sq ft => $12.1M**
**Low Bay would have **_**<**_** $150/sq ft to fit the budget of $15M**
**Not very likely, but it may be close (@ $300 HB => $250 LB)**
**Scenario 2 – down sizing at a constant rate **
**Total floor space allowed @ $350/sq ft = 42,800**
**Current floor space = 50,000 sq ft => reduce by ****7200**** sq ft**
**Eliminate/Relocate EB Welding (850), Sheet Metal Shop (1900), Plasma Cutter (1100) =3850 sq ft**
**Reduce Tool Crib/Storage Area by 40% (1260) & Machine Repair Shop by 50% (2200)**
**Total Reduction = ****7310**** sq ft**
**Possible, and it does not affect the core functions of the *****AMF***

- R. Stanek

## Discussion on $ Limits of SLI Program (cont’d)

**Scenario 3 – suppose the present project = $20M**
**Need to reduce the floor space by 25% = ****12,500**** sq ft**
**Eliminate/Relocate EB Welding (850), Sheet Metal Shop (1900), Plasma Cutter (1100), Machine Repair Shop (4400) **
**Reduce Tool Crib/Storage Area by 40% (1260), Cut Shop by 20% (550), Lathe Area by 20% (1180), EZ Trak/Bridgeport Area by 25% (475) and the CNC Mill/DeVlieg Area by 20% (1260)**
**Total Reduction = ****12,975**** sq ft**
**This hurts more, and it does touch the core functions of the *****AMF.  *****However, depending on the total number of machinists stationed in the building it may be possible.  It does not affect the ability of this facility to function as the “shop of the future” **

- R. Stanek

## Reasons to build the Advanced Manufacturing Facility

**Safety**
**Improved building conditions **
- machine spacing, aisle width, crane coverage, lighting, staging area...
**Efficiency**
**Improved work flow **
- Logic to the layout of equipment (flow of fabrication process, high bay/low bay)
- Minimize transportation of components and people
**Minimize redundant supervisory burden**
- Optimize location/number of satellite shops (allow main shop to absorb personnel)
**Better tracking of job progress**
**Reduced Maintenance Costs**
**Fewer buildings and more modern construction techniques**
**Room for Expansion**
**Specific areas assigned for future machine upgrades and to allow the Shops to perform more complete fabrication process including better integration with MCD/Procurement and QC Groups**
**Improved Location**
**Village area is no longer the “right” place for heavy, industrial traffic and is not close to the current hub of activity**

- R. Stanek

## Conclusion

**We strongly believe the infrastructure of the Fermilab Machine Shops MUST be upgraded in order for the Shops to continue to support the Lab’s mission**
**The existing facilities do not lend themselves to cost effective improvements**
**The SLI Program is the perfect vehicle to achieve these improvements in the Lab infrastructure**
***	***_***The Advanced Manufacturing Facility offers the right solution to the problem***_

- R. Stanek