# Presentation: 367774

## FNAL - EMU Manpower Review

_**March 30, 2001**_
_**The Technical Division **_
_**Cathode Strip Chamber**_
_**Quality Assurance Program**_
**by**
**Nelson Chester, Project Engineer**

## Technical Requirements and Quality

**Within the Technical Division of Fermilab, the Team involved with the Development and Production  of the USCMS End Cap Muon Chambers strive to perform **_**QUALITY WORK**_**.**
**QUALITY WORK**** means that all work performed ****Complies with All**** ****Approved Engineering and Manufacturing Specifications and Requirements**** (the Project Requirements).**

## Quality Work

_**How do we know**_** we are performing**** ****QUALITY WORK****.....**
**	****or that the work we are doing complies with the....**** **
**	****Approved Engineering and Manufacturing (Project) Requirements and Specifications?**

## Quality Assurance

**In the world of Quality Assurance this process is known as  the *****“Plan, Do, Study, Act”***** process (first developed by Shewhart later known as the Deming Wheel).**

## Basic Quality Assurance Program

**The Technical Division ****Quality Assurance Program**** involves several important, necessary practices and methodologies:**
**Engineering Drawings and Specifications**
**Bills of Material Maintenance and Revision Control**
**Manufacturing Process Specifications (Travelers)**
**Inspection, Measurement, Test, and Performance Specifications and Validation**
**Equipment and Tooling Calibration, Repair, and Certification Procedures**
**Materials Handling, Inventory and Part Distribution Controls**
**Overall Product Configuration Control**

## Engineering Drawings and Specifications

**Specify exactly **_***WHAT ***_**is required so as to comply with the ****Product Design Requirements**** called for in the ****CMS Muon Project, Technical Design Report.**
**Component Detail Drawings and Component Specifications define component configuration requirements needed to meet overall Customer Requirements**
**Assembly Drawings define which components form a sub-assembly; The number and type of components that are needed; And any Special Technical Requirements related to the assembly process that from a design standpoint cannot vary.**

## Bills of Materials & Revision Control

**BOM’s define the**** ****SPECIFIC**** ****list of parts needed to produce a product and form the basis for determining and maintaining:**
**Project Component Quantity Requirements**
**Commonality among  similar products**
**Cost Effective buying strategies**
**Cost Effective Optimized inventory strategies**
**Process and Handling Minimization throughout the manufacturing cycle**
**Efficient, continuous flow of ****ONLY *****“QUALITY”***** PARTS**** to Manufacturing**

## Manufacturing Process Specifications

**TRAVELERS *****DEFINE***** ****and**** *****DOCUMENT***** ****critical**** IN-PROCESS ****manufacturing**** ASSEMBLY MEASUREMENTS, TEST RESULTS, other REQUIRED TECHNICAL DATA ****specific to a particular Chamber being manufactured**
**Verification of proper manufacturing technique, personnel and equipment performance ----comparison of achieved results to needed results**
**Place to document Achieved Results, Abnormalities, Corrective Actions,  Repair Techniques, and Lessons Learned **
**Source of Information to be Databased**
**Source of information to capture unit to unit variation**
**History Book and Bible for Archive and Future Use**
**Source of Vital Specific Information to help determine cause of Latent Defects or Abnormalities**

## Manufacturing Process Specifications - Continued

**TRAVELERS ****define**** *****HOW *****a***** *****product is to be manufactured such that it complies with the defined set of Design Engineering Specifications***** *****or other Customer Requirements**
**Identifies the specific parts and quantities of each to be used**
**Specifies order in which parts are to be assembled**
**Identifies specific assembly and manufacturing methods, procedures and techniques to be followed**
**Identifies Critical Check and Validation Points in the Manufacturing Process requiring Technique,  Measurement and Test, and Result Verification and Signoff**

## The Quality Assurance Watch Dog

**TRAVELER COORDINATOR**** --- Quality Assurance Specialist & Records Manager (Gatekeeper) of Traveler Documentation**
**Writes, Circulates, Revises and Updates Travelers**
**Is the “Watch Dog” that Keeps the “Foxes” from *****RUNNING***** the “Hen House”**
**Validates that all required activities defined in the Traveler are being performed accurately, completely, and in the proper manner**
**Prepares Discrepancy Reports when mistakes are made, errors are found, and when corrective action is required to bring the Product into Specification Compliance**
**Insures *****ALL***** steps in Traveler are properly carried out and that the product has been Produced and Tested in *****strict accordance***** with the Traveler and is in *****full compliance***** before the product is *****Released***** for shipment and the Traveler is ****“closed out”****.**

## Inspection

**Inspection ****(at all levels) - Based on ****Project Risk**** and ****Criticality**** to the Overall Function**
**Vendor Visit and Validation**
**Receiving Inspection**
**In-Process Inspection, Measurement, Test**
**Final Product Performance Validation**
**Vendor Validation (of key components)**
**Vendors are chosen *****NOT***** only by ****$’s****, but by their ability to produce ****Quality Parts**** by  performing ****Quality Work**** by ****Qualified People**
**Inspection Level vary:**
**From 100%**** - Anode Protection Boards; Panel Wire Tension and Spacing and most other Assembly related functions**
**To 10%**** for Critical Unique Parts ( Wire Fixation Boards)**
**To just ****visual sample checks**** (Purchased Hardware)**
**Inspection Features are Limited**
**To Critical or Representative Features**
**Defined in a Book given to TD Inspection Department****	**

## Inspection Defects

**	****It took 3 Wire Fixation Bars Vendors Some Time to learn how to Do It  Right the First Time.  One Vendor could not be relied upon and was dropped.  **
**Receiving Inspection Photos showing defective Wire Pads**

## 100% In-ProcessMeasurement and Test

**Cut Panel Features Measured and Recorded - Hole and Strip Locations**
**Assembled Panels Measured for Resistance and Capacitance;  Measurement Data Recorded**
**Wound Panels Measured for Tension and Wire Spacing;  Measurement Data Recorded**
**Gas Leak Rate Measured and Recorded**
**Electrical Leakage Measured and Recorded Several Times**
**Training High Voltage and Leakage Currents Measured and Recorded Several Times**

## Equipment and Tooling Calibration, Repair, and Certification Procedures

**All Manufacturing Tooling, Testing, and Measuring Equipment and Hardware is Maintained in Proper Operating  Condition.  Preventative Maintainence is performed where necessary**
**All Measuring Instruments are kept Calibrated in accordance with Recognized national Standards**

## Materials Handling, Inventory and Part Distribution Controls

**Procurement**
**Vendor Selection for Bidding**
**Bid Preparation and Solicitation**
**Bid Tracking, Bid Assessment**
**Vendor Selection, Vendor Qualification**
**Purchase Order Preparation and Tracking Order Progress**
**Ongoing Vendor Interface; Delivery Date Assessment and Parts Flow Tracking**
**Inventory and Parts Distribution**
**Transfer of Parts to TD Receiving**
**Part Counting and Inventory Database Entry**
**Stock Location Identification and Component Packaging**
**Parts Stocking and Parts Retrieval**
**Kit Preparation and Kit Distribution**
**Special Parts Request**

## Overall Product Configuration Control

**Product Configurations are Approved Configuration Control Board members (Level 2 and Level 3 Product Managers) prior to Product Release to insure Integration Control**
**Product Configurations may only be changed by approval of Configuration Control Board Project Manager**
**Documents Representing Approved Configurations bear the Approval Signature of the Configuration Control Board Members**