# Presentation: 101169

## Endcap Muon  Project - CSC

**Nelson Chester**
***Chamber Project Engineer***
**DOE/NSF Review**
**February 17 - 19, 1999**

## OUTLINE:Chamber Project Engineer

**Chamber Engineering**
**Drawings/BOM’s: **
- ME234/2	(assembled at FNAL)
- ME2/1 & 3/1	(provide Kits for PNPI)
- ME1/2 & 1/3	(provide Kits for IHEP)
**Factory Layout**
**Production at Lab 8**
- Floor Plan / Production Rate / Flow
**Production in MP9**
- Floor Plan / Production Rate / Flow
**QA/QC System**
**Travellers**
**Discrepancy Reports**
**Environment, Safety, and Health**
**Procurements & Kits for Foreign Sites**
**Summary and Conclusions**

## Lab 8 Facilities

## Drawing / BOM Status

_**Chamber**__**	**_**    **_**Drawings**_**   **_**BOM’s**_**      **_**Required**_
**ME 234/2 (FNAL)****	****        Complete*            Complete*          March 1, 1999   ****	**
**ME 2/1 (PNPI)                   80%                       99%              April 1, 1999**
**ME 1/2 (IHEP)****	****              0%****	****	****50%****	****        April 1, 1999**
**ME 3/1 (PNPI) ****	****              60%****	****	****80%               Sept. 30, 1999****	****	**
**ME 1/3 (IHEP)****	****	****70%****	****	****50%****	****        Sept. 30, 1999**
***Some Changes Req’d. for P2’’**

## Lab 8 - Large Panel Flow

## Lab 8  - Small Panel Flow

## MP 9 - Pre-Production Setup

## MP 9 - Full Production Setup

## Quality Assurance & Control

**Use the **_**infrastructure already in place at Fermilab**_** and within Technical Division (TD) that has led to the success of past mass production projects**** ****(the Main Injector Magnet Program being the last).**
**Create and follow a ****Compact Muon Solenoid-Cathode Strip Chamber (CMS-CSC) Specific Quality Implementation Plan (SQIP)**** with oversight by the TD Quality Assurance Officer and implemented by the Fermilab Project Site Management as approved by the CMS Project Management.**
**Integrate Quality Assurance and Quality Control into all aspects of the CMS-CSC Project Design and Manufacturing as defined in the CMS-CSC SQIP.**

## Quality Element Cross Reference- CSC SQUIP vs Magnet Quality Plan -

## Tool Design & Drawings

**Panel Preparation Tooling Complete:**
**Axxiom Machine**
**Gerber Machine**
**Panel Handling Equipment on Order**
**Major Assembly Tooling Complete:**
**FR4 Strip Epoxy Gluing Station**
**Epoxy Curing Station**
**Anode Wire Winding Station**
**Anode Wire Gluing Station**
**Anode Wire Soldering **
**Ionized Air Cleaner**

**Carts, Racks, and Assembly Tables Complete:**
**Anode Panel Cart**
**Panel Assembly Table/Cart**
**Chamber Assembly Table**
**Sealing (RTV) & Transport Cart**
**Quality Assurance Tooling:**
**Anode Panel Tension Tester Complete**
**HV Test and Train Instrumentation Complete**
**Cosmic Ray Test Station Complete**
**Vendor and FNAL Panel Inspection Tooling Under Development**

## Production Technicians

_**Lab 8**__**	**_**     **_**FTE’s**_
_**	**__**	**__**	**_**    ****Axxiom Machine****	****	**** 0.7     **
**Gerber Machine****	****	**** 1.0   **
**Inspect, Clean, & Wrap****	**** 1.0   ****	****	**
_**Handling & Shipping**_**         **_**0.3**__**	**__**Total**__**	**__**	**__**	**__**3.0**_
_**IB 4**__**	**__**	**__**	**_
**Kit Preparation and Shipping **_**1.0**__**	**_

_**MP 9**__**	**__**	**_**     **_**FTE’s**_
**Panel Preparation****	****1.6**
**Anode Winding****	****	****1.0**
**Machine Soldering****	****1.0**
**Hand Work****	****	****1.5**
**Assembly****	****	****1.5**
**Test ****	****	****	****1.0**
_**Handling & Shipping**_**	**_**0.4**_
_**	**__**Total**__**	**_**        **_**8.0**_

## Production Rate Summary

**Avail.  Days**** = ****260 Days - 10 Hol. - 5 Vac. =**** ****245 Open Plant Days**** ****	****                ****(Max. Days Machines Run) =**** ****100%**
_**Panel Production - Lab 8**_**	**
**	**
_**Axxiom Machined Panels:**_**               ****Req’d. / yr:  = 721 Panels Max.**
**	****	****               ****Capacity  @  4 per Day =****  ****180 Days Max. **
**	****	****	****	****                    ****=  **_**74% of Capacity**_
_**Gerber Machined Panels:**_
**Req’d. Long   = 265 Panels  @ 2.5 Panels  / Day =  106 Days to Complete**
**Req’d. Short  = 353 Panels  @ 3.0 Panels  / Day =  **_**118 Days**_** to Complete**
**	****	****        **_**Capacity @ 2.5 / 3.0 Panels**_** / Day =****   ****224 Days to Complete ****	****	****	****                   =   **_**92% of Capacity**_
_**Chamber Assembly - MP 9**_**:****	**
**	****	**
**50 Chambers Assem.  / yr.  Req’d.    =****   ****One / Week Conservative Capability**
**Anode Panel Prep., Wind, Solder      =****  Five /Week  Conservative Capability**

## Overall Production Flow

**ICB & IB4**
**Materials Control**
**Technical Division**

**Lab 8**
**Panel Preparation**
**Particle Physics Div.**

**MP 9**
**Chamber Assembly**
**IB 4**
**Kit Assembly and Shipping**
**Technical Division**

## Chamber Procurement Status

**Panel Material- WBS 1.1.3.2.4.1 - 4.5**
_**In Fermi Inventory:**_**	**
**3100 5’ x 12’ Sheets (Skins) GE      @ $164.40 ea    = $510,400**
**1100 4’ x 12’ Sheets (Skins) GE      @ $131.74 ea    = $144,914**
**84 Ship Crates, GE, 50 shts. ea.      @ $120.00 ea    = $  10,080**
**14 Panels from Plascore - 5’ x 12’   @ $550.00 ea    = **_**$    7,700**_
**    ****(R & D Samples)**
_**	**__**	**__**	**_**   ****	****	****	****	**** **_**Total**_**           **_**$ 673,094**_
_**Pending Procurements:**_
**Pre-Production Panel order from Plascore**
**P2’’ (ME 234/2) Pre-Production Parts**
**Production Order of Panels from Plascore**
**Balance of Procurements to be in concert with Production Schedule  **
**Kit Preparation for IHEP and PNPI to be per Manufacturing and Delivery Plans and Schedule as agreed upon.**

## Production Manufacturing Plan

## Chamber & Panel Count & Cost

## Lab 8   E S & H Concerns and Actions

**1.   How panels are unpacked, loaded onto and off of Axxiom and Gerber Machines, and      repacked for movement.  Human manual effort presents safety and health risks.**
**2.   Airborne machining particulate may cause health risks.**
**3.   Locating panels on Gerber machine requires workers to stand on top surface of Gerber      machine.  Provision for safe access must be provided. **
**4.   Operators must be properly trained before using equipment to avoid injury.**

**1. *****Vacuum lifting & transport system  evaluated, selected, and ordered such that together with panel transport carts, to eliminate safety and health risks.***
**2.  *****Little airborne material is generated.  Operators instructed to use proper protective equipment. Vacuum systems to be used to capture waste materials.***
**3.  *****Approved ladders to be used for this purpose.***
**4.  *****Only trained operators to use equipment.  Equipment Operating Procedures and Travellers being developed to guide operators though manufacturing process.  On the job training planned to bring operators up to speed.***

## MP 9   E S & H Concerns and Actions

**1.  Manual Panel Cleaning cannot be sustained.**
**2.  Operators must be protected from  moving parts of winding machine and wire that is under tension during winding.  Panel must be protected against coming loose during winding.**
**3.  Human reaction to epoxies must be addressed.**
**4.  Human sensitivity to light and fumes from soldering station must be addressed.**
**5.  Operators must be protected from touch hazards during the panel and chamber high voltage tests and cosmic tests.**
**6.  Operators must be properly trained before using equipment to avoid injury.**

***1.  An automated cleaning machine to be purchased from outside vendor.***
***2.  Guards have been installed over pulleys and belts;  Operators are otherwise stationed by the control panel where there is no danger.  The wire tension and wire mass is such that there is no danger posed of a wire under tension breaks.***
***3.  Operators do not directly handle epoxy - machine dispensed.  Operators instructed to wear proper protective equipment. ***
***4.   Vacuum system  installed to collect  fumes at soldering station; Curtains installed to shield light from eyes  Video camera installed for remote viewing of operation.***
***5.  Proper materials to be used and proper procedures to be followed. ***
***6.****** ******Only trained operators to use equipment.  Equipment Operating Procedures and Travellers being developed to guide operators though manufacturing process.  On the job training planned to bring operators up to speed.***

## Gerber Machine Production Rates

## Axxiom Machine Production Rates

## Axxiom & Gerber Machine Operations

## MP 9  Production Machine Rates

_**Required:**_**       ****1 Chamber/wk = 3 Anodes + 4 Cathodes + Assembly**
_**Conservative Capability:**_
**Cleaning Machine****	****	****15 min/panel est.    =    140/wk**
**Anode Bar Glue & Cure****	****1 panel/day             =****	****5/wk **
**Winding Machine****	****	****1 panel/day****	****    =****	****5/wk**
**Wire Gluing Machine****	****	****1 panel/day****	****    =****	****5/wk**
**Soldering Machine****	****           .75 panel/day****	****    =     ****	****4/wk**
**Wire Tension Tester****	****	****1 panel/day             =   ****	****5/wk**
**Ionized Air Cleaning****	****	****1 panel/day             =         5/wk**** **
**Hand Component Work****	****1 panel/day****	****    =****	****5/wk**
**Final Assembly****	****               1Chamber/wk         =         1/wk****  **
**High Voltage Test & Train****	****1 Chamber/wk         =****	**** 1/wk**

## Summary and Conclusions

**  ****Drawings and BOM’s are coming along.**
**  ****Remaining ME 234/2 issues must be resolved**
**  ****Production Rates, Floor Plans, and Work Flow   Well Understood and Workable**
**  ****Firm QA/QC and ES & H Plans in place and being Administered**
**  ****Procurement Plans are Understood;**
**  ****Plans for Kits to PNPI and IHEP to be Finalized.**

## Discrepancy Report

_**What is it**_
**A document used to describe the essential information about a nonconforming condition that has taken place.  The nonconformance may be a discrepancy with respect to the design specifications, to the traveler (manufacturing process), or to other conditions that are not normally expected.**
_**Why is it used**_
**To identify the condition and communicate to all those that *****“have a need to know” *****that there is a deviant condition, and what is being done about it.**
**To document for historical purposes in a place where the record may easily be found the essential information about the discrepancy and how it was dealt with.**

_**When it is to be used**_
**Whenever a condition occurs in that does not conform with the established specifications, engineering drawings, manufacturing practices, or otherwise the normally expected conditions or results.**
_**Who is to fill out the paperwork**_
**To identify the condition and communicate to all those that *****“have a need to know” *****that there is a deviant condition, and what is being done about it.**
**To document for historical purposes in a place where the record may easily be found the essential information about the discrepancy and how it was dealt with.**