# Presentation: 922303

## Outline

_**Fermilab Production **_
_**Plan & Status**_
_**CMS Muon Chambers**_
_**by: Nelson Chester**_
_**Muon Chamber Project Engineer**_
**Objectives**
**Resources**
**Production Plan**
**Production Status**
**Chamber Design**
**Tool Design & Equipment**
**Facilities**
**Personnel**

## Production StatusChamber Design

_**ME 2, 3/2 - (Fermilab)**_
**Panel Artwork Update Complete**
**Anode Bar, Gap Bar, and Guard Strip Component Drawings Updated and Complete**
**One man month needed to Update and Complete All Remaining Drawings;  Then to be checked and Released**
_**ME 2, 3/1 - (PNPI)**_
**ME 2/1 (P3) Drawings Complete; To be Checked, Updated and Released after P3 Testing**
**ME 3/1 - Drawing in Process; Estimated Completion by 10/1/98;   Then to be checked and Released**
_**ME 1/ 2, 3 - (IHEP)**_
**Estimate Starting Design Activity Mid August**

## Objectives

**Develop finished Engineering Drawings, Bills of Material, and Manufacturing Process Sheets (Travellers) for all Chambers and Chamber Tooling**
**Setup and Maintain Effective Production Manufacturing Facillities**
**Establish an efficient trained labor group to produce Chambers and Chamber ‘Kits’**
**Produce *****High Quality***** completed Chambers and Chamber “Kits” in accordance with overall CMS Muon Chamber Plans **
**Establish an Effective Production Tracking and Reporting Methodology**

## Resources Employed

**The Established and Effective Development and Production Policies, Procedures, and Practices in Place:  *****(Used for Main Injector Magnet Production)***
**Generation of Engineering Releases (ER’s) and Engineering Change Orders (ECO’s) to Effectively Process Design or Manufacturing Changes**
**Generation and Use of Manufacturing Process Instructions  (Travellers) for Quality Assurance and to MaintainConsistency of Manufactured Products**
**Experienced and Knowledgeable Personnel in the Following Areas:**
**Product Design and Development**
**Tool Design and Development**
**Production Planning and Reporting**
**Prodution Labor, Supervision, and Management Oversight**
**Contracts Development**
**Parts Procurement, Vendor Quality Assurance, and Receiving Parts Inspection**
**Parts Storage, Material Handling, and Kit Disbursement**
**Packaging and Shipping**
**Physics, Test and Evaluation, and Science Support both In House and from Universities**

## Facility  Resources

_**Industrial Bldg. #4**__** **_
**Receiving **
**Receiving Inspection**
**Materials Storage**
**Shipping**
_**Lab 8 **_
**Axxiom and Gerber Machines for Precision Panel Cutting, Drilling, and Milling**
**Panel Cleaning**
_**MP 9**_
**Suitable and Available Building to Carry Out Assembly and Initial Testing of Chambers**** **

## Chamber & PanelCounts

##     Production Milestones

**January, 1999****        -    ****ME2, 3 / 2 Design Finalized &****	****	****            ****Panel Production Begins**
**June, 1999****              -     ****Production of ME 2, 3/2**
**	****                                       ****Chambers begin**
**December , 1999****    ****-    ****Complete Assembly and Test ****	****	****            of**** ****6  Chambers**** **
**Jan. - Dec., 2000****    -    ****Complete Assembly and Test ****	****	****            of**** ****17 Additional  Chambers****	****	****            ****( *****23 Chambers Complete*****)**
**      ****-      ****Begin Production of Smaller  ****	****	**** **
**	****          ****Panels forForeign Site Assembly**
**January, 2001****       -      ****Begin Chamber Production****	**
**                                            ****at Foreign Sites**
**October, 2003****        -    ****All 148 ME2, 3 / 2 Chambers****	****	****            Assembled and Tested;****	****	****            All Parts “Kits” Shipped**

## Annual Production Deliverables

##                     Production Deliverables

_**FR-4 Material- WBS 1.1.3.2.4.1 & 4.2**_
**Ordered from GE****	**
**1000 Sheets  ****	****	****     @164.40 ea    = $164,400**
**20 Shipping Crates, 50 sheets ea.       @ $120.00 ea = **_**$    2,400**_
_**	**__**	**__**	**__**	**__**	**__**Total      **__**	**__**           $166,800**_
**To  be Shipped to FNAL by 6/25/98**
**Concern:**
_***Will GE be able to produce FR4 Panels after November?***_

## Production Flow Plan

## Production CapabilitySummary(Single Shift Operation)

**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 - 6 per Day =  ****180 Days Max. **
**	****	****	****	****                    ****=  **_**74% of Capacity**_
_**Gerber Machined Panels:**_
**Req’d. Long   = 265 Panels  @ 2.4 Panels  / Day =  110 Days to Complete**
**Req’d. Short  = 353 Panels  @ 3.0 Panels  / Day =  **_**118 Days**_** to Complete**
**	****	****      **_**Capacity @ 2.4 / 3 Panels**_** / Day =   ****228 Days to Complete ****	****	****	****                   =   **_**93% of Capacity**_
_**Chamber Assembly - MP 9**_**:****	**
**	****	**
**50 Chambers Assem.  / yr.  Req’d.    =   ****One / Week Conservative Capability**
**Anode Panel Prep., Wind, Solder    =****  Three /Week  Conservative Capability**

## Production Labor (techs)

_**Lab 8**__**	**__**	**__**	**__**	**_**    **_**FTE’s**_
**	****Axxiom Machine****	****	****     0.7**
**	****Gerber Machine****	****	****     1.0**
_**	**_**Inspect, Clean, & Wrap****	****     1.0**
**	**_**Handling & Shipping**__**	**__**	**__**     0.3**_
_**	**__**	**__**	**__**	**__**	**__**	**__**3.0**__**	**_
_**MP 9**_
_**	**_**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**_
_**	**__**	**__**	**__**	**__**	**__**	**_** **_**8.0**_

##           Production Support Personnel

## Tooling Summary

**Panel Preparation Tooling Complete and Ready:**
**Axxiom Machine**
**Gerber Machine**
**Major Assembly Tooling Complete or Undergoing Minor Upgrade:**
**Automated Gluing Station**
**Epoxy Curing Station**
**Anode Wire Winding Station**
**Anode Wire Gluing Station**
**Anode Wire Soldering **
**Carts, Racks, and Assembly Tables:**
**Prototype needs complete**
**Production needs under consideration or design**
**Quality Assurance Tooling**
**Anode Panel Tension Tester and HV Test and Train Instrumentation complete**
**Other equipment and tooling under consideration**

## Production Summary

_**Conclusions:**_
**Design Requirements Well Understood****	**
**Design and Manufacturing Process Optimized for Mass Production****	**
**Critical Manufacturing Requirements Identified****	**
**Good Experience and Knowledge Gained from Completion of Two Full Size *****"Large" *****CSC Prototype Chambers****	**
**Adequate Manufacturing and Support Facilities in Place****	**
**Adequate Component Storage and Handling Capability in Place****	**
**Adequate Knowledgeable Labor, Supervisory, and Support Staff Available****	**
_**Concerns:**__**	**_
**One Suitable Vendor (GE) for FR-4 Panel Material****	**
**Axxiom and Gerber Machine Performance and Reliability**

## Tooling Summary

## Tooling (Cont’d)