# Presentation: 136040

## Advanced Manufacturing FacilityPeer ReviewAugust 26 – 27, 2003Vision of the Future

**Rich Stanek**

## Future Vision

**	****What are the assumptions?**
**Fermilab has a strong and vibrant future.  The Lab will continue to operate and perform High Energy Physics experiments even after the LHC turn-on**
**New, large-scale projects will be funded in the near future **
**	****(BTeV & CKM, Proton Driver, NLC, VLHC...)**
**The on-site shops (Machine Shop) will continue to add value to the Lab’s operation, because they can do things that complement outside vendors**

- R. Stanek

## How Should/Will the Shops Operate

**	****What needs improvement?**
**The Shops need to become _______**
**More integrated with the projects**
**More efficient and cost competitive**
**More technically capable **
**	****(improved space, new machines, better trained personnel)**
**More technologically and managerially savvy **
**	****(implementation of job scheduling software and of new management techniques)**

- R. Stanek

## Defining a New Shop Structure

**	****What is the model for the “Shop of the Future”?**
**Move towards a structure that consists of one main shop and a “few” small satellite shops **
**	****(maintain a close relationship with the scientific community)**
**Eliminate unnecessary shop locations**
**	****(some are more historical than practical)**
**Provide a “central” location for the main machine shop; one with adequate space for shop equipment, inspection and assembly areas and all related offices**
**	****(maximize efficiency and control costs)**
**Use all of the tools available to “link” the Shops together and develop stronger customer relationships through better communication and accurate estimates**
**	****(rely heavily on the CIS Department for assistance)**

- R. Stanek

## Defining a New Shop Structure (cont’d)

**Balance the size of the work force with the amount of work coming in. If we hold the line on hiring...**
**	****(must allow for pulse loads that increase the demand)**
**Provide flexibility in “embedding” machinists within projects or working groups**
**	****(short term assignments of “matched” candidates)**
**Integrate the Shops with the Procurement Group of the Material Controls Department**
**	****(provide a one-stop shopping location for all fabrication activities – “get the best price and delivery” and this will also help to link the Shops to the projects)**
**Through the Shop Steering Committee (SSC), define the “needs” of future projects with a long enough lead time to allow the Shops to procure necessary equipment**

- R. Stanek

## Technical Capabilities of the Future Shop

**	****What technical capabilities do we need?**
**Provide quick and efficient turnaround on component fabrication and modification **
**Perform high precision machine operations in a temperature controlled environment**
**Measure, assemble and check components with minimal required transportation between buildings**
**	****(integrate the Shop efforts with the MCD/QC Group)**
**	****=> That’s why it’s called the *****“Advanced ***_***Manufacturing***_*** Facility”***
**Fabricate rapid prototypes of complex geometries in composite and other unique materials**
**Investigate challenging machine and welding processes that offer solutions to manufacturing problems of the future **
**	****(diamond turning, laser welding, rapid prototyping...)**

- R. Stanek

## Design of the Advanced Manufacturing Facility

**The size of the *****AMF***** building is dictated by the following:**
**The desire to move all of the operations (cut shop, weld shop, machine shop, machine repair, inspection) into one building**
**The need to maintain a broad range of machining capabilities including large bed machines, CNC and conventional machines and specialized machines (EDM, water jet...) **
**The desire to provide a temperature controlled environment for QC and precision machining operations**
**The need to provide a safe and efficient layout of machines**
**The number of machinists in the building**
**The desire to have room to expand for the future, both in terms of the number and type of machines and additional consolidation of satellite shops**
**The location of the *****AMF***** Building brings the Main Machine Shop closer to the areas of activity**

- R. Stanek

## Design of the Advanced Manufacturing Facility (cont’d)

**Advantages of the *****AMF***** Building design:**
**Incorporate the Main Machine Shop, Cut Shop, Weld Shop, Sheet Metal Shop, Machine Repair Shop, Wilson Hall Shop and IB4 Shop all into one building**
- Allows us to pick out the “best” machines to use so that the older (maintenance intensive) models can be retired
- Reduces the cost of building maintenance and operation
**Maximize the machine floor space (under the crane coverage) while providing adequate office and support areas in the single story buildings**
**Provides logical work flow pattern for material while still maintaining a reasonable building size**
**Consistent aisles throughout all of the buildings**
**Staging and delivery areas**
** ****Have a designated area for a temperature controlled environment (precision machining and measurement)**
**Room to expand**

- R. Stanek

## Conclusion	

**	**_***Shop of the Present***_
**The present Machine Shop can be improved and made more efficient but only if the infrastructure allows for changes.  The existing facilities are dated and have many operational problems, high maintenance costs and little room for expansion.  They do not offer the flexibility to be transformed into the desired “shop of the future”**
**	**_***Shop of the Future***_
**The Machine Shop of the future will be more integrated into the Lab’s projects, be more responsive to its users and have better technical capabilities.  As part of a more complete fabrication and manufacturing facility it will be capable of supplying the project with the “best price and delivery” on a component either from an internal or external source.  It will have room for future expansion involving new types of machining or welding applications and offer assembly and inspection services as required**
***	***_***The Advanced Manufacturing Facility offers the right solution to the problem.***__** **_

- R. Stanek