Daresbury Laboratory APA Production Readiness Review
AGENDA • • • Fabrication Overview (Daresbury Laboratory) Review the Production Readiness Review Checklist Open Design Review Items (if applicable) Review the ESH requirements Review QC Checklists/Procedures Review Drawing Status Review QC Plan Status Summary/Recommendations Tour of Lab Alan Grant - 6/11/17 2
Overview Technology Department Accredited Quality Management ISO 9001: 2008 Alan Grant - 6/11/17 3
TD - Quality Management Technology Department Groups • Controls Systems Group • Detector Systems Group • Electrical Engineering Group • Nuclear Physics Group • Projects and Mechanical Engineering Group Alan Grant Mechanical and Vacuum Engineering Group • Technical, - 6/11/17 4
Documentation Alan Grant - 6/11/17 5
Processes • • • Quality Management for ISO 9001: 2008 is process driven Currently planning for ISO 9001: 2015 Process 05 A - important for Project Management Alan Grant - 6/11/17 6
Process 5 A Preferred Process for Project Management For more in depth details refer to other Processes or Local Instructions Alan Grant - 6/11/17 7
Project Folders • Typical folder structure for a project • Additional folders can be added if required – not limited • Link to Proto. DUNE project management files. . pm Project Management Alan Grant - 6/11/17 8
Local Instructions Local instructions allow maximum flexibility to Run the Quality Management Local instructions can be tailored to suit how each group within the Quality system wishes to operate. Alan Grant - 6/11/17 9
Audits • External Audits Ø Frequency every 6 mths Ø Carried out by BSI Ø Aim is to highlight any non conformances and suggest areas for continual improvement Ø Can audit anything he chooses too, processes, procedures, local instructions, projects…. Ø Non conformances need to be put right before next assessment. If not, could ultimately lose accreditation. • Internal Audits Ø Frequency every 6 mths Ø Carried out by internal staff - trained in auditing Ø Same aims as above with same freedom Ø Non conformances to be put right before next external audit. Alan Grant - 6/11/17 10
Fabrication Overview (Daresbury Laboratory) Alan Grant - 6/11/17 11
APA Frames • University of Sheffield responsible for the procurement and delivery of the APA frames • APA frames contracted out to Portabello, local Sheffield. • APA frame material – used same supplier as PSL • Portabello maintained a QA dossier for tracking all stages of the APA manufacture and tests. • APA frames pickled and passivated to increase the cleanliness – outsourced to chemical cleaning specialist • Used specialist Metrology company for carrying out weld tests – using NDT techniques • Survey of frames carried out by specialist company Alan Grant - 6/11/17 12
Winding Machine and Process Equipment • STFC Daresbury responsible for procurement of all other equipment • Procurement of components carried out by Technical Group at Daresbury who are accredited to ISO 9001: 2008 • Generally all component detail drgs supplied by PSL. • Modifications in some instances due to material stock availability. • Request for quotes go through the Technical Group who have a preferred suppliers list, approved by the Research Councils procurement office Link to request for services -. . meng - Mechanical Engineeringrfs - Request for Services Alan Grant - 6/11/17 13
Quotations broken down into following areas • • • Adhesive – UK agent APA frames - Portabello APA#1 Boards - PSL Camera – UK agent Clean Room Relocation – Local specialist Mesh – Gantois Industries Process Cart – UK supplier modified PSL design Tensioning Mechanism – Technology Group DL Winding Machine – Technology Group DL Wire Spools – PSL Link to quotations. . meng - Mechanical Engineeringquo - Quotations Alan Grant - 6/11/17 14
Construction Area – Nov 2015 • Area 3 clearing work commences for SBND winding machine Construction Area – Nov 2016 • SBND cleanroom & winding machine installed • First winding machine components delivered for Proto. DUNE Alan Grant - 6/11/17 15
Assembly & Commissioning • Assembly of winding machine carried out by STFC technicians supported by staff from University of Liverpool and University of Manchester • Weekly meetings with PSL during construction phase to pass on advice and guidance • Stiffening struts added to minimise deflection of the vertical travel – agreed with PSL • Voltage supply differs between UK and USA so could not use like for like motor gearbox - used the same supplier with UK equivalent • Difficulties loading and running the PLC and GUI – worked through this with motor controls supplier and advice from PSL • Difficulties in loading the receipes for the winding operation • Used alternative method for fitting the mesh – this was done in the process cart. Alan Grant - 6/11/17 16
Status – APA 1 • Currently setting up for winding U-Layer • G-layer components available • Shipping crate available • PSL preparing CR boards and head end yolks • DL ordering cover board materials for shipping Status – APA 2 & 3 • Frames available • PSL preparing boards to meet winding requirements Alan Grant - 6/11/17 17
Production Review Checklist Alan Grant - 6/11/17 18
Date Completed Deliverable Complete response to Design Review APA Comments Final Drawings Issued and approved by PSL Calculations Issued and approved by PSL Bill of Material Issued and approved by PSL Printed Circuit Board Documentation Issued and approved by PSL Inspection, Test and Integration Procedures Manufacturing Travelers QC Plan APA frames Aug-17 APA#1 X-plane tensions Sep-17 APA#1 V-plane tensions Oct-17 Test Reports Software Verification and Validation Documentation Nonconforming Items Documentation APA frame 2 mm short Missing pin - hence wire Supplier Documentation Oct-17 Portabello Frame Dossier Welder Qualifications Oct-17 Aug-17 Steven Daggett - BS EN ISO 17637: 2011 Apr-14 Qualified Weld Procedure Specifications Personnel Training and qualification Dan Salibury - STFC Elec Tech Diego Garcia Gamez - Manchester Post Doc Slawomir Kubecki - Manchester Mech Tech Mathew Henderson - Liverpool Elec Tech Liam Boynton- Liverpool Elec Apprentice Final Production Plans Manufacturing Procedures Mar-17 Handling, Storage and Packaging Procedures Shipping Plan APA#1 Hazard Analysis Documentation Dec-17 APA Assembly Cold tank delivery and operation proceedure Final Prototypes Alan Grant - 6/11/17 Mar-17 May-17 19
Review the ESH requirements Alan Grant - 6/11/17 20
Health & Safety Documentation Construction Area & Winding Machine - STFC • Risk assessments, Method statements and Hazard Posters are in place for working in the construction area and operating the winding machine • Included in the risk assessment are controls we are working towards to manage the risk of operating moving machinery • The design of this safety system has been agreed and we have received quotes – this safety control software needs to be installed at a time to be agreed Link to HSE documentation -. . hse - Health & Safety Environment Cold Tank – University of Lancaster • Risk assessments for the vessel delivery & operation are in place • Coshh worksheet and procedure papers are also in place. • Cooling tests of the cold tank took place at Lancaster prior to shipping to Daresbury. • Cold tests have been carried out on SBND prototype APA Link to HSE documentation -. . hse - Health & Safety EnvironmentLancaster - cooling tank Alan Grant - 6/11/17 21
Review QC Checklists/procedures Alan Grant - 6/11/17 22
Checklists & Procedures • Working to the procedures developed and written by PSL • • • Step 1 – Prep for winding Step 2 – Installation of first (X) wire layer Step 3 – Installation of second (V) wire layer Link to procedure documentation -. . trav - TravelerPSL APA-001 Procedures 2017 • Use PSL traveler format for recording test results for • • • APA frames Electrical test results Tension test results Link to traveller records -. . trav - Traveler Alan Grant - 6/11/17 23
Review Drawing Status Alan Grant - 6/11/17 24
Review Drawing Status • All models and drawings have been supplied by PSL • PSL use Solidworks CAD package – DL have bought Solidworks licence to allow compatibility • All manufacturing drgs supplied by PSL are approved • All models and drawings from PSL are held in the Solid works vault in the Proto. DUNE project folder. . meng - Mechanical Engineeringdwg - DrawingsSolid. Works Vault Ø Breakdown into following folders • • • Alan Grant - 6/11/17 8757 D 002 – APA assembly Process Cart Tooling Transport Cart Winder Machine 25
Review Drawing Status • Were PSL incompatibility issues exist – eg stock material, design work carried out DL. • All DL manufacturing drawings approved • All DL models and drawings stored in PDMLink database • Access to approved drawings is through online drawing registry http: //engregserve/menu/index. htm • Assembly drawings contain parts lists & quantities…. all information supplied with request for services (RFS) . . meng - Mechanical Engineeringrfs - Request for Services • Procurement is tracked and recorded . . meng - Mechanical Engineeringpro - Procurement Alan Grant - 6/11/17 26
Review QC Plan Status Alan Grant - 6/11/17 27
• Traveler document templates developed by PSL for APA frames, electrical tests and X, V, U and G layer tension tests are available and being used • Outstanding Procedures • U & G layer installation procedure – this should be identical to V and X installation procedure. • Shipping procedure Alan Grant - 6/11/17 28
Non Conformances • Length of APA frame short by 2 mm Cause Likely caused by missing shims during construction Remedy Rework hole positions in the frame, to allow the APA frame to be used as-is (with incorrect length) Discussed & agreed with PSL and Regina. Alan Grant - 6/11/17 29
Non Conformances • Broken Pin on V-layer Cause Accidentally driving the tension-measuring head into the pin. Remedy The wire that would have gone around the broken pin has been removed, and the APA will be used with a missing wire. Discussed & agreed with PSL and Regina. Alan Grant - 6/11/17 30
Summary/Recommendations Alan Grant - 6/11/17 31
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