APA Production at Chicago Ben Stillwell on behalf of the Chicago APA - - PowerPoint PPT Presentation

APA Production at Chicago

Ben Stillwell

• n behalf of the Chicago APA factory team –

Ed Blucher, Dave Schmitz, Rich Northrop, Marc Berthoud, and Zack Siegel APA Workshop 10-11 June 2019

2 June 10-11, 2019 APA Production at Chicago

Outline

• Factory layout
• Factory planning (presently funded by NSF and UChicago)
• Building preparation
• Facility design
• Mockup testing
• Project management
• Safety
• Factory set-up and operation (funding to be requested from NSF)
• Cost estimates
• Schedule milestones
• Staffing

3 June 10-11, 2019 APA Production at Chicago

Factory Layout - Overview

557 m2 of dedicated space (excluding truck bay area).

4

• Incoming and outgoing

shipments will use indoor truck bay at north end of building.

June 10-11, 2019 APA Production at Chicago

Factory Layout – Truck Loading and Transfer Areas

5

• Clean tent to be built on

lower level.

• Bare frames moved in for

mesh and initial comb base/board installation, then out for crane lift to mezzanine.

• Completed APAs moved

in for QA and shipping prep, moved out for crane lift into shipping crate.

June 10-11, 2019 APA Production at Chicago

Factory Layout – Prep and QC Area

6

• Soft-wall

cleanroom around (perhaps

• n

frame

• f)

2T bridge crane.

• Loading

deck to be built at N end for transfer from building crane.

• T

wo winders in L configuration allows shared controls area.

• Room

for multiple process carts.

• Clean tent built around

(or attached to) bridge crane frame.

• APAs shuttled between

building crane and cleanroom crane with process cart.

• Winders in ‘L’ with

shared controls area.

June 10-11, 2019 APA Production at Chicago

Factory Layout – Winding Area

Factory Planning

7 June 10-11, 2019 APA Production at Chicago

• Weekly team meetings to identify and resolve issues.
• Developing detailed internal project schedules (Berthoud)
• Coordinating with University management and facility services

and to get needed building cleanup and improvements done.

• Working with divisional safety representative to ensure that all

needed controls will be in place.

• Designing facilities and getting costs for equipment and

materials (Northrop)

• Fabricating “mockup” equipment to validate facility plan (Siegel)

Building Preparation

8 June 10-11, 2019 APA Production at Chicago

• Budget of $270k paid from University funds.
• Major items managed by University facility services.
• Design and install mezzanine extension.
• Design and install stair covering on lower level.
• Modify HVAC duct to maximize winding area clean tent.
• Add door from hall to mezzanine extension.
• Minor items managed by PSD facilities personnel.
• Clean out high bay.
• Epoxy coat floors.
• Install stops on existing overhead crane rails.
• Route new electrical service.
• Install personnel barriers.
• Maintain emergency egress routes.

Building Preparation – Schedule Milestones

(As suggested by internal schedule. Assumes funds available June 24, 2019)

9 June 10-11, 2019 APA Production at Chicago

• Feasibility study and budgetary estimate for mezzanine

extension and stair cover – Feb 12, 2019 ✓

• High bay cleanup – Aug 24, 2019 (Effort has begun)
• Detailed designs for facility modifications – Aug 6, 2019
• Install mezzanine extension – Dec 10, 2019
• Install stair cover – Dec 20, 2019
• Epoxy coat floors – Jan 24, 2020
• Ready for factory set up – Feb 3, 2019

Facility Design (Northrop)

10 June 10-11, 2019 APA Production at Chicago

3D full-factory model Winding area clean tent Prep/QC area clean tent

Mockup Testing (Siegel)

11 June 10-11, 2019 APA Production at Chicago

• Verify that layout provides adequate clearance and visibility for moving APAs

through factory with overhead crane and process cart.

• Establish and refine safe working procedures for moving APAs with overhead

crane.

• Better understand time and effort required for various steps in process.
• Ensure needed facilities and equipment are properly planned for.
• Begin training Chicago staff on basic factory operations.

Mockup Testing – Activities

12 June 10-11, 2019 APA Production at Chicago

• Receive and build process cart frame ✓
• Draft detailed test plan – 6/28/19 (in progress)
• Tape floors and roll process cart through tight spots – 7/26/19
• Receive simplified APA frame – 8/30/19 (design in progress)
• Order and install process cart interface arms – 8/30/19
• Transport, load/unload APA frame with crane – 8/30/19
• Receive complete APA frame – 10/21/19
• Prep APA frame for winding (install meshes, boards) – ??
• Load APA frame into/out of shipping container – ??

Project Management (Berthoud)

13 June 10-11, 2019 APA Production at Chicago

Internal project schedules for three phases:

• Factory planning and mockup testing,

through Sept 2020.

• Factory setup, Sept 2020 – Oct 2021
• Factory operation, June 2021 – Aug 2025

The goals are to:

• Track and help organize facility work
• Provide input for funding proposals.
• Understand impact and respond

appropriately to issues that will occur during production.

Safety

14 June 10-11, 2019 APA Production at Chicago

Discussions have begun with PSD safety specialist Kimberly Mormon. Identified hazards include:

• Overhead crane, other material moving activities
• Fall from elevated area
• Chemical exposure (epoxy, cleaning solutions)
• Automated equipment (winder)
• Lead exposure (solder)
• Beryllium (wire)

Controls for these will be developed and presented in more detail at the factory design review.

Factory Setup – M&S Cost Estimate

15 June 10-11, 2019 APA Production at Chicago

• Winding area clean tent - $106k1
• Prep area clean tent - $53k1
• Overhead crane for winding area - $100k2
• Four process carts - $81k1
• Jigs and test hardware - $150k
• Misc tools, equipment, and consumables - $60k3
• Total - $550k
• 1. Quotes based on updated designs will be requested soon.
• 2. Based on vendor quotes.
• 3. Includes some items unique to Chicago factory.

Factory Operation – M&S Cost Estimate

16 June 10-11, 2019 APA Production at Chicago

• Solder and epoxy - $72k
• Wire - $36k
• Combs - $183k
• Electron diverters - $44k
• SHV and wire harness - $30k
• Cover boards - $61k
• APA shipments - $108k1
• Total - $535k
• 1. Based on recent quote for Chicago to Lead, SD.

Factory Setup – Schedule

(Assumes no human resource limitations)

17 June 10-11, 2019 APA Production at Chicago

Milestones

• Request purchase orders – Sep 1, 2020
• Preparation clean tent ready – Oct 23, 2020
• All (four more) process carts built – Dec 18, 2020
• Winding area crane installed – Dec 11, 2020
• Winding clean tent complete – Feb 12, 2021
• APA line 1 complete – Jun 15, 2021*
• APA line 2 complete – Oct 19, 2021*

* Schedule significantly impacted by time to receive parts and build winders.

Factory Operation – Schedule

18 June 10-11, 2019 APA Production at Chicago

Total operational days through Aug 31, 2025*: Winder 1: 1018 Winder 2: 928 Total APAs complete assuming 40 days/APA: Winder 1: 25 Winder 2: 23 Total: 48 Completing 60 APAs would require a rate of 1 APA / 32 days. * Assumes two weeks closure during winter holidays + 6 additional university holidays.

Factory Setup – Staffing

19 June 10-11, 2019 APA Production at Chicago

Effort Engineer Technician Student Total Participate in planning, reviews 450 h

• 450 h

Install clean tents and prepare space1 900 h 900 h

• 1800 h

Assemble and set up two winders 3300 h 900 h 1800 h 6000 h Assemble and set up four process carts

• 96 h

320 h 416 h Total2 4200 h 1896 h 2120 h 8216 h Total FTE-Y3 2.6 1.2 1.3 5.0

• 1. Values are double the estimate from PSL since there are two clean tents.
• 2. One FTE-Y, not included here, is also assumed for technical, project, and safety mgmt.
• 3. FTE-Y ≡ (220 days)(7.5 hours/day) = 1650 hours.

Factory Setup – Staffing

20 June 10-11, 2019 APA Production at Chicago

0.00 0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00 4.50 Sep Oct Nov Dec Jan Feb Mar Apr May Jun July Aug Sep Engineer - FTE Technician - FTE Student - FTE

Cleanroom installation Winder assembly and installation To reduce human resource needs early in the setup phase, a contractor will be utilized to build the clean tents.

Factory Operation – Staffing

21 June 10-11, 2019 APA Production at Chicago

Activity Engineer Technician Students, etc Winder 1, 30 APAs 9760 h 24400 h 19520 h Winder 2, 30 APAs 9760 h 24400 h 19520 h SHV boards, wire harness, covers 1800 h Total 19520 h 50600 h 39040 h 11.8 FTE-Y 30.7 FTE-Y 23.7 FTE-Y

• The above is consistent with FNAL cost book v7.
• Engineer and technician hours are as described in the pre-proposal.
• The pre-proposal describes slightly more student effort: 2 undergraduate

FTEs + 5 graduate students.

Factory Operation – Staffing

22 June 10-11, 2019 APA Production at Chicago

• Technical management
• Engineering – 0.5 FTE
• Safety – 0.25 FTE
• Project – 0.25 FTE
• Production engineer
• Winding – 2 FTE
• Prep/QC – 0.4 FTE
• Production technician
• Winding – 2 FTE
• Prep/QC – 2 FTE
• Float – 1 FTE
• Rigging / packaging – 1 FTE
• Undergraduate students
• Winding – 2 FTE
• Graduate students / post docs
• Winding – 2 FTE
• Prep/QC – 1FTE
• Float – 1 FTE

Notes:

• 1. The FTE numbers assume production at a

rate of 40 days/APA → 12.2 APAs / year.

• 2. Although based on the same number of

hours, the FTE count comes out slightly higher than what was given in pre-proposal (1.2 engineers + 3 technicians per winder). This is due to assumptions of 1650 hours/FTE (UChicago).

Next Steps

23 June 10-11, 2019 APA Production at Chicago

• Complete designs for clean tent structures.
• Refine M&S cost estimates for NSF proposal.
• Complete mockup testing to validate factory layout.