Production CM QA/QC Plans and Systems Production Cryomodule Final Design Review Jamie Blowers 12-May-2015

2 LCLS-II Production Cryomodule FDR, May 2015 Outline My background “Big Picture” (FNAL, JLAB, SLAC) Procurement strategy Internal and external quality-related systems Design Controls Incoming Inspection Production control, Travelers, and NCRs Summary

3 My background LCLS-II Production Cryomodule FDR, May 2015 Engineering Physicist by title Department Head (Quality & Materials, Machine Shop) and Technical Division QA Manager by role BS Physics, coursework towards MS in Accelerator Physics Been with Fermilab 16 years Implemented QA and QE programs prior to Fermilab Started my quality career in the automotive industry ASQ certifications: CQE, CQA, CQM

4 “Big Picture” LCLS-II Production Cryomodule FDR, May 2015 QA staff from SLAC, Jefferson Lab, and Fermilab have been working closely to coordinate quality efforts related to LCLS-II Cryomodule work All three have formal QA programs, and LCLS-II-specific QA Plans have been put in place FNAL and JLab QA have frequent telecon’s (currently every three weeks or so), to work on coordination; SLAC participates as necessary SLAC LCLS-II QA Manager has assessed the QA programs at JLab and FNAL-TD (so-called “crosswalk”), and gave them both passing marks (Nov/Dec 2014) Both JLab and Fermilab are including SLAC-specific QA requirements into their plans (e.g. Acceptance Criteria Strategies) FNAL ACS forms:

5 “Big Picture” (con’t) LCLS-II Production Cryomodule FDR, May 2015 Cryomodules at both labs are being built to the same design using identical components end result will be CM’s which are mechanically identical, and that all meet the functional requirements We recognize that staff, tooling, and processes will not be identical working on a set of common parameters that both labs will include in their production processes; will report and compare them (electronic) travelers will be used in both Labs, and as they are being developed we are sharing and comparing

6 Procurement Strategy LCLS-II Production Cryomodule FDR, May 2015 Procurements split between the two labs For any given procurement, a “Lead Lab” has been identified As the name implies, they lead and make the procurement The other Lab is involved in a supporting role Each Lab performs their own receiving inspections Allows for each Lab to work in their preferred way (to a common set of requirements) Eliminates the natural tendency to reproduce/redo work Each Lab has named an technical person to work on each procurement (for both lead and supporting); “SOTR”

7 LCLS-II Production Cryomodule FDR, May 2015 Sub-Contracting Officer’s Technical Representative (SOTR) Important Role / Responsibility “Glue” between design, prototyping, procurement and assembly phases Technical expertise for sub-system components Design Phase Develops technical specifications from higher level requirements Prepares drawings and supporting technical documents Prototyping Phase Works with Acquisition/Procurement to procure prototypes from industry/partner labs Participates in prototype development and testing Feeds forward experience into production process Production Procurement Phase Provides technical leadership and point of contact with suppliers Inspection/Assembly/Integration Provides sustaining engineering during receiving inspection & manufacturing Technical judgment to resolve non-conformances (Ed Daly)

8 LCLS-II Production Cryomodule FDR, May 2015 FNAL, TD, and SLAC Quality Systems

9 LCLS-II Production Cryomodule FDR, May 2015 JLab Quality Systems (Johnny Leung)

10 Design Controls LCLS-II Production Cryomodule FDR, May 2015 The outputs of all engineering work are managed in Teamcenter Requests for design work are formalized Design releases are reviewed and approved using a Teamcenter workflow Design changes that affect the functional requirements will be brought to the attention of the SLAC Change Control Board for review and approval To ensure that consideration is given to the effects of “smaller” design changes, they will be discussed during weekly Fermilab/JLab coordination meetings and communicated to the appropriate SOTRs Parts and material are not procured without approved drawings Both Labs pull final (approved) drawings from Teamcenter

11 Incoming Inspection LCLS-II Production Cryomodule FDR, May 2015 All parts and materials are inspected upon receipt SOTRs are working with QC folks to define inspection drawings/plans The two Labs are comparing inspection plans and data, along with ACSs

12 LCLS-II Production Cryomodule FDR, May 2015 Incoming Inspection example (Fermilab)

13 LCLS-II Production Cryomodule FDR, May 2015 Incoming Inspection example (JLab) (Frank Marhauser)

14 LCLS-II Production Cryomodule FDR, May 2015 Production control The LCLS-II Project has committed to using travelers Provide detailed step-by-step instructions covering whole process

15 LCLS-II Production Cryomodule FDR, May 2015 Process Control System: Vector (Fermilab) All travelers are fully electronic; System is currently read-only to the world, so easy data sharing is in place As much as we could, we replicated the functionality and flexibility of a paper traveler:

16 Process Control System: Pansophy (JLab) LCLS-II Production Cryomodule FDR, May 2015 (Valerie Bookwalter)

17 LCLS-II Production Cryomodule FDR, May 2015 Document Control All Travelers and Operating Procedures are under version control and any changes to those documents need to be reviewed and approved by Responsible Authorities JLab Fermilab

18 LCLS-II Production Cryomodule FDR, May 2015 Nonconformance handling (Vector) All non-conformances will be recorded using built-in Discrepancy Report System and have to be resolved by the Lead Engineer before proceeding to next step Rework Steps will be issued if process repeat is needed

19 LCLS-II Production Cryomodule FDR, May 2015 Nonconformance handling (Pansophy) (Valerie Bookwalter)

20 Summary LCLS-II Production Cryomodule FDR, May 2015 Quality systems are in place at both Labs, and have proven effective in numerous past projects SLAC-specific requirements have been incorporated Completed QA Cross-Walk exercises in Nov/Dec 2014 On-going regular QA discussions between JLab and FermiLab on project QA. Both Labs are using electronic travelers, and will be collecting a common set of parameters Designs are controlled through Teamcenter Both SLAC and JLab have access Our quality systems are in use now for the pre-production Cryomodule work Thanks to Anne McEwen, Johnny Leung and Valerie Bookwalter for their help