PVC Module Production (2.5) Ken Heller University of Minnesota May 8, 2012 Minerba Betancourt, Jianming Bian, Tom Chase, Dan Cronin-Hennessy, Ben DeYoung, James Geddes, Chris Kluge, Susan Lein, Tina Lorsung, Jarek Nowak, Greg Pawloski, Jim Parker, Nathaniel Pearson, Ron Poling, Nick Raddatz, Dominick Rocco, Kanika Sachdev, Alex Smith, Brian Sherwood, Dick Wildberger, Robyn Woolands, Jan Zirnstein undergraduates typically 15 hrs/wk (~ 240 is full staffing) Technician Accounting Engineer Physicist

Manifold Parts DOE IPR May 8, 2012 Ken Heller WBS 2.52 Raceway holder

End Seal Parts 3 DOE IPR May 8, 2012 Ken Heller WBS 2.5

Module Production Status All machines & QA – operating. All molds & dies – completed and in production. Parts – flowing in. QA, process, & inventory software – operating Asynchronous 2 to 1 operation – in production Module production – ramping up Management of students working part time (170 students working a minimum of 10 hrs/wk) – in operation Module shipping – 4 planes (48 modules) to Ash River on schedule Factory floor – filling up DOE IPR May 8, 2012 Ken Heller WBS 2.54 Slow ramp-up for first month good modules produced Initial process adjustments to minimize Fiber damage Optical connector leaks Outer seal leaks Visual inspection flaws

Module Factory Stable 2 to 1 Production DOE IPR May 8, 2012 Ken Heller WBS complete 2 to 1 (8.5 blocks = 29% of far detector) Failure rates overall Flatness – 0.7% End Cut – 0.7% Failure rates April Flatness – 0% (125 done) End Cut – 1.6 % (125 done) Peak 2 to 1 production rate 38/day (average needed 24/day) Slowing 2 to 1 production to put effort into module production Factory and annex are almost full 2 to 1 storage annex 2 to 1 operation

Scenes from the Factory Floor DOE IPR May 8, 2012 Ken Heller WBS 2.56 Production floor Stringing stations Gluing extrusions

Scenes from Production – Final Stages DOE IPR May 8, 2012 Ken Heller WBS 2.57 Painting Stacking finished modules Closed fiber testing Packing

Scenes from Production DOE IPR May 8, 2012 Ken Heller WBS 2.58 Pressure testing Fly cutting Sealing endplate Open fiber testing Stringing

Production Snap Shot DOE IPR May 8, 2012 Ken Heller WBS 2.59 In full production each step would have the 24 modules/day. A single module goes through all the steps in 6 days. snoutstringopen fiber test flycutopen fiber testoptical connector leakopen fiber testInner seal coverInner seal end plateclosed fiber testend plate squarenessInner seal leakouter sealclosed fiber testpaintfinal inspectionstackpackship2to1flatnesstrim end length outer seal leak One day production process 5/7/12

Production Progress DOE IPR May 8, 2012 Ken Heller WBS Fiber: 12 Optical connector: 16 Failures week 2 Fiber: 13 Final inspection: 1 Failures week 3 Fiber: 6 Optical connector: 1 Fly cut: 1 Failures week 4 Fiber: 4 Final inspection: 1 Failures week 1 Fiber: 2 Optical connector: 1 Failures week 5 Goal is 120/wk 166 good modules Goal is 2%

Module Parts Received DOE IPR May 8, 2012 Ken Heller WBS Plastic Part module units (12500)% Manifold Cover 388 (382 = 1 block) 3 End Plate Top Raceway Bottom Raceway Top Fiber Tray Generic Fiber Tray Bottom Fiber Tray Raceway Cover Raceway Support Snout Front Snout Back Manifold Side Seal End Plate Side Seal Optical Connector Fiber Ring External Center Seal

Redesign of Manifold Cover & Tooling Analysis & Testing DOE IPR May 8, 2012 Ken Heller WBS Tight fit 10 mil gap Ang Lee (Fermilab) FEA New cover and clamp design - max stress between 1000 & 1400 psi. Measured material strength between 6400 & 5100 psi.

Manifold Cover Strength Tests DOE IPR May 8, 2012 Ken Heller WBS

Manifold Cover Ultrasound Scans DOE IPR May 8, 2012 Ken Heller WBS Section 1 Section 2 No flaws observed in structure or strength of manifold covers

Vigilance is the Price of NO A DOE IPR May 8, 2012 Ken Heller WBS photos.org/photo/2673.html It’s all about QA/QC Parts inspected when received 2 to 1 Flatness Length Squareness Glue strength Fiber Continuous as strung Open ended after stringing After fly cutting After sealing Fly cut dimensions Optical connector leak check Inner seal leak check Outer seal leak check Final visual inspection, fiber test, dimension check Glue strength Chemical compatibility 3 QA audits by Fermilab project staff Training

Cross section cuts to check glue flow DOE IPR May 8, 2012 Ken Heller WBS Cross-section cut every 0.05” Snout Joints Optical connector Cross-section cut every 0.015”

Scintillator Interaction Testing DOE IPR May 8, 2012 Ken Heller WBS Alpha only Noise Run Scintillator only Ratio of Compton to alpha to take out phototube variation Pulse height counts Test all glue types and all parts

Risks and Mitigation DOE IPR May 8, 2012 Ken Heller WBS Parts do not meet specifications Have manufacturer pay attention to their QC and remake parts. Adequate parts are buffered so should not cost production time. Add weekend production if necessary. Utility rates increase for factory Project contingency held to cover up to a doubling of utility rates. Extrusion delivery interrupted Factory already has over 6 months of stored extrusions so should not cost production time if extrusion factory can make up the deliveries later. Unable to ship completed modules Factory stores several months of completed modules so should not cost production time if shipments can resume. Module production interrupted Factory stores several months of completed modules so detector assembly can continue. Weekend production can make up the time.

Module Shipping/Receiving Damage DOE IPR May 8, 2012 Ken Heller WBS Visual inspection of modules at Ash River by module factory personnel found damaged fiber. 5 modules (21%) in stack 1 6 modules (25%) in stack 2 Investigation plan Ship 1 stack of modules to Ash River and back to module factory Monitor shock and temperature Check for fiber damage Autopsy any damaged modules to determine location of damage All good leaving factory

Looking Ahead Expand staffing from 170 to ~210 students in Fall 20 DOE IPR May 8, 2012 Ken Heller WBS 2.5 Ramp up to 24 modules/day (now at 12) – end of May Summer means easier management control fewer students (~70) working full time Get to ~ 2% module failure rate (now at 7%) Production ramp up going well process improvements decrease defects rate increasing Investigate and eliminate fiber damage in shipping Gluing seals & snouts Stringing Unloading extrusions