Assembly Organisation and Duration

Work Site Organisation STORAGE SMA18 UNLOADING CLEAN ROOM CERN-SITE CLEANING MANUFACTURE DIRTY TRIAL ASSEMBLY ISO7 ISO5 PREPARATION CLEANING SMALL PARTS ISO5 Baldaqun Large Parts Small Parts Cavities SM18/SMA18 AREA CM Cryostat parts

Manpower and Assignment of Roles Role# FTEIdentified person(s)CompetencyRemark Assembly coordination1Y.Leclercq, L.WilliamsEng Assembly workforce Clean-Room tech.2 teams of 2G.Barlow+ X1, X2+X3 Mech Tech: Clean-room Trained and Cryo-module Trained 1 shift of 8h/day Components preparation (outside clean-room)1J.B.Deschamps, M.Souchet+FSUMech Techincludes cleaning Quality Control Team Quality Manager1 (part time)J.A.BousquetEng or tech eng Vacuum leak checks1 (part time)Technician to be identifiedVac Tech Survey alignment/checks2 (part time)G.Kautzmann, C.GaydeSurvey Tech Electr. Tests1 (part time)Technician to be identifiedElec Tech Assembly Support Team Assy follow-up and documentation1 (part time)J.A.BousquetEng Storage and Logistics1 (part time)J.B.Deschamps+FSUTech Cryo-module Design & Integration1 (part time)J.DequaireDes eng, Des tech Tooling design1 (part time)P.MinginetteDes eng, Des tech Workshop supporton needTBDWks Techre-work components/tooling Dirty trial assembly 1 (part time) TBD Mech Tech Maintenance Team Clean-room Housekeeper1 (part time)TBDTech Clean-room tooling1 (part time)J.A.Bousquet+FSUMech Tech Supporting Services Handling and transport1 (part time) TechSM18/SMA18 Cleaning1 (part time)M.Malabaila's teamTech HSE safetyon needTBDEng

On-site Quality Assurance Should be independent of the production Tasks specific to the first assembly: Take ownership of the draft procedures Follow the work in progress Modify/update the procedure in work according to lessons learned Photographic support Text update support Feedback to worksite Take action to modify procedures to come that may be affected by current changes General Tasks: Keep a manufacturing/assembly file up to date as work progresses Manage results of QA tests including preventive/corrective actions on non-conformities

Estimates of Time Required Recently, three people well informed about our project, did 3 independent estimates Of these, one person considered the assembly in “production-line” terms where – All resources are in place meaning: All parts immediately to hand Procedures fully tested and validated All tooling fully tested and validated Clean-room assembly staff well trained and practiced Unforeseen problems very largely ironed out of the process – This could also be called a well mastered “routine” activity. – Where we had already assembled a few cryo-modules of the same type – Where the total time required comes close to the sum of the times needed for the suite of component activities

“Routine Task” Time Required ProcedureProcedure stageTime taken in days 1Vacuum vessel assembly3 2Thermal shield and vessel assembly3.5 3Chimney assembly1.5 4Chimney on to the lifting frame1 5Top plate assembly1.5 6Upper thermal shield and He tank2 7Insertion of the chimney2.5 8Installation of the support frame4.5 9Installation of the solenoid3 10Installation of the cavities5 11Installation of the cavitiy auxiliaries7 12Cryomodule vessel closure days total Approximately 8 weeks

Real Time required? Our situation for the first cryo-module is quite different; New activity at CERN, new people, new tooling, new draft procedures, new QA activities. Equipment and tooling is now arriving on a just in time basis

What may we expect in reality? A first prototype – Debugging on 1 st CM; will be better on 2 nd – Some Re-work on components, procedures New activity, new clean-room, new tooling: – Running in phase may be long – Incomplete learning curve on 2 units (just debugging) Missing resources: slow build-up of assy team: – Specific training is needed on CM assembly New Clean-room: – Training is needed for productive clean-room work Uninterrupted work depends on “continuous flawless coordination” around the assembly (inside and outside the clean-room) Reasonable? …