1. Corrective and Preventive Maintenance at NSCL

2. Outline Introduction to NSCL & MSU Quality Management at NSCL
Tools used at NSCL for availability
Future
Questions

3. NSCL
National Superconducting Cyclotron Laboratory (NSCL) is a world leader in rare isotope research and nuclear science education
NSCL employees 454 Faculty,
Staff and Students
Located on the campus of
Michigan State University
Ranked as the #1 graduate program in nuclear physics
In the United States by U.S. News & World Report 3

4. Cyclotrons & Beam Lines4

5. Michigan State University
The United States pioneer land-grant university, established in 1855
In 2010, MSU enrollment consisted of 47,131 students
from all 50 United States and 130 countries
MSU has over 11,000 employees
Throughout the world, there are nearly
half a million MSU alumni
Land-grant universities (also called land-grant colleges or land grant institutions) are institutions of higher education in the United States designated by each state to receive the benefits of the Morrill Acts of 1862 and 1890.The Morrill Acts funded educational institutions by granting federally controlled land to the states for the states to develop or sell to raise funds to establish and endow "land grant" colleges. The mission of these institutions as set forth in the 1862 Act is to focus on the teaching of agriculture, science and engineering as a response to the industrial revolution and changing social class rather than higher education's historic core of classical studies.[1]

6. Why is a Robust Maintenance Program Important?
It allows a facility to do what it does best……….
It allows a facility to meet the demands of its funding agencies……….
It allows a facility to meet its operational goals……….
“Operate the laboratory reliably, efficiently and safely. Maintain high (>90%) level of availability and seek further gains in efficiency through improved procedures and automation of NSCL operations without compromising safety. Encourage the professional development of staff to raise the overall skill, performance, and knowledge bases within the laboratory.”
This is item #2 as stated in NSCL Long Term Objectives, item #1, is Operate a first-class research & education laboratory. Foster continued high-productivity and high-quality science output from NSCL by encouraging active leadership and idea exchange among NSCL staff and users, seeking out new collaborations & initiatives, attracting highly promising young
science leaders, and recruiting and educating excellent undergraduate students, graduate students and post doctoral researchers.
NSCL has a Quality Management System (QMS) to meet all of the above

7. NSCL Quality Management System
NSCL Quality manual states:
“NSCL developed and implemented a Quality Management System in order to document the laboratory’s best operational practices, better satisfy the requirements and expectations of its users and improve the overall management of the laboratory”
The Quality Management System of NSCL meets the requirements of the international standard ISO This system addresses the production and delivery of rare isotope beams
This manual describes the Quality Management System, delineates authorities, inter relationships and responsibilities of the personnel responsible for performing within the system.

8. NSCL QMS Scope
The Scope of the NSCL Quality System is: All NSCL processes related to the production and delivery of rare isotope beams to the experiment
The quality manual outlines the policies, procedures and requirements of the Quality Management System. The system is structured to comply with the conditions set forth in the International Standard ISO 9001.

9. NSCL QMS Quality Objectives
Rare isotope beams will be delivered within 24 hours of the scheduled time
Rare isotope beams will be delivered with 90% availability
Availability (Total Time - Scheduled Off - Unscheduled Offexcl) / (Total Time - Scheduled Off)

10. NSCL Availability

11. Tools Logging & Reporting Administrative Document Handling
Inventory Management
Planning
Scheduling
Tools…the actual hand tools

12. Logging and Reporting HourLog
Allows for both narrative and system status reporting
Reliability statistics are derived from HourLog
Trouble Reports
Used to report a problem with a system or process and even a suggestion
Allows the trouble report to be tagged for various management systems

13. Administrative Reliability Committee
Trouble Reports are reviewed bi-weekly
Committee can reopen a solved Trouble Report for further investigation
Repair Team
Meeting called by department head
All system experts are present
Actionable items generated

14. Document Handling Alfresco document management
Workflow determined by users
Mechanical Design department design review approval
Revision control 14

15. Inventory Management Developed in-house, using IRMIS
IRMIS is a descriptive documentation
Tool *
Uses relational database and associated applications to comprehensively document the large and complex EPICS-based control systems *
Handheld Bar Code Scanners MC55
* An Overview of IRMIS, 4/19/2005 ( 15

16. Scheduling Administration Schedule ~ 1 day resolution
Determined 3 months out
Operations has final review
Short Term Schedule
~ 1 hour resolution
Determined daily
STS Coordinator 16

17. Maintenance Planning
Experimental schedule is determined months in advance
Preventive maintenance is scheduled in between experimental periods
The maintenance group solicits tasks from other departments to add to the maintenance schedule
Microsoft Project 2008 is used to build the maintenance schedule
NSCL written software is used by the employees to get a list of their tasks
The same software is also used by the employees to report the status of their tasks back to the project leader 17

18. Breakdown Plans
In order to reduce downtime during breakdown repairs lasting at least 24 hours, but less than 7 days, a breakdown response plan is proposed to better allocate resources, and use time more effectively. The scope of this document is to explain the process for using and creating canned breakdown response plans. The initial scope of the breakdown, and such considerations as duration and level of support by other departments should be determined by a repair team meeting. 18

19. Tools…the actual tools
Modified 5S method
5S is a system to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results *
Provides a basic set of tools to address an immediate need without wasting valuable time
Vault Tool Box
* Lean Manufacturing and the Environment, 19

20. Tool Integration 20

21. Maintenance Engineers
Operator Structure
During experiments, all personnel rotate through shifts as operators
During maintenance, all personnel become part of the resource pool used during scheduled maintenance
Operations/Maintenance
Operating Engineers
Maintenance Engineers

22. Future
Tighter Integration of tools
Written with common software 22

23. Questions 23