1. G. PassalevaFirenze - September 8, 2004 Production Readiness Review Firenze MWPC Production Site G. Passaleva

2. Firenze - September 8, 2004 Agenda 10:00 Introduction:G. Passaleva30’ 10:30 Panel preparation and clean room operationsM. Lenti30’ 11:00 Results on the first chambersM. Lenzi30’ 11:30 Panel preparation and general chamber acceptance criteriaG. Carboni30’ 12:00 Discussion1h lunch 14:00 Visit of the production center1h30’ 15:30 Referees private meeting

3. G. PassalevaFirenze - September 8, 2004 Goals of the PRR The PRR has to verify/assess: Readiness of the tooling and of the production site Quality controls and assurance tests Material procurement and its flow Manpower availability Production ( and installation ) schedule

4. G. PassalevaFirenze - September 8, 2004 Production program in Firenze We have to produce: 148 M5R4 70 M1R4

5. G. PassalevaFirenze - September 8, 2004 Status of the production site Just a bit of history: In November 2002 it was decided to abandon the RPC technology and shortly after we proposed to set up in Florence a MWPC production site In April 2003 the proposal was approved by the INFN and by the Collaboration In may 2003 we got the first funding and we started placing the first orders The bulk of the orders for the main production tools was placed in july 2003 In fall 2003 we got the first equipments but due to the transfer of the Physics Department and INFN to the new Polo Scientifico we could get the first working tools only in February 2004. (in this period we contributed providing all the electrical layouts for HV bars and cathodes) We got the first 4 M5R4 panels at the beginning of may Production and testing tools were finalised by the end of June 2004 The first M5R4 chamber was closed the 12th of july 2004, exactly one year after the order for the wiring frame was placed !

6. G. PassalevaFirenze - September 8, 2004 Status of the production site Today we have: All the tools working 3 chambers completed and tested (2 tested @LNF, one in Florence); two of them are almost acceptable…(see Michela’s talk) Infrastructure almost complete. Still missing: Solder fumes evacuation system (available but not yet installed) Radioactive source test Storage setup for assembled chambers Database for chamber assembly and test data storage

7. G. PassalevaFirenze - September 8, 2004 Infrastructure Wiring machine in the clean room Consolle of the wiring machine View of the open area and the “grey room” Yunshan in the “grey room” picking up panels for measurements

8. G. PassalevaFirenze - September 8, 2004 Panel gluing 1.Panels are checked for planarity… 2.…cleaned under the hut with isopropilic alcohol… 3.…glued on the gluing machine with automatic glue dispensing… 4.…measured again after gluing… 1 2 3 4 3

9. G. PassalevaFirenze - September 8, 2004 wiring machine Laser soldering bridge Glue dispensing bridge and wire tensioning torque motor

10. G. PassalevaFirenze - September 8, 2004 Assembly tables Panels wired glued soldered and cleaned are… 1.…measured with WTM… 2.…and with WDM, 3.tested for HV. 4.On the same table we glue side bars 1 2 3 4 Final chamber assembly table (thanks to ROME 2 for the realization of the tools) 3

11. G. PassalevaFirenze - September 8, 2004 Quality controls: WTM, WDM,HV test WDM cameras WTM hammer laser spot and photodiode HV connections

12. G. PassalevaFirenze - September 8, 2004 EDR recommendations A small ‘pre-production’ series should be constructed and tested for each chamber type –the goal was to build and test 3-4 M5R4 chambers and to test them in LNF with the radioactive source: we succeeded in building 3; 2 were tested in LNF and 1 in Firenze with a prototype test setup. At least one of these pre-production chambers of each type should have undergone a successful ageing test –actually we have never tested our prototypes for ageing. We plan to test one of our chambers in a test beam in October

13. G. PassalevaFirenze - September 8, 2004 EDR recommendations A wire replacement procedure should be defined and tested for each chamber type. –we exercised the procedure several times on our chambers with success As the gap size is probably the most critical parameter for pulse height uniformity, an effort should be made to produce panels of best possible flatness. –we check all the panels for planarity with a precision rod and we discard the (few) ones out of specifications

14. G. PassalevaFirenze - September 8, 2004 EDR recommendations The precision of the wiring should be checked on all pre-production chambers –we do it for all the wired planes Gluing should be handled with the utmost attention, with well tested, constant procedures, in particular under <50% humidity –the humidity control is very effective and the gluing procedures are already automatic and controlled by PC apart for the closing bars and the side bars.

15. G. PassalevaFirenze - September 8, 2004 EDR recommendations A well-defined testing procedure during production should be established with the pre-series, including some final two weeks of operation at nominal voltage with final gas mixture and flow. –HV test on each wired plane is routinely done; we then perform an HV test of the closed chamber. Storage shelves have been ordered and we will place there the chambers for long term HV test On the basis of the experience gained with the pre-production series, the production schedule should be re-evaluated – we still have to experience the actual mass production, but we are quite confident in the proposed production schedule even though the possibiliy to have Saturday or even weekend shifts is being seriuosly considered

16. G. PassalevaFirenze - September 8, 2004 Operations performed in our production site (see Massimo’s talk for details) In the labs: –Cleaning of panels and HV bars –Gluing HV bars –Measurement of panels after gluing –Soldering connectors and ground contacts In the clean room: –Wiring soldering and wire gluing –Wire cutting and panel cleaning –WTM,WDM,HV tests –Chamber assembly In the open area: –Gas leak test –HV and gas conditioning and test –Radioactive source test

17. G. PassalevaFirenze - September 8, 2004 Material procurement All the chamber pieces are shipped to us through LNF CERN provides wire and glue We buy ourselves soldering wire, cleaning and gluing consumables, some extra glue etc. We have now in hands material for about 40 chambers For the moment we don’t see problems in material availability

18. G. PassalevaFirenze - September 8, 2004 People Staff physicists –Giovanni Passaleva –Giacomo Graziani –Massimo Lenti –Michela Lenzi –Michele Veltri Staff technicians –Fernando Maletta –Gabriella Gheri (part-time) –Giuseppe Giarrizzo (part-time) –Roberto Ciaranfi (electronics team) –Marco Ottanelli (electronics team) –Marco Montecchi (electronics team) Non staff –Yunshan Li (IHEP Beijing)

19. G. PassalevaFirenze - September 8, 2004 Production schedule FIRENZE Start date 01-set-04 end prod date 100M5R401-ott-05 48M5R402-apr-06 70M1R412-ott-06 218 (195 equivalent chambers) Assuming an average production rate of 2 ch/week

20. G. PassalevaFirenze - September 8, 2004 Conclusions Up to know we managed to build and test 3 chambers The chambers have shown several problems and we tried to correct the assembling procedures accordingly As you will see in the talk of Michela, on or more quality control criteria are not fulfilled but the situation is (hopefully !!!) improving The accurate test of these chambers is an invaluable source of information to correct and/or tune the production steps

21. G. PassalevaFirenze - September 8, 2004 Conclusions We already started but we still need a training period. Our goal is to reach the nominal production rate by the end of September Production of two panel/day is feasible but with no margin: –Time contingency is gone: we are considering Saturday/weekend shifts –Possible failure in the tooling –We are ordering spare parts for the most critical items –Maintenance of the tooling –Time to switch from one chamber type to another Recovery could be possible only having some more man power: we will try to have two more people most probably by the end of the year Two years production is a very big effort especially for a small group like we are: we are aware of all the risks and we are trying hard to by on schedule

22. G. PassalevaFirenze - September 8, 2004