FCal1 Production Monitoring and QC

FCal1 Production Advancement ReviewFebruary 20, 2002

1

Peter LochUniversity of Arizona

Tucson, Arizona 85721

Production Monitoring and QC

FCal1 Production Monitoring and QC FCal1 Production Monitoring and QC FCal1 Production Monitoring and QC FCal1 Production Monitoring and QC




2




Quality Control:Quality Control:

large numbers of small, identical parts (tubes, rods): mechanical dimensions checked for ~2% samples (shipment

acceptance inspection); mechanical features (straightness, edges, out-of-roundness)

checked for each part individually prior to processing; individual inspections of all rods and tubes after de-burring,

sanding (rods only), drilling (rods only), and cleaning; final inspection after retrieval from storage, right before insertion; final acceptance defined by go/no-go at insertion;

absorber, far end and signal plates: overall dimensions checked for each plate (shipment acceptance

inspection); ~100 electrode and ground pin holes (signal and far end plates

only) in each plate checked for dimensions (go/no-go gauges); individual inspections of all plates and tubes after cleaning;

large numbers of small, identical parts (tubes, rods): mechanical dimensions checked for ~2% samples (shipment

acceptance inspection); mechanical features (straightness, edges, out-of-roundness)

checked for each part individually prior to processing; individual inspections of all rods and tubes after de-burring,

sanding (rods only), drilling (rods only), and cleaning; final inspection after retrieval from storage, right before insertion; final acceptance defined by go/no-go at insertion;

absorber, far end and signal plates: overall dimensions checked for each plate (shipment acceptance

inspection); ~100 electrode and ground pin holes (signal and far end plates

only) in each plate checked for dimensions (go/no-go gauges); individual inspections of all plates and tubes after cleaning;


3




traveler forms are used to trace tubes, rods, etc. during the processing;

information is later merged with logbook entries into electronic database, if applicable;

traveler forms are used to trace tubes, rods, etc. during the processing;

information is later merged with logbook entries into electronic database, if applicable;

original packaging informationoriginal packaging information

date of QC and bagging is in logbookdate of QC and bagging is in logbook

cleaning batch number is reference for tube insertioncleaning batch number is reference for tube insertion

tags are used to identify cleaning batches through the cleaning procedure;

tags are used to identify cleaning batches through the cleaning procedure;

Tracing of Small Parts by Batches:

Tracing of Small Parts by Batches:


4




T ub eT r ave ler(1/ b ox )

Box #XX

~12 0 0 t ub es

T ube Bat ch(~132 t ubes)



R ollingI nspec t ion

D e-B ur r ing

who/when

who/when

CleaningCleaning Cleaning

Cleaning Q CCleaning Q C Cleaning Q C

B at c h #

M M D D Y Y -Xw

ho/w

hen/

trea

tmen

t de

tails

who

/whe

n/re

sult

T ub e F ileB ox # X X

(1/ b ox )

(8 -12 / b ox )

C leaningL ogB ook

CleaningQ C

L ogB ook

who

/whe

n/en

viro

nmen

tal

cond

itio

ns

who/w

hen/ rejections

S t or ageS t ic k er onPlas t ic B ag

I nser t ion

I nser t ionL ogB ook

who/when/which bat

ch #

for

eac

h tu

be

A r chive

S wagingL ogB ook

S waging

who

/whe

n/w

hich

who

/whe

n/whi

ch/b

atch

# f

or e

ach

tube

who

/whe

n/whi

ch

E lec t r od e M ap(E X CE L D at aB ase)

treatment details of individual tubes can be traced through batch numbers;

all traveler forms, tags, logbooks are archived at Arizona (present model);

information available electronically can be distributed to a central archive at CERN, for example…

treatment details of individual tubes can be traced through batch numbers;

all traveler forms, tags, logbooks are archived at Arizona (present model);

information available electronically can be distributed to a central archive at CERN, for example…

Example: Tracing of Tubes after Insertion:

Example: Tracing of Tubes after Insertion:


5




Production Monitoring:Production Monitoring:

preliminary data collection for production monitoring, with minimum impact on the production itself (no computer input) done by crew as they go;

relevant data is stored electronically in spreadsheets as soon as possible, to allow calculation of trends and status with respect to schedule, for example;

comparison to schedule at least once/week at a local FCal1 production meeting (Tuesdays); results reported to FCal WG at the weekly phone conference (Wednesdays);

preliminary data collection for production monitoring, with minimum impact on the production itself (no computer input) done by crew as they go;

relevant data is stored electronically in spreadsheets as soon as possible, to allow calculation of trends and status with respect to schedule, for example;

comparison to schedule at least once/week at a local FCal1 production meeting (Tuesdays); results reported to FCal WG at the weekly phone conference (Wednesdays);


6




FCal1C Electrode Holes

-50

-40

-30

-20

-10

0

10

20

30

40

50

-50 -40 -30 -20 -10 0 10 20 30 40 50

X [cm]

Y [

cm]

Holes without tubesHoles with tubes J une 21, 2001Holes with tubes J une 25, 2001Faults (1)Holes with tubes J une 26, 2001Holes with tubes J une 29, 2001Holes with tubes J uly 2, 2001

total stuff ed: 25.31%

3103 12260/

tube insertion and swaging are traced using MS EXCEL spreadsheets;

tube insertion and swaging are traced using MS EXCEL spreadsheets;


7




Rod Processing (1)

0

5000

10000

15000

20000

25000

30000

0 5 10 15 20 25

W eek #

Rod

s Pr

oces

sed S chedule

Sanded

De-Burred

Center Punch

Rolling

comparisons to schedule can be done at any time using the same spreadsheets;

comparisons to schedule can be done at any time using the same spreadsheets;


8




Projected Week Of Completion

0

5

10

15

20

25

30

35

40

0 5 10 15 20 25

Week #

Proj

ecte

d W

eek

#

Sanding

De-Burring

Center Punch

Rolling

scheduled end of process

scheduled end of process

projections of completion dates are also possible from the same data;

projections of completion dates are also possible from the same data;


9




FCal1 quality control methods and documentation are in place for most detector parts;

new methods are developed and the corresponding documentation is added as we go;

process sheets have to be updated to describe the actual procedures (this is in part writing history for processes like tube cleaning, for example);

production monitoring is in place for presently running processes; new monitoring will be added as we go;

major concern: we need to make the essential information on our process organization available on the web (only fragments right now);

FCal1 quality control methods and documentation are in place for most detector parts;

new methods are developed and the corresponding documentation is added as we go;

process sheets have to be updated to describe the actual procedures (this is in part writing history for processes like tube cleaning, for example);

production monitoring is in place for presently running processes; new monitoring will be added as we go;

major concern: we need to make the essential information on our process organization available on the web (only fragments right now);

Conclusions:Conclusions:


10




Important:Important:

We build a “perfect” detector. This means that all parts in the module, specifically the electrodes, are technically ok after mechanical manipulations. As shorts in the electrodes are the major concern, we test each and every electrode with 600 V at 1 mA trip current immediately after assembly. Electrodes which do not hold this voltage are re-assembled after swabbing the tube, using a new rod.

Shipping to CERN generates a hazard to the detector, and we have to re-test all electrodes after arrival. Problematic electrodes will be replaced, so that we maintain the “perfect” detector as long as technically possible.

FCal1 Production Monitoring and QC

Documents

Transcript of FCal1 Production Monitoring and QC