LOI Backup Doc: Strips Production

Feb Mtg 2012

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Assembly

• Basic model (barrel):– 6 mo. ramp, 2 years production– ~500 staves needed (inner + outer)– 1 stave/day (1 core, 2 bus tapes)– 24 modules– 48 hybrids– 2 EOS– 48 PPB, HCC if not integrated

Basic Model

• Avoid single point bottlenecks– Certain critical capabilities to be duplicated– 2 stave core sites– 2 bus tape sites– 2 module attach sites

• Front load industrial production aspects so inventory is on-hand and pre-tested

• Many hybrid/module production/test sites• Identical fixtures, software, procedures, QA

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Production Effort Model

• Assy = mounting, gluing• Bond = wirebonding• Insp = metrology, probing• Test = electrical test and burn-in• Model is for barrel only, assume 0.5 year ramp, 2 years production, 6 mod, 4 hybrid

sites, average 1 stave/day total. This determines all the other required rates• Total technician workforce = ~60 “shifts” • If peak rate needs to be higher add shifts rather than acquire additional capitol

equipment?• Bottlenecks may be testing and burn-in rather than assembly steps• This does not include engineering, physicist oversight, armies of postdocs, students

req

  req   per site assy per tech assy bond per tech bond insp per tech inspect test per eng test

item /day nsites /day /day total N techs /day total N techs /day total N techs /day tot N eng

stave core 1 2 0.5 0.5 2 0 0 1 1 0 0

bus cable 2 2 1 0 0 0 0 1 2 0 0

hybrids 48 4 12 12 4 12 4 0 0 12 4

modules 24 6 4 4 6 2 12 0 0 4 6

eos 2 1 2 0.5 4 0 0 0 0 0.5 4

module mounting 1 2 0.5 0.25 4 0 0 0.5 2 0 0

stave bonding 1 2 0.5 0 0 0.5 2 0 0 0.5 2

totals         20   18   5   16

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Production Example• Wirebonding: 48 hybrid, 24 modules, 2 EOS, 1 stave / day• From prototype build and estimate: ~60 technicians

– 2 modules bonded/shift = 12 shifts– 12 hybrids bonded/shift = 4 shifts– 1/2 stave = 1 shift– +overflow

• 6 module / 4 hybrid sites• Other calculations for assembly (2-3/site), inspection (2), test (3)• Large equipment required

– Bonding machines– CMM– Glue dispensing systems– Assembly robot?, alignment systems (like SCT)– Temperature controlled chambers– HSIO systems