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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
Peter LochUniversity of Arizona
Peter LochUniversity of Arizona
FCal1 Production Advancement ReviewFebruary 20, 2002
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Peter LochUniversity of Arizona
Tucson, Arizona 85721
Production Monitoring and QC
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;
FCal1 Production Advancement ReviewFebruary 20, 2002
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Peter LochUniversity of Arizona
Tucson, Arizona 85721
Production Monitoring and QC
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:
FCal1 Production Advancement ReviewFebruary 20, 2002
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Peter LochUniversity of Arizona
Tucson, Arizona 85721
Production Monitoring and QC
T ub eT r ave ler(1/ b ox )
Box #XX
~12 0 0 t ub es
T ube Bat ch(~132 t ubes)
T ube Bat ch(~132 t ubes)
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:
FCal1 Production Advancement ReviewFebruary 20, 2002
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Peter LochUniversity of Arizona
Tucson, Arizona 85721
Production Monitoring and QC
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);
FCal1 Production Advancement ReviewFebruary 20, 2002
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Peter LochUniversity of Arizona
Tucson, Arizona 85721
Production Monitoring and QC
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;
FCal1 Production Advancement ReviewFebruary 20, 2002
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Peter LochUniversity of Arizona
Tucson, Arizona 85721
Production Monitoring and QC
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;
FCal1 Production Advancement ReviewFebruary 20, 2002
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Peter LochUniversity of Arizona
Tucson, Arizona 85721
Production Monitoring and QC
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;
FCal1 Production Advancement ReviewFebruary 20, 2002
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Peter LochUniversity of Arizona
Tucson, Arizona 85721
Production Monitoring and QC
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:
FCal1 Production Advancement ReviewFebruary 20, 2002
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Peter LochUniversity of Arizona
Tucson, Arizona 85721
Production Monitoring and QC
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.