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CMS Upgrade Workshop. Updated ME4/2 chamber construction costs and prototype Status and plans of prototype construction Cost estimation for ME4/2 chamber factory production. ME4/2 Chamber Prototype Construction. - PowerPoint PPT Presentation
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CMS Upgrade Workshop, FNAL, Nov 19-21, 2008 1O.Prokofiev
CMS Upgrade Workshop
Updated ME4/2 chamber construction costs and prototype
Status and plans of prototype construction
Cost estimation for ME4/2 chamber factory production
CMS Upgrade Workshop, FNAL, Nov 19-21, 2008 2O.Prokofiev
ME4/2 Chamber Prototype Construction
- we can use new material (lost vendors due to out-of-business, discontinue products,…)
- critical tooling is available (Axiom, Gerber, winding, tension, soldering, tension,…) - knowledge and technology has not been lost
- a prototype performance meets our technical specs
We have a plan to install a prototype on the disk during this shutdown that is prototype will be completed in the nearest time. It will be a working chamber.
We use a production tooling with standard procedures and travelers to provide a high quality of the ME4/2 prototype.
In framework of preparation of the EMU upgrade project it was decided to constructthe ME4/2 chamber prototype to be ensure that:
CMS Upgrade Workshop, FNAL, Nov 19-21, 2008 3O.Prokofiev
Prototype Status
- All required chamber parts have been prepared for prototype construction.
- 10 panels have been machined with using Axxiom and Gerber machine. - All tooling and panels were relocated in Nov. 2008 from Lab.8 (original location for chamber production) to MP-9 (clean room, more space, experience people).
- Started work with prototype construction last week. Hand cleaning for the anode panels have been completed.
- Assembly anode and cathode panel gluing tooling will be completed on the next week.
- Winding machine wasinstalled in the clean room and ready for winding. Expectation is to start winding in December.
CMS Upgrade Workshop, FNAL, Nov 19-21, 2008 4O.Prokofiev
Tooling Status
A list of critical tooling:
Automatic panel cleaning machine (will do not use for prototype) Axxiom machine (panel cutting and drilling) – restored, works
Gerber machine (strip milling) - restored, works properly Gluing machine (restored) Clamping tables for anode and gap bar gluing (in preparation) Winding machine – prepared for winding Soldering machine (will do not use for prototype) Wire spacing and tension measuring machine (will be moved from Purdue, assembled and used for prototype production) Ionized air cleaning machine (will do not use) Panel, chamber carts (assembled, ready for production) Assembly table (assembled, ready for production) Quality control and test equipment (available production)
All tension machine was disassembled and stored at Purdue. Equipment will be shipped to FANL in the nearest time for assembly and testing. This machine will be used for prototype production.
CMS Upgrade Workshop, FNAL, Nov 19-21, 2008 5O.Prokofiev
Axiom and Gerber Machines
AXIOM and Gerber machines (panel cutting, drilling and strip milling) are in operation mode.
10 panels: 5 with new and 5 with old GE skins were machined.
Axxiom machine Gerber machine
Lifting machine
CMS Upgrade Workshop, FNAL, Nov 19-21, 2008 6O.Prokofiev
Chamber Tooling at MP-9
All tooling and chamber pars are at MP-9.
A clean room for winding, clean production area
Good support from MP-9 people with experience of ME234/2 chamber production
CMS Upgrade Workshop, FNAL, Nov 19-21, 2008 7O.Prokofiev
Hand Panel Cleaning
Completed anode panels
Very hard and dirty work: ~ 3 hours per panel (2 technicians)
For mass production automatic panel cleaning machine must be used
Dents, roughness
Hand cleaning
CMS Upgrade Workshop, FNAL, Nov 19-21, 2008 8O.Prokofiev
Prototype Production Plans
Prototype assembly has been started at MP-9
We have a good support from TD to complete a prototype in the nearest time
To restore tension and wire spacing machine we need an expert from Purduewho will help with machine assembly and testing.Preliminary, Adam Bujak from Purdue can come to FNAL to help with machineoperation and help with measurements.He could come in December to setup machine and then in Jan/Feb to help with measurements and prototype tests.He could be stay at FNAL for 2 months in total. It is a great help for prototype testsWe need funding for Purdue.
It is planning to complete prototype production in February with shipping to CERN in March 2009. It will be a completed and working chamber.
A scope of work what we are doing at MP-9 is comparable with work required for the factory setup for the ME4/2 chamber mass production.
We need additional funds for prototype construction.
CMS Upgrade Workshop, FNAL, Nov 19-21, 2008 9O.Prokofiev
CSC Factory Production: Labor and Cost Estimation
Chamber parts cost estimation
Factory setup
Panel production (Lab.8)
Chamber production (MP-9)
Input chamber part QC/QA (IB-4)
Procurement, kit preparation, shipping
Cost comparison (CERN and FNAL)
CMS Upgrade Workshop, FNAL, Nov 19-21, 2008 10O.Prokofiev
Chamber Parts Cost Estimation (2008)
Old Cost production
(150 CSCs, 2003)
Cost production 2008)
(75 CSCs)
$2,482k $1,910 k
* Price of FR-4 skin increased from $164 (2003) to $ 660 (2008)
Material Cost
Skins $2,296 quote $9,220 * $691,500.00Panels $3,409 quote $3,150 $178,875.00Anode bars $870.00 quote $1,058.00 $79,350.00Gap bars $1,435.00 quote $1,476.00 $110,700.00Wire $1,968.00 quote $2,376.00 $178,200.00Resistors $35.00 quote $51.00 $3,825.00Capacitors $162.00 quote $208.00 $15,600.00Frames $633.00 +20% $760.00 $57,000.00HV harnessOther parts $5,400.00 +20% $6,480.00 $522,000.00
TOTAL $16,548.00 $25,459.00 $1,909,425.00
Expected (2008)
MaterialsOld Cost per ME23/2
(150 CSCs, 2003)Cost for 75 CSCs
(2008)New Cost per ME4/2
(75 CSCs, 2008)
$340.00 +100% $680.00 $50,900.00
Skins $2,296 quote $9,220 * $691,500.00Panels $3,409 quote $3,150 $178,875.00Anode bars $870.00 quote $1,058.00 $79,350.00Gap bars $1,435.00 quote $1,476.00 $110,700.00Wire $1,968.00 quote $2,376.00 $178,200.00Resistors $35.00 quote $51.00 $3,825.00Capacitors $162.00 quote $208.00 $15,600.00Frames $633.00 +20% $760.00 $57,000.00HV harnessOther parts $5,400.00 +20% $6,480.00 $522,000.00
TOTAL $16,548.00 $25,459.00 $1,909,425.00
Expected (2008)
MaterialsOld Cost per ME23/2
(150 CSCs, 2003)Cost for 75 CSCs
(2008)New Cost per ME4/2
(75 CSCs, 2008)
$340.00 +100% $680.00 $50,900.00
CMS Upgrade Workshop, FNAL, Nov 19-21, 2008 11O.Prokofiev
FR-4 Copper Clad Skin Problems
GE who made sheets discontinued this line of production
Spent more than 3 years looking for around new vendor
3 candidates: Aurora Technology, US Laminate, Plascore
Small quantity production: - Aurora Technology setup 93k$, $2,850/sheet - US Laminate no charge for setup, $1,250/sheet received 10 sheets - Plascore is interested only for large quantities production
Large quantity (1100 sheets): - Aurora Technology $660/sheet - US Laminate $719/sheet - Plascore no quote
It is terribly bad to have just one vendor for the production (price, quality,..) We have had renew negotiation with Plascore and they started work to make FR-4 sheet of 5’ x 12’ size. Plascore looking for raw material to get copper foil and fiber glass material. It is expected to have a respond from Plascore in few weeks. After getting quotes for raw material we will prepare a detailed R&D plan for small quantity skin production at Plascore. We need funding for this program.
CMS Upgrade Workshop, FNAL, Nov 19-21, 2008 12O.Prokofiev
Factory Setup Preparation
CSC factory production setup:
Semi-clean room construction, area cleaning,
Tooling preparation (restoration, adjustment, calibration)
Personnel training, learning, start production
FNAL estimation:
Technicians: 3 techs for 6 months to construct clean room, assemble panel lifting, prepare tooling, training and start chamber production Cost: 152 k$
Engineering support: 1 engineer for 2 months to help with tooling startup Cost: 33 k$
M&S: clean room parts, Gerber and Axxiom machine repair / maintenance,… Cost: 50k ---------------------------------- Total: 235 k$
CERN estimation:
Technicians: 6 techs for 6 months Cost: 108 k$
Engineering support: 1 engineer from FNAL for 2 months to help with tooling startup Cost: 33 k$ + travel (15k$) = 48 k$
M&S: clean room parts, Gerber and Axxiom machine repair/maintenance,… Cost: 50k ---------------------------------- Total: 206 k$
CMS Upgrade Workshop, FNAL, Nov 19-21, 2008 13O.Prokofiev
Panel Production at Lab.8EMU CMS Panels production at LAB8 at FY 00 Panel' s
Panel production per month FTEs used per month
0
10
20
30
40
50
60
70
80
90
100
1 2 3 4 5 6 7
month of FY00
Pan
els
per
mo
nth
0
0,5
1
1,5
2
2,5
3
FT
Es
per
mo
nth
Average =2.22FTEs
Muon CMS Production Status for FY00 (ME234/2)Production Rate for GERBER
0
5
10
15
20
25
1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46Number of week in production
Nu
mb
er o
f P
anel
s p
er w
eek
0
5
10
15
20
25
Pro
du
ctio
n r
ate
(pan
els/
wee
k) f
rom
beg
inin
g o
f F
Y
Gerber Production Speed =13.2 panels/week
Muon CMS Production Status for FY00.
Panels Production at Axxiom.
-80-40
04080
120160200240280320360400440480520560600640680720
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47
Week in production
Nu
mb
er
of
Pan
els
Shortage
Goal=770 panels
DONE
Axxiom production rate = 14.1 panels/week
Production rate at FY00 (second year of production):
- Axxiom – 14.1 panel/week - Gerber – 13.2 panel/week - Labor – 2.2 FTE/month - QC/QA, travelers – 1.0 FTE/month
ME4/2 upgrade (72 x 7 plus spares ~600 panels)
Production time: 600/13 = 46 weeks (1.0 year) technicians (3.2 FTE/year) floor manager (0.5 FTE/year) engineering support (0.25 FTE/year)
Labor: panel cutting, drilling, milling, QC/QA, packing
CMS Upgrade Workshop, FNAL, Nov 19-21, 2008 14O.Prokofiev
Chamber Production at MP-9
Panel Cleaning: 3.5 h /Chamber Anode FR4 Gluing: 12.5 h /Chamber Cathode FR4 Gluing: 28 h /Chamber Anode Wire Winding: 15 h /Chamber Anode Wire Gluing: 9 h /Chamber Anode Wire Soldering: 6.5 h /Chamber Anode Component Soldering: 45 h /Chamber Cathode Component Soldering: 12 h /Chamber Anode Tension Testing: 6 h /Chamber Anode Electrical Testing: 10 h /Chamber Chamber Assembly: 33 h /Chamber Chamber HV Training: 6 h /Chamber Chamber Packing & Shipping: 3.5 h /Chamber Total 190 h /Chamber
CMS EMU chamber assembly manpower analysis (FNAL, 2001)
An ME234/2 chamber requires 190 “Worked FTE (WFTE) hours” to be completed in MP9. In order to complete 4 Chambers/month, we require 190x4= 760 WFTE hours/month. At 80% efficiency utilization (vacation, thick days,…) this corresponds to 912 “Charged FTE (CFTE) hours” per month. A standard technician charges on average 173 h/month. This puts the manpower requirement in MP9 to 5.3 FTE (912/173) to achieve the stated goals.
FR4 Anode Gluing Time
0.0
4.0
8.0
12.0
ME23
4/2-
001
ME23
4/2-
007
ME23
4/2-
012
ME23
4/2-
017
ME23
4/2-
022
ME23
4/2-
027
ME23
4/2-
032
ME23
4/2-
037
ME23
4/2-
042
ME23
4/2-
047
Chamber
Tim
e (
da
ys
)
Mean+STDEV
Mean-STDEV
Mean
Winding Time
0.0
2.0
4.0
6.0
ME234
/2-0
01
ME234
/2-0
07
ME234
/2-0
12
ME234
/2-0
17
ME234
/2-0
22
ME234
/2-0
27
ME234
/2-0
32
ME234
/2-0
37
ME234
/2-0
42
ME234
/2-0
47
Chamber
Tim
e (
da
ys
)
Mean+STDEV
Mean-STDEV
Mean
75 chambers production at FNAL:
4 chamber/month 2 years production
Labor estimation for chamber production at FNAL : production tech (5.3 FTE / year) QC/QA tech (1.0 FTE / year) floor manager (1.0 FTE / year) engineering support (0.25FTE)
CMS Upgrade Workshop, FNAL, Nov 19-21, 2008 15O.Prokofiev
Procurement, QC/QA, Kit Preparation, Shipping
FNAL’s experience:
Procurement: parts for all chamber types were procured at FNAL
QC/QA: checked 10 % of all chamber parts
Kit preparation: all parts for 1 chamber production
FNAL’s Labor:
Procurement: ~18% overhead (possible discount for panel production)
Input part QC/QA: 0.5 FTE/year tech
Kit preparation: 0.3 FTE/year tech
Packing, shipping: 0.2 FTE/year tech----------------------------------------------- Total: 1.0 FTE tech/year
Panel cleaning and shipping (option: only panel production at FNAL)
- machine cleaning (600 panels): 14 panels/day for 2 persons 85 days ~ 0.3 FTE in total - packing, shipping: 0.2 FTE/year -------------------------------------------- Total: 0.7 FTE tech in total (FNAL rate)
CMS Upgrade Workshop, FNAL, Nov 19-21, 2008 16O.Prokofiev
Chamber Production Cost Estimation
FNAL’s Labor estimation ( 100% overhead included):
Tech: ~ $50/hour $8.6k/month $103 k/yearFloor manager: ~$80k/hour $13.8k/month $165 k/yearEngineer: ~ $100/hour $17.3k $206 k/year
Procurement: 20% overhead
PNPI / IHEP tech 3k$/month 36k$/year
Chamber Production at FNAL:
Chamber production (tech) : 5.3 x 2 = 10. 6 FTE/year 1,091 k$
Input QC/QA, kit preparation, packing (tech) : 1.0 x 2 = 2.0 FTE/year 206 k$
Floor manager: 1.0 FTE X 2 = 2.0 FTE/year 330 k$
Engineering support: 0.25 x 2 = 0.5 FTE/year 100k$
Shipping cost to CERN (5 containers), making treated wood crates 100k$
----------------------------------------- Total: 1,827 k$
Chamber Production at CERN:
Chamber production (tech) : 5.3 x 2 = 10. 6 FTE/year 381 k$
Input QC/QA (USA rate): 0.5 x 2 =1.0 FTE/year 52 k$
kit preparation, (tech) : 0.3 x 2 = 0.6 FTE/year 22 k$
Floor manager: 1.0 FTE X 2 = 2.0 FTE/year 72 k$
Engineering support: 0.25 x 2 = 0.5 FTE/year 18 k$
Panel cleaning, packing: 0.7 FTE/year (FNAL rate) 72 k$
Shipping to CERN: panels, tooling, (6-7 containers), crates 120 k$
----------------------------------------- Total: 665 k$
CMS Upgrade Workshop, FNAL, Nov 19-21, 2008 17O.Prokofiev
FNAL Cost Estimation
FNAL’s Labor with overhead (100%):
Technician: ~ $50/hour $8.6k/month $103 k/yearFloor manager: ~$80k/hour $13.8k/month $165 k/yearEngineer: ~ $100/hour $17.3k $206 k/year
Procurement: 18% overhead
Panel production at FNAL:
panel production (technician): 3.2 x 2 = 6.4 FTE/year $659 k$
floor manager: 0.5 x 1 =1.0 FTE/year 82k$
engineering support: 0.25 x 1 = 0.25 FTE/year 25 k$
M&S (repair, milling bit, diamond saw blade) 60 K$ --------------------------------------- Total: ~ 718k$
Panel cleaning and shipping (option: FNAL is used only for panel production)
- machine cleaning (600 panels): 14 panels/day for 2 persons 85 days ~ 0.3 FTE in total - packing, shipping: 0.2 FTE/year -------------------------------------------- Total: 0.7 FTE tech in total (FNAL rate) - 72 k$
CMS Upgrade Workshop, FNAL, Nov 19-21, 2008 18O.Prokofiev
Production Scenario
Options: CSC factory production at CERN or FermiLab Parts procurement at FNAL or University
Description Cost, k$FNAL Panel production + cleaning + shipping 790
University Parts procurement 1910
CERN Chamber production (PNPI +IHEP) 665
Total 3365
FNAL Panel production + cleaning + shipping 790
FNAL Parts procurement 2292
CERN Chamber production (PNPI +IHEP) 665
Total 3747
FNAL Panel production 718
FNAL Parts procurement 2292
FNAL Chamber production 1827
Total 4837
Preliminary, ME4/2 chamber upgrade could be completed in 2.5 years (factory setup + production)
The chamber factory at FNAL is the best technical solution: optimal infrastructure, technical expertise, tooling experts and QC&QA program, but it is additional cost of 1.5M$.
Making chamber at CERN gives a big saving in money but we should be careful with manpower estimation, quality control and production schedule. A factory setup will be a complicated issue.
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