1 LHC-DFBX Fabrication Oversight Plan Joseph Rasson LBNL Presented at the DFBX Production Readiness Review 23-24 October 2002, LBNL Brookhaven - Fermilab

1

LHC-DFBX

Fabrication Oversight Plan

Joseph Rasson

LBNL

Presented at the

DFBX Production Readiness Review

23-24 October 2002, LBNL

Brookhaven - Fermilab - Berkeley

US LHC ACCELERATOR PROJECT

2

Outline

Production Oversight Fabrication Oversight Plan Vendor Monitoring Oversight Level of Effort Change Control Procedures Summary

3

Production Oversight

Project oversight tasks: Manage fabrication activities at LBNL Manage current leads procurement Transfer GFM to cryogenic vendor Monitor fabrication, assembly and acceptance tests at

cryogenic vendor Manage Change Control Process Update engineering drawings to include as-built modifications Update Interface Specifications Manage hardware and document transfer to CERN Report status to LHC-PMO

4

Fabrication Oversight Plan

Fabrication oversight is critical to delivering a quality product on schedule

Vendor is requested to provide detailed fabrication and assembly milestones to track progress

Implement a Change Control Procedures Plan constant monitoring of vendor performance to:

Assist in resolving fabrication issues Insure that DFBX is given the appropriate scheduling priority Supervise the transfer GFM to the vendor Witness critical assembly processes Witness inspection tests Manage change control process

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Vendor Monitoring

Frequent visits to vendor fabrication facility MTM is within a driving distance to FNAL Will consider retaining professional QA support from local

firms if PHPK wins the award LBNL representative will have unrestricted access to the

Subcontractor facility during normal working hours Subcontractor will provide office space to LBNL

representative

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Vendor Monitoring (cont.)

Request Reports and Scheduled Meetings Post Award Conference to kick-off DFBX production Monthly Progress reports Monthly meetings at the vendor’s facility to review Progress Weekly phone or video conference meetings to review status Meetings to be attended by Subcontractor’s Project Manager

and lead engineer

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Oversight Level of Effort

Fabrication oversight will be made up of LBNL and FNAL staff The balance between LBNL and FNAL will depend on who the

location of the vendor DFBX Project Engineer is committed to stay with project

throughout the production phase On the average 2 FTE’s are available for project management

and production oversight

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DFBX Oversight Level of Effort

-

0.20

0.40

0.60

0.80

1.00

1.20O

ct-0

2

No

v-0

2

De

c-0

2

Jan

-03

Fe

b-0

3

Ma

r-0

3

Ap

r-0

3

Ma

y-0

3

Jun

-03

Jul-

03

Au

g-0

3

Se

p-0

3

Oct

-03

No

v-0

3

De

c-0

3

Jan

-04

Fe

b-0

4

Ma

r-0

4

Ap

r-0

4

Ma

y-0

4

Jun

-04

Jul-

04

Au

g-0

4

Se

p-0

4

Oct

-04

No

v-0

4

De

c-0

4

Jan

-05

Fe

b-0

5

Ma

r-0

5

Ap

r-0

5

Ma

y-0

5

Jun

-05

Jul-

05

Au

g-0

5

Se

p-0

5

FY2003 FY2004 FY2005

FTE

Jon Zbasnik Joseph Rasson Ray Hafalia or equivalent Peterson, Tom

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Change Control Procedures

Established project change control procedures to manage production cost and schedule

Change Control Procedures is a supplemental document to LBNL-LHC QA Plan

Procedures apply to LBNL or vendor generated change requests Procedures insure that documents and drawings are updated and

archived in the Document Control Center Change requests that impact cost or schedule will be

communicated to the vendor by LBNL Procurement Officer Process flow charts and forms are available and being reviewed

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LBNL Generated Changes

Engineering Design Change initiated at LBNL or FNAL

DesignChange Notice

Form submitted to DFBX Project Engineer for

approval

No furtheraction taken

Doeschange affectan in-house or

an outsidefab?

Project Engineer issues an RFI to vendor to determine

cost and/or schedule impact

Project Engineer negotiates technical issues of change

with fabrication vendor

Is costchange more than

$5k?

Project Engineer makes changes to drawings and/or specifications

Submittedto FNAL PM Office

for approval

Project Engineer requests Procurement Officer to issue contract mods (outside only)


Revised drawings and/or specifications filed in the Document Control Center

Hardware is fabricated based on new prints and/or specifications

Accepted RejectedIn-house

Outside

>$5k

<$5k

Accepted

Rejected

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Vendor Generated Changes (1)

Vendor identifies inconsistencies in LBNL

drawings or specifications

Vendor issues a Corrective Action Report


Project Engineer requests Procurement Officer to issue

contract modifications



Reportreviewed by LBNL

Project Engineer forapproval


$5k?


for approval

AcceptedRejected >$5k

<$5k

Accepted

Rejected



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Vendor identifies potential changes to simplify a

fabrication or assembly

Vendor issues a Deviation Request






Requestreviewed by LBNL

Project Engineer forapproval


$5k?


for approval

AcceptedRejected >$5k

<$5k

Accepted

Rejected



13


Inspected parts or assemblies do not conform to drawings

and/or specifications

Vendor issues a Nonconformance Report





Hardware is reworked based on new prints and/or specifications

ProjectEngineer & Material

Review Board determine necessary action

Isthere a cost

impact?

Use as isScrap No

Yes

Reject and scrap parts


Rework



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LBNL Design Change Notice Form

DFBX Design Change Notice Form

LHC-DFBX DCN No. DFBX-

Requester: Date: Affected Document: Short Title of Change: Description of Proposed Change: Justification for Proposed Change: Impact on Cost/Schedule: Impact on other subsystems or the Interface Specifications: Reviewed by Lead Engineer: Reviewed by Project Engineer Concurrence: Approval Date: Rejection and reason for rejection:

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Deviation Report D e v i a t i o n R e q u e s t

L H C -D F B X P O . N o . D e v i a t i o n R e q u e s t

R o u t i n e ? U r g e n t ? E m e r g e n c y ?

D R -

D a t e : T o L B N L D F B X P r o j e c t M a n a g e r :

S u p p l i e r N a m e , A d d r e s s , P h o n e , e t c :

T y p e : M a t e r i a l ? P a r t ? S u b a s s e m b l y ? F i n a l A s s e m b l y ? P r o c e d u r e ? D e s i g n C o n f l i c t ? S p e c C o n f l i c t ? I t e m N a m e a n d S e r i a l N u m b e r

D W G # o r S p e c # Q T Y N o n c o n f o r m i n g I t e m s

D e s c r i p t i o n o f D e v i a t i o n S e e a t t a c h e d ?

R e q u i r e m e n t s V i o l a t e d S e e a t t a c h e d ?

O r i g i n a t o r

D a t e P r i n c i p a l S u p p l i e r P l a n n e r D a t e

R e m e d i a l A c t i o n / J u s t i f i c a t i o n S e e a t t a c h e d ?

C a u s e a n d C o r r e c t i v e A c t i o n S e e a t t a c h e d ?

P r i m e C o n t r a c t o r A p p r o v a l s R e c o m m e n d e d D i s p o s i t i o n A c c e p t ? R e d e s i g n ? R e j e c t ? R e p a i r ?

C o s t / S c h e d u l e I m p a c t

D a t e D a t e

L B N L A p p r o v a l s

C u s t o m e r D i s p o s i t i o n : A c c e p t R e q u e s t ? D e n y R e q u e s t ? S e e a t t a c h e d ?

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Summary

Fabrication oversight plan has been developed and being reviewed LBNL and Fermilab will play active roles in oversight activities Change Control Procedures and forms have been developed Tailor fabrication oversight plan to vendor Changes that impact cost or schedule will be communicated to

vendor through LBNL Procurement Officer

Documents

1 LHC-DFBX Fabrication Oversight Plan Joseph Rasson LBNL Presented at the DFBX Production Readiness Review 23-24 October 2002, LBNL Brookhaven - Fermilab