APA Production at Chicago Ben Stillwell on behalf of the Chicago APA factory team – Ed Blucher, Dave Schmitz, Rich Northrop, Marc Berthoud, and Zack Siegel APA Workshop 10-11 June 2019
Outline • Factory layout • Factory planning (presently funded by NSF and UChicago) • Building preparation • Facility design • Mockup testing • Project management • Safety • Factory set-up and operation (funding to be requested from NSF) • Cost estimates • Schedule milestones • Staffing 2 June 10-11, 2019 APA Production at Chicago
Factory Layout - Overview 557 m 2 of dedicated space (excluding truck bay area). 3 June 10-11, 2019 APA Production at Chicago
Factory Layout – Truck Loading and Transfer Areas Incoming and outgoing • shipments will use indoor truck bay at north end of building. 4 June 10-11, 2019 APA Production at Chicago
Factory Layout – Prep and QC Area Clean tent to be built on • lower level. Bare frames moved in for • mesh and initial comb base/board installation, then out for crane lift to mezzanine. Completed APAs moved • in for QA and shipping prep, moved out for crane lift into shipping crate. 5 June 10-11, 2019 APA Production at Chicago
Factory Layout – Winding Area • Clean tent built around (or attached to) bridge • Soft-wall cleanroom crane frame. around (perhaps on APAs shuttled between • frame of) 2T bridge building crane and crane. cleanroom crane with • process cart. Loading deck to be Winders in ‘L’ with • built at N end for shared controls area. transfer from building crane. • T wo winders in L configuration allows shared controls area. • Room for multiple process carts. 6 June 10-11, 2019 APA Production at Chicago
Factory Planning • Weekly team meetings to identify and resolve issues. • Developing detailed internal project schedules (Berthoud) • Coordinating with University management and facility services and to get needed building cleanup and improvements done. • Working with divisional safety representative to ensure that all needed controls will be in place. • Designing facilities and getting costs for equipment and materials (Northrop) • Fabricating “mockup” equipment to validate facility plan (Siegel) 7 June 10-11, 2019 APA Production at Chicago
Building Preparation • Budget of $270k paid from University funds. • Major items managed by University facility services. • Design and install mezzanine extension. • Design and install stair covering on lower level. • Modify HVAC duct to maximize winding area clean tent. • Add door from hall to mezzanine extension. • Minor items managed by PSD facilities personnel. • Clean out high bay. • Epoxy coat floors. • Install stops on existing overhead crane rails. • Route new electrical service. • Install personnel barriers. • Maintain emergency egress routes. 8 June 10-11, 2019 APA Production at Chicago
Building Preparation – Schedule Milestones (As suggested by internal schedule. Assumes funds available June 24, 2019) • Feasibility study and budgetary estimate for mezzanine extension and stair cover – Feb 12, 2019 ✓ • High bay cleanup – Aug 24, 2019 (Effort has begun) • Detailed designs for facility modifications – Aug 6, 2019 • Install mezzanine extension – Dec 10, 2019 • Install stair cover – Dec 20, 2019 • Epoxy coat floors – Jan 24, 2020 • Ready for factory set up – Feb 3, 2019 9 June 10-11, 2019 APA Production at Chicago
Facility Design (Northrop) 3D full-factory model Winding area clean tent Prep/QC area clean tent 10 June 10-11, 2019 APA Production at Chicago
Mockup Testing (Siegel) • Verify that layout provides adequate clearance and visibility for moving APAs through factory with overhead crane and process cart. • Establish and refine safe working procedures for moving APAs with overhead crane. • Better understand time and effort required for various steps in process. • Ensure needed facilities and equipment are properly planned for. • Begin training Chicago staff on basic factory operations. 11 June 10-11, 2019 APA Production at Chicago
Mockup Testing – Activities • Receive and build process cart frame ✓ • Draft detailed test plan – 6/28/19 (in progress) • Tape floors and roll process cart through tight spots – 7/26/19 • Receive simplified APA frame – 8/30/19 (design in progress) • Order and install process cart interface arms – 8/30/19 • Transport, load/unload APA frame with crane – 8/30/19 • Receive complete APA frame – 10/21/19 • Prep APA frame for winding (install meshes, boards) – ?? • Load APA frame into/out of shipping container – ?? 12 June 10-11, 2019 APA Production at Chicago
Project Management (Berthoud) Internal project schedules for three phases: • Factory planning and mockup testing, through Sept 2020. • Factory setup, Sept 2020 – Oct 2021 • Factory operation, June 2021 – Aug 2025 The goals are to: • Track and help organize facility work • Provide input for funding proposals. • Understand impact and respond appropriately to issues that will occur during production. 13 June 10-11, 2019 APA Production at Chicago
Safety Discussions have begun with PSD safety specialist Kimberly Mormon. Identified hazards include: • Overhead crane, other material moving activities • Fall from elevated area • Chemical exposure (epoxy, cleaning solutions) • Automated equipment (winder) • Lead exposure (solder) • Beryllium (wire) Controls for these will be developed and presented in more detail at the factory design review. 14 June 10-11, 2019 APA Production at Chicago
Factory Setup – M&S Cost Estimate • Winding area clean tent - $106k 1 • Prep area clean tent - $53k 1 • Overhead crane for winding area - $100k 2 • Four process carts - $81k 1 • Jigs and test hardware - $150k • Misc tools, equipment, and consumables - $60k 3 • Total - $550k 1. Quotes based on updated designs will be requested soon. 2. Based on vendor quotes. 3. Includes some items unique to Chicago factory. 15 June 10-11, 2019 APA Production at Chicago
Factory Operation – M&S Cost Estimate • Solder and epoxy - $72k • Wire - $36k • Combs - $183k • Electron diverters - $44k • SHV and wire harness - $30k • Cover boards - $61k • APA shipments - $108k 1 • Total - $535k 1. Based on recent quote for Chicago to Lead, SD. 16 June 10-11, 2019 APA Production at Chicago
Factory Setup – Schedule (Assumes no human resource limitations) Milestones • Request purchase orders – Sep 1, 2020 • Preparation clean tent ready – Oct 23, 2020 • All (four more) process carts built – Dec 18, 2020 • Winding area crane installed – Dec 11, 2020 • Winding clean tent complete – Feb 12, 2021 • APA line 1 complete – Jun 15, 2021* • APA line 2 complete – Oct 19, 2021* * Schedule significantly impacted by time to receive parts and build winders. 17 June 10-11, 2019 APA Production at Chicago
Factory Operation – Schedule Total operational days through Aug 31, 2025*: Winder 1: 1018 Winder 2: 928 Total APAs complete assuming 40 days/APA: Winder 1: 25 Winder 2: 23 Total: 48 Completing 60 APAs would require a rate of 1 APA / 32 days. * Assumes two weeks closure during winter holidays + 6 additional university holidays. 18 June 10-11, 2019 APA Production at Chicago
Factory Setup – Staffing Effort Engineer Technician Student Total Participate in planning, reviews 450 h - - 450 h Install clean tents and prepare space 1 900 h 900 h - 1800 h Assemble and set up two winders 3300 h 900 h 1800 h 6000 h Assemble and set up four process carts - 96 h 320 h 416 h Total 2 4200 h 1896 h 2120 h 8216 h Total FTE-Y 3 2.6 1.2 1.3 5.0 1. Values are double the estimate from PSL since there are two clean tents. 2. One FTE-Y, not included here, is also assumed for technical, project, and safety mgmt. 3. FTE- Y ≡ (220 days)(7.5 hours/day) = 1650 hours. 19 June 10-11, 2019 APA Production at Chicago
Factory Setup – Staffing Winder assembly and installation Cleanroom installation 4.50 4.00 3.50 3.00 2.50 2.00 1.50 1.00 0.50 0.00 Sep Oct Nov Dec Jan Feb Mar Apr May Jun July Aug Sep Engineer - FTE Technician - FTE Student - FTE To reduce human resource needs early in the setup phase, a contractor will be utilized to build the clean tents. 20 June 10-11, 2019 APA Production at Chicago
Factory Operation – Staffing Activity Engineer Technician Students, etc Winder 1, 30 APAs 9760 h 24400 h 19520 h Winder 2, 30 APAs 9760 h 24400 h 19520 h SHV boards, wire harness, covers 1800 h Total 19520 h 50600 h 39040 h 11.8 FTE-Y 30.7 FTE-Y 23.7 FTE-Y • The above is consistent with FNAL cost book v7. • Engineer and technician hours are as described in the pre-proposal. • The pre-proposal describes slightly more student effort: 2 undergraduate FTEs + 5 graduate students. 21 June 10-11, 2019 APA Production at Chicago
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