glast lat projectcdr/cd3 review may 12-16, 2003 document: lat-pr-01967-01section 15 manufacturing...

GLAST LAT Project CDR/CD3 Review May 12-16, 2003

Document: LAT-PR-01967-01 Section 15 Manufacturing Process 1

GLAST Large Area TelescopeGLAST Large Area Telescope

Manufacturing Process

Jerry ClintonChief Manufacturing EngineerStanford Linear Accelerator Centerjclinton@SLAC.stanford.EDU(650) 926-5435

Gamma-ray Large Gamma-ray Large Area Space Area Space TelescopeTelescope

GLAST LAT Project CDR/CD3 Review May 12-16, 2003

Document: LAT-PR-01967-01 Section 15 Manufacturing Process 2

Manufacturing OverviewManufacturing Overview

• Anticoincidence Detector manufactured by GSFC

• Tracker Towers manufac-tured by INFN

• Calorimeter Module manu-factured by NRL

• DAQ/Tracker electronics manufactured by SLAC

• Grid Box manufactured by SLAC

• Radiators manufactured by Lockheed-Martin

GLAST LAT Project CDR/CD3 Review May 12-16, 2003

Document: LAT-PR-01967-01 Section 15 Manufacturing Process 3

RequirementsRequirements

• 433-MAR-001 GLAST LAT Mission Assurance Requirements• LAT-DS-00039 GLAST LAT Performance Assurance

Implementation Plan• Assemblers trained and certified to workmanship standards

NASA-STD-8739.1, 8739.2, 8739.3, 8739.4 and 8739.7• Assembly and test performed in Class 100K clean room

compliant with LAT-MD-00404• Production Readiness Reviews

GLAST LAT Project CDR/CD3 Review May 12-16, 2003

Document: LAT-PR-01967-01 Section 15 Manufacturing Process 4

Production Readiness ReviewProduction Readiness Review

• Conducted by IPO• Required before start of flight manufacturing• Iterative reviews to support subsystem delivery schedules• Review of processes, specifications, drawings, parts and

materials lists– Documentation released for manufacturing– Processes verified on prototype or engineering-model

hardware– EEE parts on Parts Identification List and approved for the

specific application– Raw materials on Program Approved Materials List and

approved for the specific application

GLAST LAT Project CDR/CD3 Review May 12-16, 2003

Document: LAT-PR-01967-01 Section 15 Manufacturing Process 5

Production Readiness Review – Cont.Production Readiness Review – Cont.

• Personnel training and certification• Facilities readiness – MGSE, EGSE, ESD controls, compliance

with LAT-MD-0404• Parts, materials, tools, test equipment, shop supplies, etc. on

hand and in place at start of manufacturing

GLAST LAT Project CDR/CD3 Review May 12-16, 2003

Document: LAT-PR-01967-01 Section 15 Manufacturing Process 6

Procurement ProcessProcurement Process

Start ProcurementProcess

Part/mat’lapproved byPCB/MPRB?

Drawing/specreleased?

Funding inplace?

Complete part/material approval

process

No

Complete drawingor spec and get it

released

No

Get fundingauthorized

Yes

Prepare purchaserequisition

QA review andapproval

Preparesupporting

documentationpackage

Sole source?Prepare sole

source justification

Yes

Yes

Specification(s) Drawing(s) Quotation (if recent) Sole Source Justification

Deliver supportingdocumentation to

purchasing

Managementreview andapproval

Submit approvedrequisition topurchasing

Yes

No

Supportpurchasing as

requested

End

GLAST LAT Procurement Process

QA review

GLAST LAT Project CDR/CD3 Review May 12-16, 2003

Document: LAT-PR-01967-01 Section 15 Manufacturing Process 7

Material ReceivingMaterial Receiving

Material arrives

Inspect shippingcontainer for

physical damage

Container OK?

Verify shippingdocuments reflectcorrect P/N, PO,

and qty

DocumentsOK?

Verify quantityreceived matches

shippingdocuments

Quantity OK?

Place receivedmaterial in stores

Open NCR Open NCR Open NCR

Notify QE and RE

QE and RE workwith purchasingand vendor to

resolvediscrepancies

Discrepanciesresolved?

Disposition andclose NCR (s)

Yes

Yes

Yes

NoNo

No

Notify QE and RE

Notify QE and RE

QE and RE workwith purchasingand vendor to

resolvediscrepancies

Yes

A

A

Discrepanciesresolved?

Disposition andclose NCR (s)

Yes

Photographdamage

BNo

Material ReviewBoard determine

disposition ofmaterial, close

NCR

Archive QualityRecords

No

B

GLAST LAT Project CDR/CD3 Review May 12-16, 2003

Document: LAT-PR-01967-01 Section 15 Manufacturing Process 8

Basic Manufacturing FlowBasic Manufacturing Flow

Prepare workorder

Built in-house?

Issue parts towork order

Pack kit forshipment to

assembly supplier

Ship kit

Assembly

Inspection

Test

Engineeringreview of test data

Final inspection Deliver to stores

ReceivingInspection

GLAST LAT Project CDR/CD3 Review May 12-16, 2003

Document: LAT-PR-01967-01 Section 15 Manufacturing Process 9

Material ControlMaterial Control

• Must be a closed loop control process • Parts/materials received from suppliers into flight stores• Parts and materials issued to work orders for assembly• Finished assemblies returned to stores• Process repeats for next higher assemblies

GLAST LAT Project CDR/CD3 Review May 12-16, 2003

Document: LAT-PR-01967-01 Section 15 Manufacturing Process 10

Non-Conforming Material HandlingNon-Conforming Material Handling

• All non-conformances are documented on a Non-Conformance Report (NCR)– Identifies non-conforming item– Describes non-conformance– Describes environment unit was in at the time the non-

conformance was discovered– Implemented using REMEDY

• Work stopped until NCR is reviewed and dispositioned by Material Review Board– Chaired by Quality Engineer– Supported by responsible engineer, manufacturing engineer,

and other specialty engineers as appropriate– NCRs archived in a data base and kept with the item work

order

GLAST LAT Project CDR/CD3 Review May 12-16, 2003

Document: LAT-PR-01967-01 Section 15 Manufacturing Process 11

Spares and RepairsSpares and Repairs

• Spares listed in Configuration Item Data List• End items delivered to SLAC for integration and test• Damaged or failed end items returned to manufacturer

• Calorimeter modules repaired by NRL• ACD repaired by GSFC• Tracker towers/trays repaired by INFN • DAQ and Grid assembly hardware repaired by SLAC

GLAST LAT Project CDR/CD3 Review May 12-16, 2003

Document: LAT-PR-01967-01 Section 15 Manufacturing Process 12

Clean Room SupportClean Room Support

• ESD-safe, clean-room lab coats• Hair covers• Face masks• Shoe covers• Nitrile gloves and finger cots• Clean-room swabs and wipes• Solvents and DI water• ESD-control wrist straps• Fastener inventory