cms upgrade workshop

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


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:


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.


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.


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


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


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


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.


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)


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


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.


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$


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


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)


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)


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$


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$


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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