Philip G. Cutino, P.E.

Engineering 10 PresentationApril 19, 2012

Chabot College, Hayward CA

Mr. Phil Cutino • ENGR10 • Sp12

Today’s Agenda SLAC National Accelerator

Laboratory Linac Coherent Light Source (LCLS) My role at SLAC over the years The Mechanical Fabrication

Department

Mr. Phil Cutino • ENGR10 • Sp12

Location: Menlo Park, CA Type: Multi-program Laboratory Contract Operator: Stanford University Website: www.slac.stanford.edu Physical Assets:

426 Acres 145 Buildings 1.8M GSF in Active Operational Buildings

Human Capital Employees: 1,496 FTE as of 4/15/08 Users, Visiting Scientists and Grad Students:

3036 Head Count

Stanford Linear Accelerator Center

Mr. Phil Cutino • ENGR10 • Sp12

SLAC Mission SLAC programs explore the

ultimate structure and dynamics of matter and the properties of energy, space and time - at the smallest and largest scales, in the fastest processes and at the highest energies - through robust scientific programs, excellent accelerator based user facilities and valuable partnerships.

Mr. Phil Cutino • ENGR10 • Sp12

Research at SLAC Accelerator Physics Astrophysics and Cosmology Elementary Particle Physics Materials and Nanoscience Molecular Environmental

Science Structural Biology Ultrafast Science http://

www6.slac.stanford.edu/Research.aspx

Mr. Phil Cutino • ENGR10 • Sp12

LCLSTotal Machine* : ~1750 meters of beam line

1242 DevicesInjector: 28 meters of beam line

& 95 devicesLinac 1003 meters 708 devices

LTU & Dump408 meters 176 Devices

*Electron Beam Line Only Does not include Photon Beam Lines

Mr. Phil Cutino • ENGR10 • Sp12

Linac Coherent Light Source

Ultrafast X-ray science Directly observe the motions of atoms on ultrafast time

scales Investigate dynamics, bonding, heating and melting, at

atomic and nanometer length scales Create and observe extreme new conditions in atoms

and materials Imaging of nonperiodic molecules and nanostructured

materials World’s first X-ray free electron laser

Producing 100 femtosecond pulses of photons in the energy range 800-8,000 eV

10^12 coherent X-ray photons/pulse Potential for sub-femtosecond pulses Lead nanoscale science revolution Master control of energy-relevant complex systems Lead the world in the investigation of dynamics of

atomic transitions, chemical bonding, catalysis and heating

Mr. Phil Cutino • ENGR10 • Sp12

Links to More Information

http://www.slac.stanford.edu http://lcls.slac.stanford.edu http://

www6.slac.stanford.edu/ExploringSLACScience.aspx

https://news.slac.stanford.edu/

Mr. Phil Cutino • ENGR10 • Sp12

Atypical career path

Mechanical Engineer Register Professional Engineer in CA

Returned to school late in life Diverse background . . . ~25 years with the same employer

Four different jobs

Mr. Phil Cutino • ENGR10 • Sp12

My Roles at SLAC Process Control Instrumentation

Technician Facilities Engineer Accelerator Engineer Mechanical Fabrication

Department Head

Mechanical Fabrication Department

Phil CutinoOctober 27, 2010

Mechanical Fabrication DepartmentPage 12

Mission and Vision

• Mission– Provide specialized manufacturing and field support

services necessary for the Lab to achieve it’s stated goals– Provide collaborative and quick turn around manufacturing– Provide services unique to the SLAC mission not available

elsewhere• Vision

– Partner with SLAC organizations to effectively deliver high quality manufacturing services in a safe and cost efficient manner supporting the scientific mission

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Delivering SLAC’s Mission

• Broad capability on site for specialized manufacturing services– High quality, consistency, capacity and unique accelerator research specific processes

developed and delivered safely• Technical know how developed over many years

– Highly trained & experienced staff available for changing needs of an experimental research user facility

• Quick turn around and collaborative manufacturing– Metal Finishing

• Documented processes developed specifically for accelerator research needs– Hydrogen Furnace Brazing– Vacuum Processing and Precision Assembly– Magnet fabrication, refurbishment and repair– Machining

• Special capability such as ability to machine exotic & low-level radioactive materials

• Field work includes installation, installation coordination, accelerator mechanical and vacuum system maintenance and operations

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Organization• 85 Full time staff members

– 6 Engineers– 12 Science & Engineering Associates– 67 technicians and trades

• 9 supervisors• 12 matrixed out

– Formal matrix agreements• 9 are temporary employees• Very experienced workforce

– 16% have 10 to 20 years of service– 19% have 20 to 30 years of service– 9% have more than 30 years of service

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Organization continued• Management (4)

– Mgmt., Admin., ES&H support• Production Planning (6)

– Job inputs, Estimating– Manufacturability Review

• Machine Maintenance (4)• Field Operations (6)• Vacuum Shop (21)

– Vacuum Processing– Precision Assembly

• Braze Shop (7)– Precision Assembly

• Machine Shop (12)• Metal Finishing (8)• Structural Fabrication Shop (7)

– Magnet Coil Shop– Sheet Metal and Welding Shops

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Core Competencies

• Broad range of technical know-how necessary to support the scientific mission– Generally very high quality on site for ongoing and urgent

operational needs as well as collaborative manufacturing• Manufacturing & Field Support Services

– Seamless integration of production planning, machining, metal finishing, magnet fabrication, precision assembly, sheet metal forming, welding operations, quality assurance, vacuum processing with installation, maintenance and repair

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Core Competencies continued

Machine Shop

Clean Machining for UHVQuick Turnaround

Radioactive MaterialsDFM & Prototype Parts

Mechanical Fabrication DepartmentPage 18

Core Competencies continued

Hydrogen Furnace BrazingAnd

Heat Treating

Mechanical Fabrication DepartmentPage 19

Core Competencies continued

Metal FinishingPlating

and Cleaning for UHV

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Core Competencies continued

Mechanical and Vacuum Processing andField Operations

Precision Assembly

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Performing Work• Customers have access to the manufacturing process

– Scope and technical changes are routinely accommodated– Collaborative manufacturing is facilitated– Problems are solved quickly

• Customer feedback is regularly provided– Cost and schedule estimates are provided as part of the job input

process– Customers can check an online tool for real time updates– Scope and technical changes are not re-estimated unless requested by

the customer• Regular planning meetings are held

– There is a standing weekly meeting for all field work– Larger projects are coordinated in project specific meetings held weekly

or as needed

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Performing Work continued• Quality assurance is integrated and documented on travelers.

– All machined parts are independently quality checked by MET unless the customer requests this step is to be skipped

– Vacuum processing reports are recorded in traveler– Vacuum leak checking is provided in the shop on assemblies and in the

field on systems• Manufacturing process is seamlessly integrated

– Procurement of materials, machining, metal finishing, vacuum processing, precision assembly and installation can be procured from a single request

– In process storage of components and assemblies is provided• Schedule updates are available to project managers

– Schedule reporting is provided to customers or to integrated schedules as requested by customers

• Change control is generally formal

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Performing Work continuedCollaborative Manufacturing Example:Wire Card for combination OTR / Wire Scanner Developed for KEK by Doug McCormick (SLAC)Resolution ~2 microns

Technical Challenge:10 micron Tungsten Wire Soldered to gold plated Macor substrate requiring high positional accuracy

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Concluding Work• Estimate vs. Actual reports are provided for all jobs.

– Actual costs are available online for future use in estimating.– Historical and real time data is searchable by part number,

customer name and job number.– Performance reporting is facilitated using manufacturing

software.– Performance reports are published monthly.

• Scope changes are not typically re-estimated.– Scope changes affect performance.– Recently began tracking jobs with significant changes.

• All Redline drawings are routed back to MED for updating.• An online feedback tool is available.

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Questions and Answers