1. SJDLO/IF/FO - May 19-20, 20041 Production & Maintenance Steven J. Durand Thursday - May 20, 2004

2. SJDLO/IF/FO - May 19-20, 20042 Manufacturing Goals Out-source board assemblies Ready the facility for manufacturing Build modules in-house as needed Maintain the Schedule

3. SJDLO/IF/FO - May 19-20, 20043 Board Design Education GTC in-house training (6 hrs) PROTEL & PADS training OJT during prototype stage –Small runs –Multiple vendors Planned for numerous revisions

4. SJDLO/IF/FO - May 19-20, 20044 Final Circuit Boards Designed for automated assembly PROTEL, PADS & ORCAD Multi-layer boards (6-14) BGA, surface mount components –Components on both sides Ready for Out-Sourcing

5. SJDLO/IF/FO - May 19-20, 20045 NRAO will Provide: Basic Ordering Agreement, 1-2 years –Long term commitment Software designs and BOMs Design reviews with vendors Dedicated test fixtures

6. SJDLO/IF/FO - May 19-20, 20046 Board Vendor Provides: Fully assembled boards Partially tested –Flying probe tests – NRAO test fixtures ESD packaged and labeled Scheduled deliveries Hazardous chemical handling

7. SJDLO/IF/FO - May 19-20, 20047 In-house Module Assembly Preparation Trained staff Same team that built the prototypes Complete assembly drawings New soldering stations Test equipment & computers in place

8. SJDLO/IF/FO - May 19-20, 20048 ESD Preparation 12 ESD stations including floor mats ESD totes and parts bins ESD shoes and wrist straps Humidity controlled facility Parts bins by area

9. SJDLO/IF/FO - May 19-20, 20049 Planning for Small Production Runs Goal is to produce 28 similar antennas Small quantity builds, 5-10 at a time AOC warehouse completed modules (not a parts warehouse) Small machine shop in AOC

10. SJDLO/IF/FO - May 19-20, 200410 Quality Control Producing written QA procedures Software support of LabView MIB open architecture Bench test fixtures MainSaver Maintenance Software

11. SJDLO/IF/FO - May 19-20, 200411 Quality Tools Shaker Table Environmental Chamber EVLA Test rack Enhanced real-time monitoring Red/Green tag procedures

12. SJDLO/IF/FO - May 19-20, 200412 Inventory Control New and old warehouse managed by Skip Lagoyda, Business Manager JD Edwards software Quantity, re-order mechanisms

13. SJDLO/IF/FO - May 19-20, 200413 Attributes of In-house Module Assembly Minimize storage problems Tight engineering control Correct mistakes, perfect design Fast turn-around time

14. SJDLO/IF/FO - May 19-20, 200414 Module Attributes Meets Scientific Requirements RFI quiet Cost effective “It takes Twenty Years to make an overnight Success” - Eddie Cantor

15. SJDLO/IF/FO - May 19-20, 200415 RFI Mitigation Goal: Minimize RFI at the source –Board level design control MIB test results –20 dB lower –In-house RFI chamber “Test as you build”

16. SJDLO/IF/FO - May 19-20, 200416 RFI Module Design No front panel penetrations Internal barrier plate Double RFI gasket RFI air filters EVLA motto: –“Too Many Screws”

17. SJDLO/IF/FO - May 19-20, 200417 Suppression Success Present hardware meets design spec DTS module over 60 dB of attenuation Cost Saving considerations: –May not need double spiral gasket –Will not need DTS H-rack

18. SJDLO/IF/FO - May 19-20, 200418 Cost Saving Techniques Prototype using coaxial components Production using MMICS, surface mount RF components Extensive use of COTS equipment 48 Volt power supplies Ethernet switches Optical communications equipment

19. SJDLO/IF/FO - May 19-20, 200419 Cost Saving Continued Low Risk, Large Procurements –Best price strategy –Minimize obsolescence costs –Freezes the design

20. SJDLO/IF/FO - May 19-20, 200420 Purchasing Support Large procurement forecast Competitive bid procedures creative selection criteria allows for best vendors – not only lowest price BOA, Blanket Orders Negotiated warranties Balanced with in-house testing

21. SJDLO/IF/FO - May 19-20, 200421 Budget vs. Cost Actual costs are now used for budgeting “To be a Success Be Daring, Be First, Be Different.” Marchant

22. SJDLO/IF/FO - May 19-20, 200422 Appropriate Funding Allocation – DTS Example Formatter board parts cost: $9,559.79 (Qty - 10) –Includes $152.16 cost for assembly & test –Includes $6,600 for 3 transponders Bogue Machine parts $2,640 (Qty – 4) Spira Honeycomb filters $442 per DTS Total $12,641

23. SJDLO/IF/FO - May 19-20, 200423 DTS Example Continued Estimated Costs (excluding samplers) Power supply board, VICOR bricks $2,700 MIB and digital board $1,500 Optical hardware $ 600 Total ~ $17,440 ea ($69,764 per antenna) Current WBS estimate $72,000 In-House Assembly/Test Labor $4,000

24. SJDLO/IF/FO - May 19-20, 200424 WBS Budget Management Tool Detailed budgets have been developed and are backed by actual cost data Quarterly reviews Managed cash flow and work load

25. SJDLO/IF/FO - May 19-20, 200425 If it all goes wrong?

26. SJDLO/IF/FO - May 19-20, 200426 Advantages of a Software Instrument Software reconfigurable: –FPGAs in most modules –MIB data collection and processing in each module –MIB module control

27. SJDLO/IF/FO - May 19-20, 200427 De-scope Options Identified Fewer wide band receivers U-band & S-band Reduce the DTS band width 120 Gbits/sec → 60 Gbits/sec Reduces configuration uncertainty

28. SJDLO/IF/FO - May 19-20, 200428 We are Ready for Production Tested designs Outsourcing commitment Cost saving steps in place COTS parts & equipment Contingency Plans