1. Philip G. Cutino, P.E. Engineering 10 Presentation April 19, 2012 Chabot College, Hayward CA

2. Mr. Phil Cutino ENGR10 Sp12 Today’s Agenda SLAC National Accelerator Laboratory SLAC National Accelerator Laboratory Linac Coherent Light Source (LCLS) Linac Coherent Light Source (LCLS) My role at SLAC over the years My role at SLAC over the years The Mechanical Fabrication Department The Mechanical Fabrication Department

3. Mr. Phil Cutino ENGR10 Sp12 Location: Menlo Park, CA Location: Menlo Park, CA Type: Multi-program Laboratory Type: Multi-program Laboratory Contract Operator: Stanford University Contract Operator: Stanford University Website: www.slac.stanford.edu Website: www.slac.stanford.edu Physical Assets: Physical Assets: 426 Acres 426 Acres 145 Buildings 145 Buildings 1.8M GSF in Active Operational Buildings 1.8M GSF in Active Operational Buildings Human Capital Human Capital Employees: 1,496 FTE as of 4/15/08 Employees: 1,496 FTE as of 4/15/08 Users, Visiting Scientists and Grad Students: 3036 Head Count Users, Visiting Scientists and Grad Students: 3036 Head Count Stanford Linear Accelerator Center

4. 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. 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.

5. Mr. Phil Cutino ENGR10 Sp12 Research at SLAC Accelerator Physics Accelerator Physics Astrophysics and Cosmology Astrophysics and Cosmology Elementary Particle Physics Elementary Particle Physics Materials and Nanoscience Materials and Nanoscience Molecular Environmental Science Molecular Environmental Science Structural Biology Structural Biology Ultrafast Science Ultrafast Science http://www6.slac.stanford.edu/Research.aspx http://www6.slac.stanford.edu/Research.aspx http://www6.slac.stanford.edu/Research.aspx

6. Mr. Phil Cutino ENGR10 Sp12 LCLS Total Machine* : ~1750 meters of beam line 1242 Devices Injector: 28 meters of beam line & 95 devices Linac 1003 meters 708 devices 708 devices LTU & Dump 408 meters 176 Devices *Electron Beam Line Only Does not include Photon Beam Lines Does not include Photon Beam Lines

7. Mr. Phil Cutino ENGR10 Sp12 Linac Coherent Light Source Ultrafast X-ray science Ultrafast X-ray science Directly observe the motions of atoms on ultrafast time scales Directly observe the motions of atoms on ultrafast time scales Investigate dynamics, bonding, heating and melting, at atomic and nanometer length scales Investigate dynamics, bonding, heating and melting, at atomic and nanometer length scales Create and observe extreme new conditions in atoms and materials Create and observe extreme new conditions in atoms and materials Imaging of nonperiodic molecules and nanostructured materials Imaging of nonperiodic molecules and nanostructured materials World’s first X-ray free electron laser World’s first X-ray free electron laser Producing 100 femtosecond pulses of photons in the energy range 800- 8,000 eV Producing 100 femtosecond pulses of photons in the energy range 800- 8,000 eV 10^ 12 coherent X-ray photons/pulse 10^ 12 coherent X-ray photons/pulse Potential for sub-femtosecond pulses Potential for sub-femtosecond pulses Lead nanoscale science revolution Lead nanoscale science revolution Master control of energy-relevant complex systems Master control of energy-relevant complex systems Lead the world in the investigation of dynamics of atomic transitions, chemical bonding, catalysis and heating Lead the world in the investigation of dynamics of atomic transitions, chemical bonding, catalysis and heating

8. Mr. Phil Cutino ENGR10 Sp12 Links to More Information http://www.slac.stanford.edu http://www.slac.stanford.edu http://www.slac.stanford.edu http://lcls.slac.stanford.edu http://lcls.slac.stanford.edu http://lcls.slac.stanford.edu http://www6.slac.stanford.edu/ExploringSLACScie nce.aspx http://www6.slac.stanford.edu/ExploringSLACScie nce.aspx http://www6.slac.stanford.edu/ExploringSLACScie nce.aspx http://www6.slac.stanford.edu/ExploringSLACScie nce.aspx https://news.slac.stanford.edu/ https://news.slac.stanford.edu/ https://news.slac.stanford.edu/

9. Mr. Phil Cutino ENGR10 Sp12 Atypical career path Mechanical Engineer Mechanical Engineer Register Professional Engineer in CA Register Professional Engineer in CA Returned to school late in life Returned to school late in life Diverse background... Diverse background... ~25 years with the same employer ~25 years with the same employer Four different jobs Four different jobs

10. Mr. Phil Cutino ENGR10 Sp12 My Roles at SLAC Process Control Instrumentation Technician Process Control Instrumentation Technician Facilities Engineer Facilities Engineer Accelerator Engineer Accelerator Engineer Mechanical Fabrication Department Head Mechanical Fabrication Department Head

11. Mechanical Fabrication Department Phil Cutino October 27, 2010

12. Mechanical Fabrication Department Page 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

13. Mechanical Fabrication Department Page 13 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

14. Mechanical Fabrication Department Page 14 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

15. Mechanical Fabrication Department Page 15 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

16. Mechanical Fabrication Department Page 16 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

17. Mechanical Fabrication Department Page 17 Core Competencies continued Machine Shop Clean Machining for UHV Quick Turnaround Radioactive Materials DFM & Prototype Parts

18. Mechanical Fabrication Department Page 18 Core Competencies continued Hydrogen Furnace Brazing And Heat Treating

19. Mechanical Fabrication Department Page 19 Core Competencies continued Metal Finishing Plating and Cleaning for UHV

20. Mechanical Fabrication Department Page 20 Core Competencies continued Mechanical and Vacuum Processing and Field Operations Precision Assembly

21. Mechanical Fabrication Department Page 21 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

22. Mechanical Fabrication Department Page 22 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

23. Mechanical Fabrication Department Page 23 Performing Work continued Collaborative 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

24. Mechanical Fabrication Department Page 24 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.

25. Mechanical Fabrication Department Page 25 Questions and Answers