1. NCSX Field Period Assembly (FPA) Operations, Cost and schedule, staffing, and metrology utilization Mike Viola Field Period Assembly Manager NCSX FPA Peer Review October 11-12, 2006 PPPL

2. NCSX October 12, 2006NCSX Field Period Assembly Peer Review M. Viola 2 FPA Concerns and Risks Heavy emphasis on Prototyping each activity Crack Work Crew and Support –Our most highly effective and ingenious technicians assigned to perform first time tasks. More time allocated for first time. John Edwards 30 years experience (Master Support Technician), Mike Duco from Lockheed (simulations, manufacturing, coatings vibrations), Ed Bush 20+ Quality Assurance then NB Ion Sources. –Augmented as needed by Cryogenic operators and NB Technicians Learning Curve (Extra time included in schedule) –Perform all tasks first with crack crew – Prove principles to mitigate risk!! And then Finalize Procedures. –Train secondary support crew to perform bulk of work Tooling –Crack Crew perform dry run of tooling Metrology (Mike Duco with Steve Raftopoulos Support) –Leica Laser: 0.0005” accuracy –Romer arm: 0.005-0.010” accuracy (2 other Romer Arms available)

3. NCSX October 12, 2006NCSX Field Period Assembly Peer Review M. Viola 3 FPA Metrology Issues Available Equipment in house –Leica Laser: 0.0005” accuracy –Romer arm: 0.005-0.010” accuracy (2 other Romer Arms available) Reliability –Hardware/Software is ~80% reliable. –Have days of crashing and unpredictable operations. Combination of Windows, Verisurf, MasterCAM, Leica Power Inspect, ROMER… Reach/Accessibility –Coils are easy to reach but need high accuracy –VVSA is hard to reach but localized activities can use lower accuracy equipment. Repeatability –Datums strategically located to provide individual activity support –May need recommendation for datum locations to be used through final machine assembly if datum shift or tolerance buildup is of concern Expert support group being considered within Fabrication Division.

4. NCSX October 12, 2006NCSX Field Period Assembly Peer Review M. Viola 4 “SAFELY SAFELY SAFELY” Documentation and ISM Work Plans –Manufacturing Facility Operation Plan (MFOP) covers overall facility conduct using ISM as its basis. –Activities Control Committee (ACC) independently reviews each station setup, operations, and plans before station is activated.

5. NCSX October 12, 2006NCSX Field Period Assembly Peer Review M. Viola 5 FPA Process Definitions FPA Manufacturing, Inspection, Test, Quality Assurance Plan (MIT/QA) –Input: Dimensional Control Plan FPA Assembly Sequence Plan FPA Specification and Assembly Drawings –Output: Individual procedures to perform tasks then revised to include developed improvements.

6. NCSX October 12, 2006NCSX Field Period Assembly Peer Review M. Viola 6 FPA Roll up Schedule

7. NCSX October 12, 2006NCSX Field Period Assembly Peer Review M. Viola 7 FPA Cost and Schedule –Station 1 $744K 6/30/06 – 1/17/08 –Station 2 $336K 10/5/06 – 1/31/08 –Station 3 $300K 7/31/07 – 4/7/08 –Station 4 $214K 10/4/07 – 6/3/08 –Station 5 $647K 9/14/07 – 7/11/08 Total FPA Cost $2.241M

8. NCSX October 12, 2006NCSX Field Period Assembly Peer Review M. Viola 8 FPA Metrology VVSA1_MTM_FINAL_NUMBERSVVSA1_PPPL_BEST_FIT Very good agreement.

9. NCSX October 12, 2006NCSX Field Period Assembly Peer Review M. Viola 9 FPA Metrology VVSA2_MTM_FINAL_NUMBERSVVSA2_PPPL_BEST_FIT Metrology is serving appropriate needs.

10. NCSX October 12, 2006NCSX Field Period Assembly Peer Review M. Viola 10 FPA Station 1 Active Station 1 setup Port prefit

11. NCSX October 12, 2006NCSX Field Period Assembly Peer Review M. Viola 11 FPA Schedule

12. NCSX October 12, 2006NCSX Field Period Assembly Peer Review M. Viola 12 FPA Station 1 Station 1 Schedule (VVSA) –All three VVSA’s received by 9/30/06 –All work performed on station 1 fixture (2 “rotisserie” stations) with Leica & 2 men augmented with 3 technicians when needed –Install VVSA external components (Diagnostic Coils, Cooling Tubes, Thermocouples) Laser or Romer Tooling Checks and Metrology Training 5/15/06 – FP#1 6/30/06 – 5/3/07 FP#2 (VVSA #3) 9/30/06 – 8/31/07 FP#3 (VVSA #2) 8/1/06 – 1/17/08

13. NCSX October 12, 2006NCSX Field Period Assembly Peer Review M. Viola 13 FPA Station 2 Station 2 Schedule (3 Coil preassembly) –Perform crude prefit – any gross interferences & Tooling checkout 10/30/06 – 6/19/07 –Perform prefit – shim and alignment –Align and Assembly Laser Tracker Tooling checks 10/5/06 – 3/4/07 FP#1 3/5/07 – 9/6/07 FP#2 9/7/07 – 11/15/07 FP#3 11/16/07 – 1/31/08

14. NCSX October 12, 2006NCSX Field Period Assembly Peer Review M. Viola 14 FPA Station 3 Station 3 Schedule (Coils onto VVSA) (Laser Tracker or Internal GPS) –Align and Assembly 2 coil three packs Tooling checks 7/31/07 – 8/27/07 FP#1 9/7/07– 10/4/07 FP#2 11/16/07 – 12/10/07 FP#3 2/1/08 – 2/21/08 –Align and Assembly Coils onto VVSA Tooling checks 7/31/07 – 8/27/07 FP#1 8/28/07– 11/7/07 FP#2 11/8/07 – 1/16/08 FP#3 1/17/08 – 4/7/08

15. NCSX October 12, 2006NCSX Field Period Assembly Peer Review M. Viola 15 FPA Station 4 Station 4 Schedule (TF Coils) Laser Align and Assembly TF Coils Tooling checks 10/4/07 – 11/14/07 FP#1 11/15/07 – 1/15/08 FP#2 1/16/08 – 2/19/08 FP#3 2/20/08 – 6/3/08

16. NCSX October 12, 2006NCSX Field Period Assembly Peer Review M. Viola 16 FPA Station 5 Station 5 Final Assembly Schedule in NCSX Test Cell to enhance efficiency and reduce HP overhead (Weld ports, Install TF Coils, Leak Check, Final metrology) –Align and Assembly Laser Tracker and Laser on Target for port welding Tooling checks 9/14/07 – 10/4/07 FP#1 11/8/07 – 4/4/08 FP#2 1/17/08 – 5/20/08 FP#3 4/11/08 – 7/11/08

17. NCSX October 12, 2006NCSX Field Period Assembly Peer Review M. Viola 17 FPA Summary To Conclude –Our best technicians are assigned to these FPA tasks. –Some assembly operations are still somewhat conceptual and will be tested out prior to actual work is performed. –Reasonable time is allocated to perform FPA including proof of principle. Open Issues –I invite the review team to offer their concerns or provide advice. –Some activities are still quite conceptual –Datum transferability and tolerance buildup –Very limited machine serviceability

18. NCSX October 12, 2006NCSX Field Period Assembly Peer Review M. Viola 18 And if all else fails We found this guy