Fermilab LCLS-II Cryomodule QA/QC Model and Software Tools ESS Cryomodule Workshop, 16-Oct-2014 Jamie Blowers Head of Machine Shop and Quality & Materials Departments, Technical Division QA Manager, FNAL LCLS-II QA Manager

Outline QA/QC “first principles” Fermilab QA and Engineering framework –SLAC LCLS-II additions QA/QC staff and function infrastructure –Collaboration with JLab on procurements Engineering Data Management Process Control and Production Date Management Our approach to-date regarding cryomodule assembly Closing Remarks Questions 16-Oct-2014J. Blowers | FNAL LCLS-II QA/QC and Software Tools2

QA/QC “First Principles” Apply our limited resources in the most effective way possible to minimize risk and assure that all requirements are met Ensure that requirements/expectations, both in-house and external, are as clear as concise as possible Culture counts; leverage its strengths, account for its weaknesses Quality cannot be inspected into something; it is designed and planned –But we still need to verify our work As much as possible leverage proven and effective processes/tools 316-Oct-2014J. Blowers | FNAL LCLS-II QA/QC and Software Tools

Internal and External Systems (a.k.a. constraints) 16-Oct-2014J. Blowers | FNAL LCLS-II QA/QC and Software Tools4

Staff/function Infrastructure 16-Oct-2014J. Blowers | FNAL LCLS-II QA/QC and Software Tools5 Hiring D. Frye L. Carpenter (C)

JLab/Fermilab Procurements Procurements split between the two labs For any given procurement, a “Lead Lab” has been identified –As the name implies, they lead and make the procurement –The other Lab is involved in a supporting role 16-Oct-2014J. Blowers | FNAL LCLS-II QA/QC and Software Tools6 Each Lab performs their own receiving inspections −Allows for each Lab to work in their preferred way (to a common set of requirements) −Eliminates the natural tendency to reproduce/redo work Each Lab has named an technical person to work on each procurement (for both lead and supporting); “SOTR”

Sub-Contracting Officer’s Technical Representative (SOTR) Important Role / Responsibility –“Glue” between design, prototyping, procurement and assembly phases –Technical expertise for sub-system components Design Phase –Develops technical specifications from higher level requirements –Prepares drawings and supporting technical documents Prototyping Phase –Works with Acquisition/Procurement to procure prototypes from industry/partner labs –Participates in prototype development and testing –Feeds forward experience into production process Production Procurement Phase –Provides technical leadership and point of contact with suppliers Inspection/Assembly/Integration –Provides sustaining engineering during receiving inspection & manufacturing –Technical judgment to resolve non-conformances 16-Oct-2014J. Blowers | FNAL LCLS-II QA/QC and Software Tools7 (Ed Daly)

Engineering Data Management The Fermilab Engineering Manual requires the use of an Engineering Data Management System Fermilab has implemented that requirement using Siemens Teamcenter (PLM) All LCLS-II Cryomodule and Cryogenic Distribution System designs are managed within Teamcenter (NX) JLab design/engineering/QA folks have (or can have) accounts, and access the Fermilab instance through a Citrix interface (web) 16-Oct-2014J. Blowers | FNAL LCLS-II QA/QC and Software Tools8

16-Oct-2014J. Blowers | FNAL LCLS-II QA/QC and Software Tools9

(No CAD software needed to do this) 16-Oct-2014J. Blowers | FNAL LCLS-II QA/QC and Software Tools10

Process Control System: Vector All travelers are fully electronic; System is currently read-only to the world, so easy data sharing is in place As much as we could, we replicated the functionality and flexibility of a paper traveler: 16-Oct-2014J. Blowers | FNAL LCLS-II QA/QC and Software Tools11

Vector (con’t) Reporting: choose any or all fields of any traveler, and the report is generated and can be saved to Excel: 16-Oct-2014J. Blowers | FNAL LCLS-II QA/QC and Software Tools12

Vector (con’t) Using the serial numbers assigned to all the various sub- components, can easily trace from full cryomodule to cavity to Nb sheet, quickly accessing all the associated data –Important to set the serialization scheme as early as possible; we’re still working on this for LCLS-II Architecture: –Enterprise database backend (we use MS SQL Server) –Coding is platform-neutral (ASP) CERN 11T dipole magnet folks set up an instance of Vector at CERN, and they made a very detailed presentation of the system: 16-Oct-2014J. Blowers | FNAL LCLS-II QA/QC and Software Tools13

Cryomodule Fabrication Model Purchase major components from industry, using detailed specifications and/or drawings Everything is inspected prior to being released to production –Inspection records are maintained for all inspections, including non-conformances –Serialized parts are inspected using a traveler (Vector) –May be sampling Every processing/testing/fabrication process is done according to a traveler, which outlines the steps to follow, the necessary data to record, and sign-offs. –Very important to understand the data needed to be recorded All discrepancies are recorded and tracked to closure. 16-Oct-2014J. Blowers | FNAL LCLS-II QA/QC and Software Tools14

Example Cavity Travelers 16-Oct-2014J. Blowers | FNAL LCLS-II QA/QC and Software Tools15

Example Discrepancy Report 16-Oct-2014J. Blowers | FNAL LCLS-II QA/QC and Software Tools16

16-Oct-2014J. Blowers | FNAL LCLS-II QA/QC and Software Tools17

LCLS-II QC Example 16-Oct-2014J. Blowers | FNAL LCLS-II QA/QC and Software Tools18

Closing Remarks Tying this with what others have already said, If ESS does not implement an EDMS/PLM system, they will have a data management model like LCLS-II –Those providing IKC’s will use their own systems –ESS will want to receive records/data for the IKC’s, but won’t have a system in which to receive it One of the ways we’re transitioning from “R&D mode” to series production is by incorporating QC prints –A good way to really think about what is most important –Minimizes QC effort, and in series production time is money Fermilab travelers combine the procedures and records into a single document –Different than DESY/XFEL, similar to JLab –Production staff only go to a single document –Allows for very easy mining of all the data –Content is critical 16-Oct-2014J. Blowers | FNAL LCLS-II QA/QC and Software Tools19

Closing Experts says you should take care of QA/QC first: Questions? 16-Oct-2014J. Blowers | FNAL LCLS-II QA/QC and Software Tools20

For further information: Jamie Blowers o1: o2: c: Oct-2014J. Blowers | FNAL LCLS-II QA/QC and Software Tools21