US Module and Rod Production Overview and Plan For the US CMS Tracker Group

April 29, J. Incandela 2 TEC R7 TEC R6 TEC R5P TEC R5S TOB r-phiTOB stereo Module Types Built in US

April 29, J. Incandela 3 Overview Module Production Production statistics to date (production started in late Feb.) 702 TOB modules 662 with Hamamatsu silicon and 40 with STM silicon 123 TEC modules 84 with Hamamatsu silicon and 39 with STM silicon Current Production Rates FNAL: steady pace of 12 TOB modules per day UCSB: steady pace of 18 TOB/TEC modules per day Production is keeping pace with hybrid deliveries High yield and high quality so far, with further improvements expected. Ramping to modules/day per site as hybrid deliveries increase Rod Production Was halted for final cleaning of on-board electronics Restarted at UCSB this past week at 2 rods per day This week: start rod production at FNAL and increase to 3/d at UCSB

April 29, J. Incandela 4 US Hybrid Testing Results PassFail% Pass L12pd00 L34p % L56p % R5N % R5S % R % R700 Total % US tasks Final wirebonding from APV chips to pitch adaptor Thermal cycle to -20C and electronic test Yield 98% Failed Hybrids 26 out of can be repaired Shorts on pitch adaptor Damaged wirebonds 9 with undiagnosed problems Under study 8 with unrepairable damage

April 29, J. Incandela 5 Module Assembly UCSB: Comfortably build 6 plates of 3 modules per plate per 8 hour day. Downtime of a several days due to wire-bonder problems Procuring a backup wirebonder to avoid downtime in future Plan to stretch to 7 or 8 plates per day relatively soon. Have capability to build 10 plates = 30 modules per day. FNAL: Currently have 6 TOB axial and 4 TOB stereo plates Have capability to build 8 plates = 24 modules per day Modules grades (A and B are both installable classes) :

April 29, J. Incandela 6 Module Testing Results Yield is high 3 of the 7 failures were caused in production and testing: 3 failures due to problems in silicon prior to assembly 1 is a hybrid or DCU failure Improvements underway We have adapted procedures to eliminate failures in production Alteration of plates, handling procedures etc. Fewer failures due to silicon Later batches of HPK silicon are even higher quality ABF% A or B L12pu % L12pd0000.0% L12su0000.0% L12sd0000.0% L34p % L56p % R5N % R5S0000.0% R % R % Total %

April 29, J. Incandela 7 Module Quality! HPK Modules are remarkably high quality Tested 596 modules having HPK sensors 189 faulty channels in A+B modules out of 492,288 total ! 20 pinholes (plucked to be opens) Many due to wirebonder problems; now fixed 63 shorts (plucked to be opens) Scratches (only significant in early HPK batches) 32 noisy channels 74 opens Few due to PA and bonding; most inherent in sensors Expected number of faults from QA at HPK: 69 Percentage of bad channels: <0.04%

April 29, J. Incandela 8 LT Testing Results: UCSB Thermal cycle (+20C to -20C), operate, and test modules in groups of 10 for 24 hours Looking for infant mortality Yield is very high PassFail% Pass L12pu000.0% L12pd % L12su000.0% L12sd000.0% L34p % L56p % R5N3400.0% R5S000.0% R % R7000.0% Total %

April 29, J. Incandela 9 Overall US Production Quality Summary of the quality of the production Hybrid Testing: 98% Yield Gantry Assembly: 99% pass mechanical specifications ARC Testing (HPK only): 99% Yield Only 1 failure which is directly related to module production. Long Term Testing (HPK only): 99.8% Yield

April 29, J. Incandela 10 Rod Assembly, Test, Transport US To build ~700 total rods US Capacity ~ 6 rods/day Limited by capacity of thermal cycle test stands Testing Quick test after assembly Crucial 72 hour test with thermal and power cycles to find problems before installation in CMS Capacity of LT test systems in US is ~ 32 rods per week. After substantial experience, and if there are no failures seen in the last 24 hours of testing, we will go to 48 testing. Capacity will rise to 48 rods/week.

April 29, J. Incandela 11 Rod LT Testing and Transport Long-term testing box: - -Complicated system - -8 rods simultaneous operation - -Interlocks, monitoring etc. - Small residual problems Transport boxes: - Carefully engineered Studied/Tested at commercial testing facility - -Has sustained up to 80 g acceleration without damage to rods

April 29, J. Incandela 12 Rod Experience Production restarted last week UCSB produced 9 rods this week, with 8 of 9 testing well. UCSB plans to produce 15 rods per week starting next week and FNAL will start to ramp up to the same level starting next week. One of 9 rods has unknown intermittent communication problems We have seen in preproduction (40 or so rods) that roughly 1 of every 5 to 10 rods has some sort of I2C communication problem. Could be any of 4 or 5 sources – under study Most likely it is due to A software problem that some rods are more sensitive to A hardware problem – in rod or module The fact that we are using pre-production DAQ modules There is also the small probability that it is an intrinsic problem that we will encounter again in operation.

April 29, J. Incandela 13 Schedule US production is now running smoothly at modules/month Rod production started and will run at high rate to catch up to module production Expect to ramp to modules/month this summer Substantial planning has gone into this. We have identified all sources of potential down time in our production chains and have procured backups and spares as required for minimal work stoppages Manpower is very nearly at the level required for peak production We have roughly 40 people trained for production and we need only 1-2 more technicians. Components are arriving at substantial levels Have large stockpiles of sensors and frames Hybrids inventory is adequate for 1-2 weeks production Sustaining hybrid deliveries is the only current weakness US is in process of qualifying a hybrid assembly company Assembled parts so far appear to be excellent Place order this June or so for 2000 assembled hybrids

April 29, J. Incandela 14 Conclusions US Production is underway and sustaining very high throughput with very high and rising yields Components are flowing, and efforts are underway to provide contingency in hybrid deliveries Rods production has just started, initial yields are reasonably high with one residual issue under study. We are confident that we can meet our required schedule