Corrective and Preventive Maintenance at NSCL

Outline Introduction to NSCL & MSU Quality Management at NSCL Tools used at NSCL for availability Future Questions

NSCL National Superconducting Cyclotron Laboratory (NSCL) is a world leader in rare isotope research and nuclear science education Located on the campus of Michigan State University NSCL employees 454 Faculty, Staff and Students Ranked as the #1 graduate program in nuclear physics In the United States by U.S. News & World Report

Cyclotrons & Beam Lines

The United States pioneer land-grant university, established in 1855 Michigan State University MSU has over 11,000 employees In 2010, MSU enrollment consisted of 47,131 students from all 50 United States and 130 countries Throughout the world, there are nearly half a million MSU alumni

It allows a facility to do what it does best………. It allows a facility to meet the demands of its funding agencies………. It allows a facility to meet its operational goals………. Why is a Robust Maintenance Program Important? NSCL has a Quality Management System (QMS) to meet all of the above “Operate the laboratory reliably, efficiently and safely. Maintain high (>90%) level of availability and seek further gains in efficiency through improved procedures and automation of NSCL operations without compromising safety. Encourage the professional development of staff to raise the overall skill, performance, and knowledge bases within the laboratory.”

NSCL Quality manual states: “NSCL developed and implemented a Quality Management System in order to document the laboratory’s best operational practices, better satisfy the requirements and expectations of its users and improve the overall management of the laboratory” The Quality Management System of NSCL meets the requirements of the international standard ISO This system addresses the production and delivery of rare isotope beams This manual describes the Quality Management System, delineates authorities, inter relationships and responsibilities of the personnel responsible for performing within the system. NSCL Quality Management System

The Scope of the NSCL Quality System is: All NSCL processes related to the production and delivery of rare isotope beams to the experiment The quality manual outlines the policies, procedures and requirements of the Quality Management System. The system is structured to comply with the conditions set forth in the International Standard ISO NSCL QMS Scope

Rare isotope beams will be delivered with 90% availability Rare isotope beams will be delivered within 24 hours of the scheduled time NSCL QMS Quality Objectives Availability (Total Time - Scheduled Off - Unscheduled Off excl ) / (Total Time - Scheduled Off)

NSCL Availability

Tools Logging & Reporting Administrative Document Handling Inventory Management Planning Scheduling Tools…the actual hand tools

Logging and Reporting HourLog Trouble Reports Allows for both narrative and system status reporting Reliability statistics are derived from HourLog Used to report a problem with a system or process and even a suggestion Allows the trouble report to be tagged for various management systems

Administrative Reliability Committee Repair Team Trouble Reports are reviewed bi-weekly Committee can reopen a solved Trouble Report for further investigation Meeting called by department head All system experts are present Actionable items generated

Document Handling Alfresco document management Workflow determined by users Mechanical Design department design review approval Revision control

Inventory Management Developed in-house, using IRMIS IRMIS is a descriptive documentation Tool * Uses relational database and associated applications to comprehensively document the large and complex EPICS-based control systems * Handheld Bar Code Scanners MC55 * An Overview of IRMIS, 4/19/2005 (

Scheduling Administration Schedule Short Term Schedule ~ 1 hour resolution ~ 1 day resolution Determined daily Determined 3 months out Operations has final review STS Coordinator

Maintenance Planning Experimental schedule is determined months in advance Preventive maintenance is scheduled in between experimental periods The maintenance group solicits tasks from other departments to add to the maintenance schedule Microsoft Project 2008 is used to build the maintenance schedule NSCL written software is used by the employees to get a list of their tasks The same software is also used by the employees to report the status of their tasks back to the project leader

Breakdown Plans In order to reduce downtime during breakdown repairs lasting at least 24 hours, but less than 7 days, a breakdown response plan is proposed to better allocate resources, and use time more effectively. The scope of this document is to explain the process for using and creating canned breakdown response plans. The initial scope of the breakdown, and such considerations as duration and level of support by other departments should be determined by a repair team meeting.

Tools…the actual tools Modified 5S method Provides a basic set of tools to address an immediate need without wasting valuable time 5S is a system to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results * * Lean Manufacturing and the Environment, Vault Tool Box

Tool Integration

Operator Structure Operations/Maintenance Maintenance Engineers Operating Engineers During experiments, all personnel rotate through shifts as operators During maintenance, all personnel become part of the resource pool used during scheduled maintenance

Future Tighter Integration of tools Written with common software

Questions