1 LHC-DFBX Fabrication Oversight Plan Joseph Rasson LBNL Presented at the DFBX Production Readiness Review October 2002, LBNL Brookhaven - Fermilab - Berkeley US LHC ACCELERATOR PROJECT

2 Outline  Production Oversight  Fabrication Oversight Plan  Vendor Monitoring  Oversight Level of Effort  Change Control Procedures  Summary

3 Production Oversight Project oversight tasks:  Manage fabrication activities at LBNL  Manage current leads procurement  Transfer GFM to cryogenic vendor  Monitor fabrication, assembly and acceptance tests at cryogenic vendor  Manage Change Control Process  Update engineering drawings to include as-built modifications  Update Interface Specifications  Manage hardware and document transfer to CERN  Report status to LHC-PMO

4 Fabrication Oversight Plan  Fabrication oversight is critical to delivering a quality product on schedule  Vendor is requested to provide detailed fabrication and assembly milestones to track progress  Implement a Change Control Procedures  Plan constant monitoring of vendor performance to:  Assist in resolving fabrication issues  Insure that DFBX is given the appropriate scheduling priority  Supervise the transfer GFM to the vendor  Witness critical assembly processes  Witness inspection tests  Manage change control process

5 Vendor Monitoring  Frequent visits to vendor fabrication facility  MTM is within a driving distance to FNAL  Will consider retaining professional QA support from local firms if PHPK wins the award  LBNL representative will have unrestricted access to the Subcontractor facility during normal working hours  Subcontractor will provide office space to LBNL representative

6 Vendor Monitoring (cont.)  Request Reports and Scheduled Meetings  Post Award Conference to kick-off DFBX production  Monthly Progress reports  Monthly meetings at the vendor’s facility to review Progress  Weekly phone or video conference meetings to review status  Meetings to be attended by Subcontractor’s Project Manager and lead engineer

7 Oversight Level of Effort  Fabrication oversight will be made up of LBNL and FNAL staff  The balance between LBNL and FNAL will depend on who the location of the vendor  DFBX Project Engineer is committed to stay with project throughout the production phase  On the average 2 FTE’s are available for project management and production oversight

8 DFBX Oversight Level of Effort

9 Change Control Procedures  Established project change control procedures to manage production cost and schedule  Change Control Procedures is a supplemental document to LBNL-LHC QA Plan  Procedures apply to LBNL or vendor generated change requests  Procedures insure that documents and drawings are updated and archived in the Document Control Center  Change requests that impact cost or schedule will be communicated to the vendor by LBNL Procurement Officer  Process flow charts and forms are available and being reviewed

10 LBNL Generated Changes Engineering Design Change initiated at LBNL or FNAL Design Change Notice Form submitted to DFBX Project Engineer for approval No further action taken Does change affect an in-house or an outside fab? Project Engineer issues an RFI to vendor to determine cost and/or schedule impact Project Engineer negotiates technical issues of change with fabrication vendor Is cost change more than $5k? Project Engineer makes changes to drawings and/or specifications Submitted to FNAL PM Office for approval Project Engineer requests Procurement Officer to issue contract mods (outside only) No further action taken Revised drawings and/or specifications filed in the Document Control Center Hardware is fabricated based on new prints and/or specifications AcceptedRejectedIn-house Outside >$5k <$5k Accepted Rejected

11 Vendor Generated Changes (1) Vendor identifies inconsistencies in LBNL drawings or specifications Vendor issues a Corrective Action Report Project Engineer makes changes to drawings and/or specifications Project Engineer requests Procurement Officer to issue contract modifications Revised drawings and/or specifications filed in the Document Control Center Hardware is fabricated based on new prints and/or specifications Report reviewed by LBNL Project Engineer for approval Is cost change more than $5k? Submitted to FNAL PM Office for approval AcceptedRejected >$5k <$5k Accepted Rejected No further action taken No further action taken

12 Vendor Generated Changes (2) Vendor identifies potential changes to simplify a fabrication or assembly Vendor issues a Deviation Request Project Engineer makes changes to drawings and/or specifications Project Engineer requests Procurement Officer to issue contract modifications Revised drawings and/or specifications filed in the Document Control Center Hardware is fabricated based on new prints and/or specifications Request reviewed by LBNL Project Engineer for approval Is cost change more than $5k? Submitted to FNAL PM Office for approval AcceptedRejected >$5k <$5k Accepted Rejected No further action taken No further action taken

13 Vendor Generated Changes (3) Inspected parts or assemblies do not conform to drawings and/or specifications Vendor issues a Nonconformance Report Project Engineer makes changes to drawings and/or specifications Project Engineer requests Procurement Officer to issue contract modifications Revised drawings and/or specifications filed in the Document Control Center Hardware is reworked based on new prints and/or specifications Project Engineer & Material Review Board determine necessary action Is there a cost impact? Use as is Scrap No Yes Reject and scrap parts No further action taken Rework Project Engineer requests Procurement Officer to issue contract modifications

14 LBNL Design Change Notice Form

15 Deviation Report

16 Summary  Fabrication oversight plan has been developed and being reviewed  LBNL and Fermilab will play active roles in oversight activities  Change Control Procedures and forms have been developed  Tailor fabrication oversight plan to vendor  Changes that impact cost or schedule will be communicated to vendor through LBNL Procurement Officer