1. Production & Maintenance
Steven J. Durand
May 2006
SJD
Advisory Committee May 2006

2. Advisory Committee May 2006
Manufacturing Goals
Out-source board assemblies
Build modules in-house as needed
Ready the facility for manufacturing
ESD protected facility
Production Success Stories
SJD
Advisory Committee May 2006

3. Outsource Circuit Cards Board Vendor Provides:
Fully assembled boards/cables
Partially tested
Flying probe tests
– NRAO test fixtures
ESD packaged and labeled
Scheduled deliveries
Hazardous chemical handling
SJD
Advisory Committee May 2006

4. In-house Module Assembly Preparation
Trained staff
Same team that built the prototypes
Complete assembly drawings
New soldering stations
Test equipment & computers in place
SJD
Advisory Committee May 2006

5. Planning for Small Production Runs
Goal is to produce 28 similar antennas
Small quantity builds, at a time
In house Module assembly
VLBA cable and small parts assembly
SJD
Advisory Committee May 2006

6. Advisory Committee May 2006
Inventory Control
New and old warehouse managed by Skip Lagoyda, Business Manager
Control of High Dollar items
PeopleSoft software re-order mechanisms
SJD
Advisory Committee May 2006

7. CDL / EVLA Coordination
SJD
Advisory Committee May 2006

8. Attributes of In-house Module Assembly
Minimize module storage problems
Tight engineering control
Perfect design
Fast turn-around time
Distributed Parts inventory
SJD
Advisory Committee May 2006

9. Advisory Committee May 2006
ESD Preparation
12 ESD stations including floor mats
ESD totes and parts bins
ESD shoes and wrist straps
Humidity controlled facility
SJD
Advisory Committee May 2006

10. Solder & Flux Compatibility, and Quality Issues
Some components only available in Lead-free.
Can be used with ‘leaded’ solder.
Duller appearance, can be grainier.
May require higher soldering temperatures, 20 to 30 degrees higher (Fahrenheit).
SJD
Advisory Committee May 2006

11. Advisory Committee May 2006
Mother Board Approach
Mother Board contains: inter-board wiring, Back panel RFI connectors, Test points
Simplifies module assembly
More robust design
SJD
Advisory Committee May 2006

12. Advisory Committee May 2006
MIB Quality
1400 MIBs required for the project
34 in each antenna - in every type of module
Turn-key Outsource Solution
Large quantity Buys lowered price per board
100 % Flying probe – 100% electrical Test
99% yield ( last run of 100 boards)
SJD
Advisory Committee May 2006

13. Design for Manufacturability
300 pin Transponder
Easy assembly
10GHz circuits N.M.H.
Changed Vendor to save $300K without a design change.
SJD
Advisory Committee May 2006

14. Advisory Committee May 2006
Conclusion
Ready to maintain Production Schedule
Looking for cost savings
Utilized every NRAO asset
Manufactured for a 20 year life
SJD
Advisory Committee May 2006

15. Advisory Committee May 2006
SJD
Advisory Committee May 2006

16. Advisory Committee May 2006
Rework procedures
Red/Green Tags
ESD Vacuum Bagger
AOC warehouse for completed modules
AOC Inventory control
SJD
Advisory Committee May 2006

17. Advisory Committee May 2006
Quality Tools
Shaker Table
Environmental Chambers
RFI Shielded Chamber
EVLA Test rack
Producing written QA procedures
SJD
Advisory Committee May 2006

18. Advisory Committee May 2006
SJD
Advisory Committee May 2006