1. NCSX NCSX Design Review Guide May 27, 2005 Wayne Reiersen NCSX

2. 27 May 2005Reiersen 2 Introduction The purpose of this presentation is to communicate project expectations, procedures, and responsibilities for the conduct of design reviews. Your cooperation in applying our systems and helping to make them better is earnestly sought.

3. NCSX 27 May 2005Reiersen 3 Make design reviews part of your plans Design reviews facilitate orderly design and implementation and are a key element in risk mitigation Design reviews are the primary means of verifying that a project element is ready to proceed to the next phase –Preliminary design –Final design –Installation –Test –Operation Job Managers should be pro-active in including design reviews in the Performance Measurement Baseline (PMB). Activities and deliverables required to support the design reviews should be included in the PMB. RLMs should call for design reviews in the WPs and review the job activites in the PMB to ensure that the design reviews and supporting activities have been identified.

4. NCSX 27 May 2005Reiersen 4 Do I need a design review? If you are designing something, conduct a PDR to confirm that the requirements are well defined and that the design meets those requirements. If you are building something or having something built to print, conduct an FDR to confirm that the design and design documentation package are indeed ready to go ahead with the fabrication or procurement. If you are buying a major off-the-shelf item (like a metrology system), conduct an FDR to confirm that the requirements are well defined and that the item optimally meets those requirements. If you are installing, testing or operating something for the first time, conduct a design review to assure that the equipment is ready, hazards have been assessed and mitigated, and appropriate installation/test/operating procedures are in place. Ultimately, the need for a design review is set by the RLM.

5. NCSX 27 May 2005Reiersen 5 Guidelines have been provided for planning preliminary and final design activities and conducting design reviews Design review objectives and input documentation are provided in ENG-033 “Design Verification”. Generic checklists for planning work in preliminary and final design are provided in NCSX-PROC-010 “NCSX Design Review Processes”. Together, these provide a clear guidelines for planning design activities and conducting design reviews –Preliminary design Requirements have been finalized (e.g. signed “Design-to” specs) The design has been shown to meet the requirements Design basis analyses and R&D have been documented Interfaces have been defined Drawings and models promoted to PD release level –Final design Technical documentation package required for fabrication or procurement is complete (e.g. signed “Build-to” specs) Drawings and models have been checked and promoted to FD release level Design basis analyses have been checked

6. NCSX 27 May 2005Reiersen 6 Define the requirements for a successful design in a charge to the review committee The charge should clearly identify –the purpose of the review and –all and only what is required for the review to be deemed successful The charge is the key for making the review add value without adding excessive burden Establish the charge using a graded approach in applying the guidelines provided in NCSX and PPPL procedures –Example: The requirements for a piece of tooling should be more modest than for a multi-million dollar, mission critical piece of hardware The charge is drafted by the RLM in consultation with the Job Manager and WBS Manager Schedule the design review when the charge elements have been addressed or completion is imminent, not before

7. NCSX 27 May 2005Reiersen 7 Conduct design reviews in accordance with (customized) PPPL procedures Follow ENG-033 “Design Verification” with a few custom changes… –The “Cog Individual” per ENG-033 is the “Job Manager” in NCSX parlance. The cog should act with the concurrence of line management up to the RLM. –Provide a charge to the Design Review Board to clearly define the purpose of the review and all and only what is required for the review to be deemed successful. –Distribute the charge and all design review documentation to the Design Review Board and Engineering Manager (or designee) at least 1 week before the design review. –Forward completed chit forms and Design Review Board report to the NCSX Administrator (Marianne Tyrrell - not the Ops Center).

8. NCSX 27 May 2005Reiersen 8 A process for electronically documenting design reviews has been implemented

9. NCSX 27 May 2005Reiersen 9 RLM responsibilities have been delegated within the project RLM assignments appear by job in the WP:Job MapWP:Job Map Assignments are as follows: –Stellarator Core (WBS 1) Nelson is the RLM for all design, procurement, and off-site fabrication activities Dudek is the RLM for all on-site fabrication, integration, and test (FAIT) activities Von Halle is the RLM for the Coil Test Facility –Electrical Power Systems (WBS 4) and NBI (WBS 25) Von Halle is the RLM –Auxiliary Systems (WBS 21, 22, 5, and 6) Dudek is the RLM –Diagnostic Systems Dave Johnson is the RLM for WBS 3 –Test Cell Prep and Machine Assembly (WBS 7) Perry is the RLM If the cognizant RLM is unavailable or is the cognizant engineer, the next RLM in line management (Reiersen or Neilson) can act on his or her behalf

10. NCSX 27 May 2005Reiersen 10 Closing out a design review The Cog Engineer is responsible for tracking the closing out of chits and other action items following a design review Notify the NCSX Administrator (Marianne Tyrrell) upon completion of chits The NCSX Administrator will track completion of past due chits on a monthly basis

11. NCSX 27 May 2005Reiersen 11 Closing out final design At the conclusion of final design, a Comprehensive Final Design Review (CFDR) will be conducted The purpose of the review is to assure that everything that needed to be completed in final design was indeed completed Criteria for completing final design have been posted here.here

12. NCSX 27 May 2005Reiersen 12 Miscellanea Peer reviews, while useful as a means for soliciting expert input for the job manager, are not to be used as substitutes for PDRs or FDRs. The title of a review should tell its purpose. When following PPPL procedures on NCSX, please substitute “send document to the Operations Center” with “send electronic copy to the Engineering Manager (or designee)”. We are a paperless project. The Engineering Web is formally a satellite of the Ops Center.

13. NCSX 27 May 2005Reiersen 13 Summary Use design reviews liberally as an important tool for design improvement and risk mitigation Incorporate design reviews and supporting activities in your plans (i.e, the Performance Measurement Baseline aka Strykowsky’s Primavera schedule) Use the charge to define the purpose of the design review and the requirements for a design review for the review to be deemed successful – it the key for adding value without adding excessive burden Follow ENG-033 (with a few custom changes) in conducting the design review Please provide feedback on how we can make this system work better