Download - Production & Maintenance
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SJD Advisory Committee May 2006 1
Production & Maintenance
Steven J. Durand
May 2006
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SJD Advisory Committee May 2006 2
Electronics DivisionManufacturing Goals
• Out-source board assemblies
• Build modules in-house as needed
• Ready the facility for manufacturing
• ESD protected facility
• Production success stories
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SJD Advisory Committee May 2006 3
Outsource Circuit Cards- Board Vendor Provides:
• Fully assembled boards/cables
• Some assemblies tested – Flying probe tests – NRAO test fixtures
• ESD packaged and labeled
• Scheduled deliveries
• Hazardous chemical handling
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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
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SJD Advisory Committee May 2006 5
Planning for Small Production Runs
• Goal is to produce 28 identical antennas
• Small quantity builds, 5-10 at a time
• In-house module assembly and test
• VLBA cable and small parts assembly
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SJD Advisory Committee May 2006 6
Inventory Control
• New and old warehouse managed by Skip Lagoyda, Business Manager
• Control of high dollar items
• PeopleSoft software re-order mechanisms
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SJD Advisory Committee May 2006 7
Antenna Date LNA's Date of Ant L- Band S-Band C-Band X-Band Ku-Band K- Band Ka-Band Q- Band Amps YearSerial Number Required Commission LN Bal HP Bal Bal Amp Upgrade New Upgrade New per Year
Antenna 14 (Az Bearing) All In-House Jan 31, 2005 2 2 - 2 - - - 0 - - 0Antenna 16 (Az Bearing) Feb 27, 2005 Apr 28, 2005 2 2 - 2 - - 2 - - - 0 14 2004Antenna 13 (retrofit) May 22, 2005 Jul 21, 2005 - - - 2 - - - 0 2 2 -Antenna 18 (Az Bearing) Jul 1, 2005 Aug 30, 2005 2 2 - 2 - - - 2 - - 2 16 2005Antenna 24 Jan 28, 2006 Mar 29, 2006 2 2 - 2 - - - 2 - 2 -Antenna 26 (Az Bearing) Aug 19, 2006 Jun 23, 2006 2 2 2 2 - - - 0 - - 2Antenna 23 Apr 24, 2006 Oct 18, 2006 2 2 - 2 - - - 2 2 2 - 32 2006Antenna 17 Dec 3, 2006 Feb 1, 2007 2 2 - 2 - - - 2 2 2 -Antenna 1 Feb 3, 2007 Apr 4, 2007 2 2 2 2 - 2 2 - 4 2 -Antenna 19 Apr 1, 2007 May 31, 2007 2 2 - 2 2 - - 2 2 2 -Antenna 21 May 28, 2007 Jul 27, 2007 2 2 2 2 - - 2 - 4 2 -Antenna 10 (Az Bearing) Aug 24, 2007 Oct 23, 2007 2 2 - 2 - - - 2 2 2 - 72 2007Antenna 11 Oct 21, 2008 Dec 20, 2008 2 2 2 2 - - 2 - 4 - 2Antenna 25 Jan 6, 2008 Mar 6, 2008 2 2 - 2 - - 2 - 2 - 2Antenna 2 Mar 3, 2008 May 2, 2008 2 2 2 2 - - 2 - 4 2 -Antenna 5 May 1, 2008 Jun 30, 2008 2 2 - 2 - - - 2 2 2 -Antenna 9 Jun 27, 2008 Aug 26, 2008 2 2 2 2 - - - 2 4 - 0Antenna 20 (Az Bearing) Sep 21, 2008 Nov 20, 2008 2 2 - 2 - - 2 - 2 - 2 82 2008Antenna 3 Dec 8, 2008 Feb 6, 2009 2 2 2 2 - - 2 - 2 - 2Antenna 7 Feb 6, 2009 Apr 7, 2009 2 2 - 2 - 2 - 2 2 2 -Antenna 15 Apr 4, 2009 Jun 3, 2009 2 2 2 2 - - 2 - 2 2 -Antenna 4 May 31, 2009 Jul 30, 2009 2 2 - 2 - 2 2 - 2 - 2Antenna 8 Jul 27, 2009 Sep 25, 2009 2 2 2 2 - - 2 - 2 2 -Antenna 27 Sep 24, 2009 Nov 23, 2009 2 2 - 2 - - - 0 2 - 2 80 2009Antenna 28 Dec 7, 2009 Feb 5, 2010 2 2 2 2 - 2 2 - 2 2 -Antenna 6 Feb 8, 2010 Apr 9, 2010 2 2 - 2 - - 2 - 2 - 0Antenna 22 Apr 5, 2010 Jun 4, 2010 2 2 2 2 - 2 - 0 2 2 -Antenna 12 Jul 24, 2010 Sep 22, 2010 2 2 - 2 - - - 0 2 2 -Retrofit Earlier Antennas Aug 1, 2010 - 6 6 4 4 - 2 2 - 4 - 2 80 2010Retrofit Earlier Antennas Jan 1, 2011 - - - 6 - 6 6 - - - 2 -Retrofit Earlier Antennas Aug 1, 2011 - - - 6 - 6 6 - - - 1 - 39 2011Retrofit Earlier Antennas Jan 1, 2012 - - - 6 - 6 6 - - - - -Retrofit Earlier Antennas Aug 1, 2012 - - - 6 - 6 6 - - - - - 36 2012Retrofit Earlier Antennas 5 6 6Retrofit Earlier Antennas 5 6 6 34 2013Retrofit Earlier Antennas 11 6Retrofit Earlier Antennas 11 6 34 2014Retrofit Earlier AntennasRetrofit Earlier Antennas 0 2015Spare LNA's Anytime - 6 6 6 6 6 6 - 6 6 6 54
66 66 28 24 35 24Sub-Totals 132 66 66 66 66 52 66 59 573
CDL / EVLA Coordination
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SJD Advisory Committee May 2006 8
Attributes of In-house Module Assembly
• Minimize module storage problems
• Tight engineering control
• Improve the design
• Fast turn-around time
• Distributed parts inventory
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SJD Advisory Committee May 2006 9
ESD Preparation
• 12 ESD stations including floor mats
• ESD totes and parts bins
• ESD shoes and wrist straps
• Humidity controlled facility
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SJD Advisory Committee May 2006 10
Solder & Flux Compatibility, and Quality Issues
• Trained staff
• Some components only available in lead-free.
• Can be used with ‘leaded’ solder.
• May require higher soldering temperatures, 20 to 30 degrees higher (Fahrenheit).
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SJD Advisory Committee May 2006 11
Mother Board Approach
•More robust design•Easy to assemble
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SJD Advisory Committee May 2006 12
MIB Quality
• 1400 MIBs required for the project• 34 in each antenna - in every type of
module
• Turn-key solution– Large quantity buys lowered price per board – 100% flying probe – 100% electrical test– 99% yield (last run of 100 boards)
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SJD Advisory Committee May 2006 13
Design for Manufacturability
• 300 pin transponder• Easy assembly• 10GHz circuits
Changed vendor to save $400K without a design change
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SJD Advisory Committee May 2006 14
Conclusion
• Ready to maintain production schedule• Looking for cost savings• Utilized every NRAO asset• Manufactured for a 20 year life