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Industrialization process

Power couplers for XFEL project

as an example

------------

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Industrialization:

Why?

Sta

rt:

Prototypes

( 30Couplers)

End

:Large

series

( 1000Couplers)

Quality:

-uneven

-rand

omanom

alies

Manufacturing:

-long

and difficult

-lack

ofprocedure

-only

a few people have

the com

petence

High cost

Quality:

-equal

for all items

-reliab

le

Manufacturing:

-regular process

-written procedures

-standardcompe

tence

Low

er cost

Ind

ustrialization

process

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Industrialization:

Whatfor ?

Obje

ctives:

1.Toimprove the quality

2.

Todefine precisely:

•allmanufacturing processes

•thecontrol plan for

qualityassurance

•the necessary equipment

•the com

petences and

thepe

ople

•the manufacturing sequences

•the sch

edule

•theroom

space neededfor allsteps

•the cos

ts

•the

risk

s(tech

nical, ofprocurement,financial)

3.

Toreduce the manufacturing costs

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Before industrialization:

specificationschanges

TTF-3 Coupler

XFEL Coupler

•4 diagnostics

removed

•motorized tuning

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Before industrialization: final design

�Review drawings

ofeachcomponent interm

sof

tolerances

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Ana

lysis

ofeach

fun

ction

resu

lts

in:

•options for design

•options formaterial

•options forge

ometry

•options for componentsjunctions

Each

option

s has

tobe inv

est

igate

din

term

sof

:

•pe

rformance com

patibility

•feasibility

•availability

•cost

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�Sim

plify

concept

Example:

Coldexternal conductor

Present

design:bellows collarsaremachined+weldedto stand

ardbellows

Alternative:bellow

s includ

ing special collars

arehyd

roform

ed togetherin 1 part

Identify cost reductionsby component

-3 -

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•Review existing design

•Identify the necessary functions

•Determ

ine max

imum

acceptab

le tolerances

•Identify possible options for design

•Seek functional simplicity :

•to minimise the num

ber of parts

•use stand

ard products whenever possible

•design for ease of assembly: several assembly solutions are possible,

investigate and

optimise

•design for ease of control and test

•design in view of packing and transport

Industrialization:

Topicsofdevelopment

-1-

�Design for «

manufacturability»

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•Other design topics to be considered:

•reliab

ility

(of components, welds, coatings)

•other risks

(of procurem

ent, logistics, financial)

•MTBF, failure analysis (welds, window

s, motions)

•maintainability

(easiness of replacement)

•ergonom

y(handling, assembly)

Industrialization:

Topicsofdevelopment

-2-

•Riskmitigation:

•Assessment and

re-design ofareas af tech

nical and process risk

•Generation

ofprod

uct and process spe

cifications

•Upd

atedesign

•Validation ph

ase:

•Mod

ellingof com

ponent

and process

•Testing

•Prototypes

•Upd

atedesign

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Industrialization: Check ?

�Verify that the desired spe

cificationsarefulfilled

�Check

the coh

erenceof interfaces

�Prod

uceprototypes

�Followa test

program

�Analyze

the results

�Corrective actions ifnecessary

�Decideon

thefinal solution

�Finalize M

anufacturing

Control Plan

�Iterative process after every

change

Verification

phase

Severalpossible new designsresult from the functional analysis:

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For the XFEL pow

er couplers, industrialization studieswill be performed

through “Definition contracts” :

•Essentially intellectual work (in dialog betw

een the ind

ustry and our Lab

):

�Define all manufacturing processes (analysis and validation mod

els)

�Risk analysis (process, logistics)

�Determ

ine cost in series and justify

•Prod

uce 2 prototype

s (to be tested at LAL –Orsay)

Particularities

•3contracts will be awardedon

the same sub

ject: «Ind

ustrial stud

ies»

•2 team

swill be selected afterfinalevaluation

•contractsformanufacturing

2seriesof 500 XFELcouplers will be awarded

withouta new call for tend

ers

•the2contracts may be awardedto a singlecompany

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Follow-up

and evaluation

ofdefinition contracts

1.Continuous evaluationof performance

-contracts will run simultaneously during21months

-Regular progress

reports

-Continuouscontrol of

industry activity

2.

Formal reviewsareke

ypoints

with delivery

of docum

ents, mod

els

andprototypes

-SDR ( System Design

Review)

-PD

R (PreliminaryDesign

Review)

-CDR (CriticalDesign

Review)

-FinalReview

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Keypoints

of the definition contracts

Contract Award:

T0

Kickoff

meeting:

soon afterT0

System Design

Review:

T0+ 3months

-functional analysis

-identification of

processes and proposalfor mod

els

-preliminary developm

ent

plan, management plan

PreliminaryDesign

Review:

T0+ 8months

-mod

els for

welding,

brazing,specific materials,Cu coating

-Quality

assurance plan

-developm

ent

plan, management plan

-Tech

nicaldesign

review

-preliminary risk analysis

CriticalDesign

Review:

T0+ 14

months

-final mod

els for validation of

Cu coating

-final justification design file

-finalrisk analysis

-preliminary cost analysis

Final

Review:

T0+ 21months

-delivery

of 2 prototypes

-plan for

logisticsof

manufacturing and

conditioning

-finalcost

report

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Deliverables for the definition contracts

1 -

Tech

nica

l re

port

s:spread

over 3 in

term

ediate reviews (see

time sche

dule)

-Conduct and com

ment all st

udiesnecessary for the fab

rication of couplers, includ

ing TiN

deposit

-Determ

ine and

explain the manufacturing pro

cess

es,

provide m

odelsfor validation of each process

-Finalize and

justify the mech

anical d

esign

in view of lower cost in series and shorter time of assembly, evaluate risks

-Define and

com

ment the sequences of ass

embly

and con

ditioning

of couplers, estimate time for assembly sequences

-Determ

ine and

com

ment the m

anufacturing log

istics

(in manpower, in building area) including cond

itioning, and evaluate

difficulties and risks

-Estab

lish a project m

ana

gement

planfor the manufacturing in series:

. PB

S, WBS

. interfaces . Cost control, time sch

edule control

. Management of ch

anges

. Quality assurance

. Risk management

. Docum

entation control

-Estab

lish a manufacturing sch

eduleinclud

ing cond

itioning and

delivery

3 -

Financ

ial re

port

:

Obje

ctive: �

Com

mitment to a unit price in series, for 500 and

for 1000 couplers

-Fill out a detailed price list includ

ing manufacturing, assembly and

HF conditioning ( Klystrons and

mod

ulators could be

provided

by the XFEL project ), packing and transport on site

-Deliveradetailedreport onprice justification analysis

2 -

Delive

r va

lidation

mod

els a

nd 2

pro

toty

pes:

-mod

els to validate each manufacturing process (welding, brazing,spinning, Cu coating, …)

-2 prototypes assembled on test stand

read

y forcond

itionning:

-alread

y cleaned,baked,assembled, vacuum

pumped and

leak tested