DD

WBS 1.7:AFE II Project Cost and

Schedule

Alan Bross DZero Run IIb AFE II Director’s Review

April 13, 2005

DD AFE II - Cost and Schedule

Full Project Plan Has been updated since the last review

DD AFE II – Cost and Schedule

Cost M&S: Production cost M&S are based on quotes for parts and

labor – contingency estimate is grounds up: Manpower

Estimates from AFE experience (from AFE I and AFE II R&D) Total Project cost approximately $1.8M Schedule critical path is AFE IIt prototype board testing Planning for adiabatic Installation

AFE I and AFEII mixed running Will need to test compatibility once AFE II prototypes are

ready Installation will be done 16 boards at a time

Credibility of installation plan is dependent on AFE IIt prototype tests

How quickly they come up Platform test and integration with trigger Software readiness Physical Installation can occur quickly

DD AFE II Milestones

TriPt production submission 5/05 AFE IIt Prototype testing 7/05 AFE IIt Platform test 9&12/05 AFE IIt Pre-production 10/05 AFE IIt production complete 3/06 Full Board complement Ready for installation 4/06

DD AFE II Schedule

Credibility/Underlying Philosophy AFE IIt boards will not have the “uniqueness” problem of

AFE I All AFE II boards behave identically

– Prototype testing to date supports this contention• Recent data shows AFE II Proto behaves the same on bench and on

the VLPC Test Cryostat (as close as we can get to the platform for now)

– TriPt testing to date supports this contention Calibration of boards occurs once during board test and

the obtained calibration constants are valid under all operating conditions of the board and are stable with time

Time calibration Cryo and Bias control calibrations

The above assumptions make the testing and installation schedules credible

Will be Validated with a rather large number ( 20 + 10 : AFE II / AFE IIt) of prototypes

DD Issues - Schedule

Bringing up the AFE II prototypes has been harder than expected (Paul has covered this).

But excellent progress has been made and this is nearing completion

STILL - No underlying technical problems have been discovered

FPGA code verified No uniqueness issues uncovered No major assembly issues uncovered

Resistor packs on VLPC input need to be changed to discrete components

An additional engineer (Stefano Rapisarda) is now on board for the AFE IIt design

His input has been used to update schedule More up-front time devoted to schematic review and design Layout delayed until the above is well along This re-evaluation has introduced an approximately 1 month

delay from previous schedule, but we believe that this approach will yield a final board that can meet our test schedule

DD Production and Testing

Critical path remains the AFE IIt layout, prototype production and test

We will produce 250-300 boards. First 200 to work are set to be installed in D0

Muon Ionization Cooling Experiment will purchase some of the extras (more later).

Board Testing 200 Fully functional Boards 8 weeks

Personnel– 3 Engineers– 5 Technicians– 3 Physicists– 1 Computer Professional

5 fully functional boards come out of the test queue per day

DD Manpower

We now have all manpower resources indicated in the project plan except for test/commission/install. As of Jan 1 everyone on board

A university group needs to be brought on-board to work on testing/commissioning/installation

Although this is later in the project: – There is a long learning curve for work with AFE boards– Now is the best time to become familiarized with the

boards D0 Spokes are addressing this issue and exploring a

number of possibilities (Jerry will discuss)

DD Manpower

We have put explicit resources (i.e., names) in for almost all tasks

Tasks have costed manpower resources and a name is now associated with EVERY entry for almost all tasks in the project

Fermilab personnel University group for Test, Installation, and

Commisssioning (ND) Over-allocation is obvious if one looks at resource

graph by name Effort is now pretty-well leveled

In order to maintain the schedule Must keep each individual’s peak effort 1-1.5 Allocation plots that follow are peak effort in the

period (Q), so being over 1 is OK so long as it is not constant

DD Manpower Profile - EE

DD Manpower Profile - ET

DD Manpower Profile - PHF

DD Manpower – Effort Allocation

DD Manpower – Effort Allocation

Expanded scale1 week/div

DD Manpower – Effort Allocation

DD Manpower Conclusion

Resources are identified and in place Again except for T/I/C- D0 University involvement

Manpower leveling looks OK At this time no one appears to be over allocated

At least that we can not deal with

Engineering resources anticipated to remain on the project through commissioning

DD M & S Profile

M&S Costs by Quarter

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EQU Dollars

R&D Dollars

DD Non-DOE Participation in AFE II Project

The Muon Ionization Cooling Experiment has now been approved in the UK and US funds have been committed to the project for the next three years by NSF (also DOE through the Muon Collaboration, but those funds directed at other parts of MICE)

The MICE commitment (in MICE project plan) is $250k USD for approximately 30 AFE II boards.

Based on assuming ½ the cost of the TriPt submission Plus 30 boards @ $4k/board

$75k in funds available from NSF currently Balance in MRI proposal to NSF

If this proposal is rejected, then UK funds will be used once an MOU with Fermilab is in place

DD Impact for D0

Obvious cost savings Also helps mitigate schedule risk

If 300 boards become the baseline production quantity

First 200 good boards going to D0 will then arrive earlier based on model that once a board fails a test station it is put into a separate “repair” queue and the testing moves on the next board.

The MICE time frame is late Fall of 2006 for delivery of all boards, so this produces little pressure on the repair queue. MICE also plans to have manpower come to Fermilab to help with testing and to gain experience/expertise with the AFE II boards (late Fall 05 is target) which is in addition to the resources we are currently assuming we have in place for the project.

DD Cost & Schedule - Conclusion

No technical issues have been discovered to date that would impact either cost or schedule

Or our philosophy/model regarding Test and Commissioning

M&S and manpower costs are well understood The contingency (M&S and manpower) in the

project plan is conservative There is no schedule contingency in the project

4 w possible if Vendor Qualification of AFE II production is deemed unnecessary

Non-DOE help may be forthcoming

Manpower is on board