Difference between revisions of "FCAL Construction Readiness Review Checklist"

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'''<font color=red>FCAL Fabrication Readiness Review Checklist ***DRAFT DRAFT DRAFT***</font>'''
 
'''<font color=red>FCAL Fabrication Readiness Review Checklist ***DRAFT DRAFT DRAFT***</font>'''
  
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== Review Check List ==
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== Review Check List ***DRAFT DRAFT DRAFT*** ==
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The goal of the Barrel Calorimeter Readiness Review is to assess whether the University of Regina is ready to begin production of the fabrication of the Hall D barrel calorimeter modules. Specifically the following questions need to be examined:
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The goal of the Forward Calorimeter Readiness Review is to assess whether the University of Indiana is ready to begin production of the fabrication of the Hall D forward calorimeter modules. Specifically the following questions need to be examined:
  
 
# Environment
 
# Environment
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##* Are the MSDS information sheets available for all products used during production?
 
##* Are the MSDS information sheets available for all products used during production?
 
##* What support do you get from university EH&S services?
 
##* What support do you get from university EH&S services?
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## Fibers
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##* Are there any materials (e.g cleaning agents/etc) that are of particular hazard during fabrication
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##* Is the lighting and handling of the fibers performed in accordance with the recommendations by Kuraray?
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##* Is the storage of fibers such that damage will be minized before and during fabrication?
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## Lead
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##* Are proper procedures taken to minimize worker exposure to lead during handling?
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##* Is the storing and handling organized to minimize any deformations or kinks of the swaged lead?
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# Procedures:
 
# Procedures:
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## Are all procedures for handling, sorting and testing fibers documented?
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## Are all procedures for accepting fabricated parts documented?
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## Are all procedures for handling, swaging and storing lead sheets documented?
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## Are all procedures for assembling components documented?
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## Are all procedures for assembling the lead/fiber matrix documented?
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## Guidance should be given for each of the steps in the fabrication procedure for ease of estimating completion times.
 
## Guidance should be given for each of the steps in the fabrication procedure for ease of estimating completion times.
 
# Training:
 
# Training:
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## How is this documented?
 
## How is this documented?
 
# Acceptance Testing
 
# Acceptance Testing
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## Fibers
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## Lead glass
 
##* Are the testing procedures clearly defined?
 
##* Are the testing procedures clearly defined?
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##* Is the criteria for rejecting fibers to be used in the matrix clearly specified?
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##* Is the criteria for rejecting glass blocks clearly specified?
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##* How are the fibers selected for use in a given module?
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##* How is the location of each block recorded?
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##* How is the origin, i.e. fiber batch number, traced to each module?
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## PMT
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## Lead
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##* How are the dimension tolerances checked on pmts?
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##* How are the dimension tolerances checked on lead sheets?
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##* How is the performance checked?
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##* How is the cleanliness of the lead assessed?
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##* What performance characteristics are recorded?
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##* Is the handling the lead minimized, so as to avoid possible damage to the lead?
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## Cockcroft-Walton base
 +
##* How are electrical components qualified?
 +
##* How are electrical boards qualified?
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##* How are the assembled boards checked?
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##* How is the complete assembly tested?
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##* How are noise sources characterized?
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##* What are the acceptance tests at each stage of the process?
 
## Machined parts
 
## Machined parts
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##* What acceptance will be performed to verify dimensional tolerances of all features of the Al front and base plates?
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##* What acceptance will be performed to verify dimensional tolerances of all features of the machined parts?
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## Matrix
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## Assembly
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##* How often are horizontal deviations measured? (every layer?)
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##* How are the mechanical tolerances checked after assembly?
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##* How often are transverse deviations measured? (every layer?)
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##* What documentation is recorded for each module?
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##* How often are vertical deviations measured? (between pressing?)
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##* Which measurements, and what frequency is planned for dimensions of the matrix during stacking?  
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##* What documentation is recorded after each layer is added?
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# Recovery Procedures
 
# Recovery Procedures
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## What are the procedures for reporting an anomally in measurements during the stacking?
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## What are the procedures for reporting an anomally in measurements during the assembly?
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## What are the procedures for rectifying any problems encountered during stacking? Is this documented?
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## What are the procedures for rectifying any problems encountered during assembly? Is this documented?
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# Acceptance Testing of Machined module
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# Acceptance Testing of completed module
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## How are the dimensions checked and verified against drawings?
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## Are all the items listed in Section 4.2 of the SOW addressed in the Quality Assurance and Test Plan Document?
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## How is the light transmission measured for a completed module?
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## Are any of the completed modules going to be tested with a source to check overall operation?
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## How is the uniformity of transmission determined?
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## What criteria are used to accept a completed module before shipment?
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## How are the modules going to be checked with cosmic-rays?
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## How many modules will be tested with cosmics?
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# Tracking
 
# Tracking
 
## Are all travelers specified for the project?
 
## Are all travelers specified for the project?
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## What information is recorded for the fibers?
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## What information is recorded for the lead glass?
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## What information is recorded for the lead?
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## What information is recorded for the pmt?
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## What information is recorded during matrix fabrication? How may for each layer?
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## What information is recorded for each of the fabricated parts
 +
## What information is recorded during assembly?
 
# Schedule
 
# Schedule
 
## How is the schedule tracked?
 
## How is the schedule tracked?
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## Note: Time for completion of a module should be revisited after completion of the first two production modules.
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## Note: Time for completion of a module should be revisited after the start of production of each subcomponent.
 
# Reporting
 
# Reporting
 
## Is the reporting chain to the project clear?
 
## Is the reporting chain to the project clear?
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== Contract Requirements ==
 
== Contract Requirements ==
 
# Final Construction Plan
 
# Final Construction Plan
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# Final Acceptance Test Plan
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# Final Quality Assurance Plan and Acceptance Test Plan.
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# Quality Assurance Plan.
+
  
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== Testing and Tracking: Section 5 of the Statement of Work ==
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== Requirements and Quality Assurance: Section 3 and 4 of the Statement of Work ==
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=== Testing ===
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The vendor shall include a draft Acceptance Test Plan with their contract proposal with the final plan to be formally approved by JLab at the Readiness Review.  The following items must be included:
+
The vendor shall prepare a Quality Assurance and Acceptance Test Plan for approval by JLab at the Readiness Review.  The following items must be included:
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# Acceptance of lead sheets upon receipt
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=== QA and Acceptance Test Plan (Section 4.2.1) ===
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# Acceptance of fibers upon receipt
+
 
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# Acceptance of swaged lead sheets
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==A Component Inspection Plan, comprised of==
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# Acceptance of fibers during sorting
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# Inspection of all materials received from the vendor’s suppliers and subcontractors and the recording of this information.
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# Dimensional tests of aluminum base plates
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# Obtaining and recording of all material certifications and analyses.
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# Dimensional tests of lead-scintillation matrix during stacking
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# The calibration and identification of standards and instrumentation used for testing; the intervals between calibrations are also to be defined.
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# Acceptance of completed modules based on the following criteria:
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# Establishment of inspection points for the incoming components, which will measure critical parameters.
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## Dimensional testing of modules after machining
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# The recording of all inspection data in such a manner so that the history of a component can be readily traced.
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## Measurement of light transmission of completed modules.
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# The submittal to JLab of all data related to the above.
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## Determination of the uniformity of transmission across the face of the BCAL module, e.g. digital photos showing the number of damaged fibers.
+
 
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# Measurements of the response of a sample of completed modules to cosmic rays.  
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==A Process Quality Plan, comprised of==
 +
# Step-by-step process documents, with instructions and prints pertaining to each assembly and/or manufacturing step. 
 +
# Safety information for the job operator, including material data safety sheets
 +
# A method of reporting any mechanical defects found during assembly of components.
 +
# A mechanism for recording all job operator work sessions.
 +
# The submittal to JLab of all data related to the above.
 +
 
 +
==Final Acceptance Test Plan, comprised of==
 +
# Acceptance of the PMTs based on their response to a nominal light source.
 +
# Acceptance of the PMT bases using electrical tests.
 +
# Acceptance of the lead glass bars based on their transparency and visual inspection for cracks, chips, or bubbles..
 +
# Acceptance of the PMT-base-light guide assembly based on dimensional tests.
  
 
===Tracking ===
 
===Tracking ===
 
The vendor must keep a record (travelers) of all raw materials and inspections that are used in the construction of each module, and document the procedures followed during fabrication.
 
The vendor must keep a record (travelers) of all raw materials and inspections that are used in the construction of each module, and document the procedures followed during fabrication.

Latest revision as of 17:49, 3 May 2010

FCAL Fabrication Readiness Review Checklist ***DRAFT DRAFT DRAFT***

Review Check List ***DRAFT DRAFT DRAFT***

The goal of the Forward Calorimeter Readiness Review is to assess whether the University of Indiana is ready to begin production of the fabrication of the Hall D forward calorimeter modules. Specifically the following questions need to be examined:

  1. Environment
    1. General
      • Are the MSDS information sheets available for all products used during production?
      • What support do you get from university EH&S services?
      • Are there any materials (e.g cleaning agents/etc) that are of particular hazard during fabrication
  2. Procedures:
    1. Are all procedures for accepting fabricated parts documented?
    2. Are all procedures for assembling components documented?
    3. Guidance should be given for each of the steps in the fabrication procedure for ease of estimating completion times.
  3. Training:
    1. What are the training procedures for first-time workers in each of the areas where they will work?
    2. How is this documented?
  4. Acceptance Testing
    1. Lead glass
      • Are the testing procedures clearly defined?
      • Is the criteria for rejecting glass blocks clearly specified?
      • How is the location of each block recorded?
    2. PMT
      • How are the dimension tolerances checked on pmts?
      • How is the performance checked?
      • What performance characteristics are recorded?
    3. Cockcroft-Walton base
      • How are electrical components qualified?
      • How are electrical boards qualified?
      • How are the assembled boards checked?
      • How is the complete assembly tested?
      • How are noise sources characterized?
      • What are the acceptance tests at each stage of the process?
    4. Machined parts
      • What acceptance will be performed to verify dimensional tolerances of all features of the machined parts?
    5. Assembly
      • How are the mechanical tolerances checked after assembly?
      • What documentation is recorded for each module?
  5. Recovery Procedures
    1. What are the procedures for reporting an anomally in measurements during the assembly?
    2. What are the procedures for rectifying any problems encountered during assembly? Is this documented?
  6. Acceptance Testing of completed module
    1. Are all the items listed in Section 4.2 of the SOW addressed in the Quality Assurance and Test Plan Document?
    2. Are any of the completed modules going to be tested with a source to check overall operation?
  7. Tracking
    1. Are all travelers specified for the project?
    2. What information is recorded for the lead glass?
    3. What information is recorded for the pmt?
    4. What information is recorded for each of the fabricated parts
    5. What information is recorded during assembly?
  8. Schedule
    1. How is the schedule tracked?
    2. Note: Time for completion of a module should be revisited after the start of production of each subcomponent.
  9. Reporting
    1. Is the reporting chain to the project clear?

Contract Requirements

  1. Final Construction Plan
  2. Final Quality Assurance Plan and Acceptance Test Plan.

Requirements and Quality Assurance: Section 3 and 4 of the Statement of Work

The vendor shall prepare a Quality Assurance and Acceptance Test Plan for approval by JLab at the Readiness Review. The following items must be included:

QA and Acceptance Test Plan (Section 4.2.1)

A Component Inspection Plan, comprised of

  1. Inspection of all materials received from the vendor’s suppliers and subcontractors and the recording of this information.
  2. Obtaining and recording of all material certifications and analyses.
  3. The calibration and identification of standards and instrumentation used for testing; the intervals between calibrations are also to be defined.
  4. Establishment of inspection points for the incoming components, which will measure critical parameters.
  5. The recording of all inspection data in such a manner so that the history of a component can be readily traced.
  6. The submittal to JLab of all data related to the above.

A Process Quality Plan, comprised of

  1. Step-by-step process documents, with instructions and prints pertaining to each assembly and/or manufacturing step.
  2. Safety information for the job operator, including material data safety sheets
  3. A method of reporting any mechanical defects found during assembly of components.
  4. A mechanism for recording all job operator work sessions.
  5. The submittal to JLab of all data related to the above.

Final Acceptance Test Plan, comprised of

  1. Acceptance of the PMTs based on their response to a nominal light source.
  2. Acceptance of the PMT bases using electrical tests.
  3. Acceptance of the lead glass bars based on their transparency and visual inspection for cracks, chips, or bubbles..
  4. Acceptance of the PMT-base-light guide assembly based on dimensional tests.

Tracking

The vendor must keep a record (travelers) of all raw materials and inspections that are used in the construction of each module, and document the procedures followed during fabrication.

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