glast lat projectcdr/cd-3 review may 12-16, 2003 document: lat-pr-01967section 15 manufacturing...

Document: LAT-PR-01967 Section 15 Manufacturing & Processes 1

GLAST LAT Project CDR/CD-3 Review May 12-16, 2003

GLAST Large Area TelescopeGLAST Large Area Telescope

Manufacturing

Jerry ClintonChief Manufacturing EngineerStanford Linear Accelerator [email protected](650) 926-5435

Gamma-ray Large Gamma-ray Large Area Space Area Space TelescopeTelescope



Manufacturing OverviewManufacturing Overview

• Anticoincidence Detector manufactured by GSFC

• Tracker Towers manufactured by INFN/UCSC/Plyform/Mipot

• Calorimeter Module manufactured by NRL/CEA/IN2P3

• DAQ and Tracker electronics manufactured by SLAC/Teledyne

• Grid Box Assy. manufactured by SLAC

• Radiators manufactured by Lockheed-Martin



RequirementsRequirements

• 433-MAR-001 GLAST LAT Mission Assurance Requirements• LAT-DS-00039 GLAST LAT Performance Assurance

Implementation Plan• Assemblers trained and certified to workmanship standards

NASA-STD-8739.1, 8739.2, 8739.3, 8739.4 and 8739.7• Assembly and test performed in Class 100K clean room

compliant with LAT-MD-00404• Production Readiness Reviews



Production Readiness ReviewProduction Readiness Review

• Conducted by IPO• Required before start of flight manufacturing• Iterative reviews to support subsystem delivery schedules• Review of processes, specifications, drawings, parts and

materials lists– Documentation released for manufacturing– Processes verified on prototype or engineering-model

hardware– EEE parts on Parts Identification List and approved for the

specific application– Raw materials on Program Approved Materials List and

approved for the specific application



Production Readiness Review – Cont.Production Readiness Review – Cont.

• Personnel training and certification• Facilities readiness – MGSE, EGSE, ESD controls, compliance

with LAT-MD-0404• Parts, materials, tools, test equipment, shop supplies, etc. on

hand and in place at start of manufacturing



Procurement ProcessProcurement Process

Start ProcurementProcess

Part/mat’lapproved byPCB/MPRB?

Drawing/specreleased?

Funding inplace?

Complete part/material approval

process

No

Complete drawingor spec and get it

released

No

Get fundingauthorized

Yes

Prepare purchaserequisition

QA review andapproval

Preparesupporting

documentationpackage

Sole source?Prepare sole

source justification

Yes

Yes

Specification(s) Drawing(s) Quotation (if recent) Sole Source Justification

Deliver supportingdocumentation to

purchasing

Managementreview andapproval

Submit approvedrequisition topurchasing

Yes

No

Supportpurchasing as

requested

End

GLAST LAT Procurement Process

QA review



Material ReceivingMaterial Receiving

Material arrives

Inspect shippingcontainer for

physical damage

Container OK?

Verify shippingdocuments reflectcorrect P/N, PO,

and qty

DocumentsOK?

Verify quantityreceived matches

shippingdocuments

Quantity OK?

Place receivedmaterial in stores

Open NCR Open NCR Open NCR

Notify QE and RE

QE and RE workwith purchasingand vendor to

resolvediscrepancies

Discrepanciesresolved?

Disposition andclose NCR (s)

Yes

Yes

Yes

NoNo

No

Notify QE and RE

Notify QE and RE

QE and RE workwith purchasingand vendor to

resolvediscrepancies

Yes

A

A

Discrepanciesresolved?

Disposition andclose NCR (s)

Yes

Photographdamage

BNo

Material ReviewBoard determine

disposition ofmaterial, close

NCR

Archive QualityRecords

No

B

Quality Records:Receiving DocumentsPurchase OrdersNon-Conformance ReportsMaterial CertificationsCertificates of Compliance



Basic Manufacturing FlowBasic Manufacturing Flow

Prepare workorder

Built in-house?

Issue parts towork order

Pack kit forshipment to

assembly supplier

Ship kit

Assembly

Inspection

Test

Engineeringreview of test data

Final inspection Deliver to stores

ReceivingInspection



Electronics Manufacturing FlowElectronics Manufacturing Flow

Start

PRRcomplete?

Complete PRR

Complete AIDS(work order)

AIDSapproved?

Get AIDSapproved

Yes

No

No

Deliver approvedAIDS to stock

room

Stock room pull kit

Kit complete?Stock room pullmissing parts

Yes

No

Yes

Deliver kit toassembly vendor

Perform internalreceivinginspection

Kit OK? No

Open NCR

Material ReviewBoard

Assemble inaccordance withdrawing, SOW

Yes

Insection

Pass

No

Pack and ship toSLAC

Perform receivinginspection

Pass

PerformAcceptance Test

in accordance withreleased

procedure

Yes

Final inspection

Pass?

Yes

Deliver to stockroom

Yes

No

NoRework or use-

as-is?

Scrap

Perform rework asdirected by MRB,document use-as-

is

Yes

No

Start a newassembly

A

A

Electronics Manufacturing Flow



Material ControlMaterial Control

• Must be a closed loop control process • Parts/materials received from suppliers into flight stores• Parts and materials issued to work orders for assembly• Finished assemblies returned to stores• Process repeats for next higher assemblies



Non-Conforming Material HandlingNon-Conforming Material Handling

• All non-conformances are documented on a Non-Conformance Report (NCR)– Identifies non-conforming item– Describes non-conformance– Describes environment unit was in at the time the non-

conformance was discovered– Implemented using REMEDY

• Work stopped until NCR is reviewed and dispositioned by Material Review Board– Chaired by Quality Engineer– Supported by responsible engineer, manufacturing engineer,

and other specialty engineers as appropriate– NCRs archived in a data base and kept with the item work

order



Spares and RepairsSpares and Repairs

• Spares listed in LAT-MD-01687, Configuration Item Data List • End items delivered by Subsystems to Integration and Test at

SLAC• Damaged or failed end items returned to manufacturers for

repair• Calorimeter modules repaired by NRL• ACD repaired by GSFC• Tracker towers/trays repaired by INFN • DAQ hardware repaired by assembly vendor or SLAC

personnel– Plan to hire qualified assemblers to support I&T

– These assemblers will work with assembly vendors to learn hardware

• Grid Box Assembly repaired by SLAC



Clean Room SupportClean Room Support

• ESD-safe, clean-room lab coats• Hair covers• Face masks• Shoe covers• Gloves and finger cots• Clean-room swabs and wipes• Solvents and DI water• ESD-control wrist straps• Fastener inventory

glast lat projectcdr/cd-3 review may 12-16, 2003 document: lat-pr-01967section 15 manufacturing...

Documents

glast lat projectcdrcd

manufacturing processes

start of manufacturing

basic manufacturing

procurement process

specific application

higher assemblies slide

materials list