Corrective and Preventive Maintenance at NSCL

1. Corrective and PreventiveMaintenance at NSCL

2. Introduction to NSCL & MSU Quality Management at NSCL Outline Tools used at NSCL for availability Future Questions

3. NSCL National Superconducting Cyclotron Laboratory (NSCL) is a world leader in rare isotope research and nuclear science education NSCL employees 454 Faculty, Staff and Students Located on the campus of Michigan State University Ranked as the #1 graduate program in nuclear physics In the United States by U.S. News & World Report

4. Cyclotrons & Beam Lines

5. The United States pioneer land-grant university, established in 1855 In 2010, MSU enrollment consisted of 47,131 students from all 50 United States and 130 countries Michigan State University MSU has over 11,000 employees Throughout the world, there are nearly half a million MSU alumni

6. Why is a Robust Maintenance Program Important? It allows a facility to do what it does best………. It allows a facility to meet the demands of its funding agencies………. It allows a facility to meet its operational goals………. “Operate the laboratory reliably, efficiently and safely. Maintain high (>90%) level of availability and seek further gains in efficiency through improved procedures and automation of NSCL operations without compromising safety. Encourage the professional development of staff to raise the overall skill, performance, and knowledge bases within the laboratory.” NSCL has a Quality Management System (QMS) to meet all of the above

7. NSCL Quality manual states: “NSCL developed and implemented a Quality Management System in order to document the laboratory’s best operational practices, better satisfy the requirements and expectations of its users and improve the overall management of the laboratory” NSCL Quality Management System The Quality Management System of NSCL meets the requirements of the international standard ISO 9001. This system addresses the production and delivery of rare isotope beams This manual describes the Quality Management System, delineates authorities, inter relationships and responsibilities of the personnel responsible for performing within the system.

8. The Scope of the NSCL Quality System is: All NSCL processes related to the production and delivery of rare isotope beams to the experiment The quality manual outlines the policies, procedures and requirements of the Quality Management System. The system is structured to comply with the conditions set forth in the International Standard ISO 9001. NSCL QMS Scope

9. Rare isotope beams will be delivered within 24 hours of the scheduled time NSCL QMS Quality Objectives Rare isotope beams will be delivered with 90% availability Availability(Total Time - Scheduled Off - Unscheduled Offexcl) / (Total Time - Scheduled Off)

10. NSCL Availability

11. Logging & Reporting Administrative Document Handling Tools Inventory Management Planning Scheduling Tools…the actual hand tools

12. HourLog Allows for both narrative and system status reporting Logging and Reporting Reliability statistics are derived from HourLog Trouble Reports Used to report a problem with a system or process and even a suggestion Allows the trouble report to be tagged for various management systems

13. Reliability Committee Trouble Reports are reviewed bi-weekly Administrative Committee can reopen a solved Trouble Report for further investigation Repair Team Meeting called by department head All system experts are present Actionable items generated

14. Document Handling Alfresco document management Workflow determined by users Mechanical Design department design review approval Revision control

15. Inventory Management Developed in-house, using IRMIS IRMIS is a descriptive documentation Tool * Uses relational database and associated applications to comprehensively document the large and complex EPICS-based control systems * Handheld Bar Code Scanners MC55 * An Overview of IRMIS, 4/19/2005 (http://www.aps.anl.gov/epics/irmis/Primer.pdf)

16. Scheduling Administration Schedule ~ 1 day resolution Determined 3 months out Operations has final review Short Term Schedule ~ 1 hour resolution Determined daily STS Coordinator

17. Maintenance Planning Experimental schedule is determined 3 - 4 months in advance Preventive maintenance is scheduled in between experimental periods The maintenance group solicits tasks from other departments to add to the maintenance schedule Microsoft Project 2008 is used to build the maintenance schedule NSCL written software is used by the employees to get a list of their tasks The same software is also used by the employees to report the status of their tasks back to the project leader

18. Breakdown Plans In order to reduce downtime during breakdown repairs lasting at least 24 hours, but less than 7 days, a breakdown response plan is proposed to better allocate resources, and use time more effectively. The scope of this document is to explain the process for using and creating canned breakdown response plans. The initial scope of the breakdown, and such considerations as duration and level of support by other departments should be determined by a repair team meeting.

19. Tools…the actual tools Modified 5S method 5S is a system to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results * Provides a basic set of tools to address an immediate need without wasting valuable time Vault Tool Box http://beyondlean.wordpress.com/2010/09/13/5s-in-the-office/ * Lean Manufacturing and the Environment, http://www.epa.gov/lean/thinking/fives.htm

20. Tool Integration

21. During experiments, all personnel rotate through shifts as operators During maintenance, all personnel become part of the resource pool used during scheduled maintenance Operator Structure Operations/Maintenance Operating Engineers Maintenance Engineers

22. Future Tighter Integration of tools Written with common software

23. Questions