SELEX Galileo
PLATO TOU Activities Presentation
Catania, 28/2-1/3 2011
PLATO 28.02.2011
SELEX Galileo for PLATO
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SELEX Galileo for PLATO
• PLATO is a exciting opportunity for SELEX Galileo that is the Italian
leader manufacturer of Space Optical Instrumentation
• SELEX Galileo can provide to PLATO Consortium with the capability to
develop the large number of TOU units within the tight time constraints
and performace requirements.
PLATO 28.02.2011
• SELEX Galileo is supporting the TOU Team ,in the frame of a small
contract from the Science Team, on the following issues:
• Support and facilities for T/V testing of TOU prototype
• Preliminary assessment of TOU MAIT plan
• Preliminary assessment of TOU lenses coatings
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SELEX Galileo for PLATO
• We focus now on the MAIT aspects which
have been highlighted by ESA in the
shown document:
• We are going to prepare a preliminary
MAIT Plan aimed to confirm just the first
part of the following sentence, excerpted
from the mentioned ESA document:
PLATO 28.02.2011
• … the only suitable italian contractor
would be Selex-Galileo which is not, at
present, sized for the full production….
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SELEX Galileo for PLATO
• SELEX Galileo has experience in “large”
production for Space instruments. Most
recent acquisitions are relevant to the
successful bids for:
• Galileo-FOC (Earth Sensor) – # 40 units
• IRIDIUM Next (Star Sensor) – # 243 units
- Standard flow for peak production rate (18 OH’s
every 2 months)
- From June 2013 to November 2016
PLATO 28.02.2011
• In both cases the commitment on
schedule is strong, and the developed
plan was judged compliant by the
Customers.
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SELEX Galileo for PLATO
• The quantity of deliverables and the delivery rate is not ordinary for the
space industry, but SELEX Galileo have the great advantage of being a
Company already structured for the production of electro-optical military
equipments and subsystems, with quantities and rate similar to the PLATO
ones, thus is positioned at best to achieve the PLATO objectives.
• The activities will be in charge to an IPT dedicated to PLATO which
includes the skilled persons to manage and execute the program.
PLATO 28.02.2011
• To guarantee the required AIT rate, personnel from the IPT will be allocated
to PLATO and in case the number of operators is not sufficient or overload
occurs new resources from the AIT shop floor will be allocated, after a
specific training, to the program.
• Firenze plant has the mechanical and optical workshops and the
environmental laboratories to satisfy the required manufacturing rates.
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SELEX Galileo for PLATO
PLATO 28.02.2011
• TOU AIT:
• A dedicated production line will be realized to guarantee the required
production rate.
• Using the experience of Firenze plant production floor, a ramp up plan will be
implemented to pass from the present production rates to the ones requested
for PLATO.
• The tools and facilities for the FM Assy & Integration and the testing activities
will be developed and realized in parallel to the TOU design and
development activities.
• Availability of the dedicated AIT line is planned for the first ground unit (QM)
AIT, in order to achieve validation of both TOU AIT line and AIT activities.
• The FM1 (and likely the FS1) will be produced and tested using the same
tools and facilities previously used for the QM allowing to reach a high grade
of maturity of the production line before to start the “massive” production of
the next FM sets.
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SELEX Galileo for PLATO
• APPROACHES & HYPOTHESYS
• A preliminary MAIT is in preparation, aiming to highlight the main technical
and production requirements and constraints to produce high rate flight
HW, as necessary for PLATO Programme.
• The MAIT necessarily assumes a number of hypotheses which shall be
better addressed in the proceeding of the Plato design.
• The current design is assumed as feasible, although an optimisation of the
design shall be later performed for its industrialisation.
PLATO 28.02.2011
• The feasibility vs performance shall be verified on TOU Prototype and QM
models.
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SELEX Galileo for PLATO
• APPROACHES & HYPOTHESYS
• A preliminary critical technology items investigation is in progress. A B/B
phase shall be implemented to improve feasibility and reduce cost/risks,
before finalizing the design.
• The planning here presented exhibits a relatively long early phase of
design verification and industrialization, aiming to reduce the schedule in
the subsequent recurrent production /AIT phase.
PLATO 28.02.2011
• The philosophy is to “prepare” the production with suitable non-recurrent
activities, also to reduce production risks in high rate manufacturing.
• This approach is a standard for our production lines (HW for Avionics,
Defence, and more recently for high-rate Space HW (i.e. Galileo-FOC –
n.40 Units; IRIDIUM Next – n.243 units).
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SELEX Galileo for PLATO
• APPROACHES & HYPOTHESYS
PLATO 28.02.2011
• The basis for any time evaluation is the definition of the TOU design and
the verification of all requirements during the TOU prototype activities.
• Only minor changes can be considered after this phase in order to have a
high confidence for the TOU QM campaign results.
• The “Design Definition” activity proposed by GA is related only to the
optical TOU components considering the optimisation of the production
tolerances, alignment tolerances and over all optical performances.
• During this phase it will be performed also the availability in GA archives of
the test samples used for the verification of the shape for the spherical
surfaces during the first polishing phases of the optical production.
• The output of this activity is the definition of the final production drawings
for the optical components.
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SELEX Galileo for PLATO
• APPROACHES & HYPOTHESYS
• The “Documentation Definition” activity proposed by GA is related to the definition of
the alignment procedures and tests procedures at sub-assembly level, as a single
lens with its cell, and at assembly level for the TOU’s.
• Management of the test reports (optical components and telescope units) will be
defined in order to guarantee the configuration of all TOU’s.
PLATO 28.02.2011
• A phase for the “Jigs and Tools Definition” has been considered for the identification
and design of the items required for the realisation of the optical components and
the handling of the items during the sub-assemblies mounting and testing.
• For all the working phases related to of the TOU’s there will be the definition of the
required supports, protections etc. for the handling, mounting and testing. In
particular for the temperature definition of the TOU’s focal planes, a dedicated setup related with a thermal vacuum chamber will be defined.
• Dedicated transport containers will be defined and procured for the delivery of the
TOU’s.
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SELEX Galileo for PLATO
• APPROACHES & HYPOTHESYS
PLATO 28.02.2011
• For the “Optical Row Material Procurement” we are foreseen an order to
satisfy the TOU QM production and then the subdivision of the
procurements of the TOU’s FM since the kind of materials, dimensions and
numbers of the lenses required for the whole program represent a
quantities of materials that can not be obtained from a single production
lot.
• For the optimisation of the schedule, it is planned to purchase the raw
material in advance, respect to the conclusion of the TOU QM activity, the
optical row material related to the first TOU group and also to start the
related production of the components.
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SELEX Galileo for PLATO
• Key success factor is the policy of risk mitigation to be adopted for MAIT
phases. This way has the effect to increase the non-recurring costs but
meets the objective of avoiding failures or anyway schedule delays during
MAIT.
• We mean, for instance:
- Concurrent engineering between design, production and AIT engineering functions from the
very beginning of the project
- Implementation of a suitable make-or-buy policy for lens elements to minimise production
time and risks
- Duplication of test facilities
- Extensive use of COTS equipments, for easy replacement
- Dedicated design of test benches, with high level of automation (including reporting)
- Development of a suitable set of spares to avoid any interruption of the production line
PLATO 28.02.2011
- Breadboarding activities at subassembly level (even if not explicitly reported in the
schedule) to consolidate the design and/or qualification status
• For the above reasons the development risks are minimized.
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SELEX Galileo for PLATO
• A detailed MAIT plan shall be prepared
in parallel with definition of final
design.
Materials storage
Shape generation and grinding
Optical Polishing & Accuracy Inspection
Final Shaping/Centering
• Suitable MAIT Processes shall be
identified, considering either the
standard as well as state_of_the_art
technologies.
SAL
Optical qual.
Inspection
NO
• The main focus is for special materials
for mechanical parts and for special
optics.
OK
NCR
YES
YES
COATING
PROCESS
VERIFICATION
on samples
COATING
QTA
NO
• The flow includes procurement of raw
materials and qualification of
processes (i.e coating and/or special
bonding and lens fastening).
NO
Final
Inspection
OK
YES
NCR
NO
OK
PLATO 28.02.2011
YES
• Typical flow for Space HW parts
manufacturing (optical part )
NCR
VdC
STORAGE
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SELEX Galileo for PLATO
PLATO 28.02.2011
• Latest Schedule request from CNES relevant to
PLATO TOU is reported here:
Delivery date to CNES
QM
TOU QM
01/07/2013
Payload 1 N-TOU FM 1
02/06/2014
N-TOU FM 2
23/06/2014
N-TOU FM 3
14/07/2014
N-TOU FM 4
04/08/2014
N-TOU FM 5
25/08/2014
N-TOU FM 6
15/09/2014
N-TOU FM 7
06/10/2014
N-TOU FM 8
27/10/2014
Payload 2 N-TOU FM 1
17/11/2014
N-TOU FM 2
08/12/2014
N-TOU FM 3
29/12/2014
N-TOU FM 4
19/01/2015
N-TOU FM 5
09/02/2015
N-TOU FM 6
02/03/2015
N-TOU FM 7
23/03/2015
N-TOU FM 8
13/04/2015
Payload 3 N-TOU FM 1
04/05/2015
N-TOU FM 2
25/05/2015
N-TOU FM 3
15/06/2015
N-TOU FM 4
06/07/2015
N-TOU FM 5
27/07/2015
N-TOU FM 6
17/08/2015
N-TOU FM 7
07/09/2015
Payload 4 N-TOU FM 8
28/09/2015
N-TOU FM 1
19/10/2015
N-TOU FM 2
09/11/2015
N-TOU FM 3
30/11/2015
N-TOU FM 4
21/12/2015
N-TOU FM 5
11/01/2016
N-TOU FM 6
01/02/2016
N-TOU FM 7
22/02/2016
N-TOU FM 8
14/03/2016
Payload 5 F-TOU FM 1
22/02/2016
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F-TOU FM 2
14/03/2016
SELEX Galileo for PLATO
• Preliminary schedule
assessment under the
hypothesis of “standard” MAIT
flow.
• We are confident to achieve
compliance with requirements
by implementing a set of
actions, presently under
evaluation, that will permit the
optimisation of MAIT processes
in terms of time schedule and
risk management.
PLATO 28.02.2011
• Black dots are the delivery
deadlines for each TOU unit.
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SELEX Galileo for PLATO
• Preliminary schedule
assessment under the
hypothesis of “standard” MAIT
flow and duplication of the
production line
PLATO 28.02.2011
• Black dots are the delivery
deadlines for each TOU unit
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•
32 PLATO TOUs
PLATO 28.02.2011
•
243 Star Sensors
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….last slide!!
Thank you for your attention
Any question?
enrico.battistelli@selexgalileo.com
PLATO 28.02.2011
giuseppe.basile@selexgalileo.com
andrea.novi@selexgalileo.com
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