Corrective and Preventive
Maintenance at NSCL
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Outline
Introduction to NSCL & MSU
Quality Management at NSCL
Tools used at NSCL for availability
Future
Questions
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
Cyclotrons & Beam Lines
Michigan State University
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
MSU has over 11,000 employees
Throughout the world, there are nearly
half a million MSU alumni
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
NSCL Quality Management System
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”
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.
NSCL QMS Scope
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 Quality Objectives
Rare isotope beams will be delivered within 24 hours of the scheduled time
Rare isotope beams will be delivered with 90% availability
Availability
(Total Time - Scheduled Off - Unscheduled Offexcl) / (Total Time - Scheduled Off)
NSCL Availability
100.00%
100.00%
95.00%
90.00%
95.00%
85.00%
90.00%
80.00%
75.00%
85.00%
70.00%
65.00%
80.00%
60.00%
55.00%
75.00%
50.00%
45.00%
70.00%
40.00%
Lifetime
Availability
QMS Availability
Tools
Logging & Reporting
Administrative
Document Handling
Inventory Management
Planning
Scheduling
Tools…the actual hand tools
Logging and Reporting
HourLog
Allows for both narrative and
system status 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
Administrative
Reliability Committee
Trouble Reports are reviewed bi-weekly
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
Document Handling
Alfresco document management
Workflow determined by users
Mechanical Design department
design review approval
Revision control
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)
Scheduling
Administration Schedule
~ 1 day resolution
Determined 3 months out
Operations has final review
Short Term Schedule
~ 1 hour resolution
Determined daily
STS Coordinator
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
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.
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
Tool Integration
Operator Structure
During experiments, all personnel rotate through shifts as operators
During maintenance, all personnel become part of the resource pool used during
scheduled maintenance
Operations/Maintenance
Operating
Engineers
Maintenance
Engineers
Future
Tighter Integration of tools
Written with common software
Questions