APPLICATION OF EDMS TO
XFEL CRYOMODULE
ASSSEMBLY AT CEA
Christelle CLOUE - Catherine MADEC
QUICK OVERVIEW
i r f u
s a c la y
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GOAL OF THE ASSEMBLY OF CRYOMODULES
To assemble 100 accelerator cryomodules
with a throughput of 1 per week !
operated by an industrial contractor
on the Saclay site and CEA infrastructures
with CEA supervision
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CRYOMODULE MBOM
In the process of assembling cryomodule, it is mandatory for
traceability to gather, record, process and archive the complete
configuration and fabrication information for each cryomodule
MBOM
The MBOM also includes inspection to be performed, the tests to
be recorded, the assembly procedures etc... The XFEL
cryomodule MBOM contains roughly 500 lines
It uses DESY’s Engineering Data Management System (EDMS).
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EXAMPLE : XM-2 MBOM
The MBOM defines how a specific part type (fabrication part) is produced
and from which components.
The part gets fabricated in a physical part and assembled to other physical
parts to form one cryomodule. This is recorded in the Bill of Material
BOM
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EXAMPLE : XM-2 BOM
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EXAMPLE : NON-CONFORMANCE REPORTS
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EXAMPLE : PHYSICAL PARTS
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DEDICATED ASSEMBLY BUILDINGS
XFel Village ~ 1350 m2
Clean
rooms
Bldg 124 North
25x15 m²
4
7
Assembly
halls
Bldg 126 North
40x11 m²
6
5
Bldg 126 South
30x17 m²
Offices
Court
Yard
3
12
8
6
Warehouse
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©GoogleMap
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WORKSTATIONS IN ASSY HALLS
Alignment Area AL-WS1 & 2
Roll-out Area
RO-WS1 & 2
Warehouse
Coupler Area CO-WS1 & 2
Reception Area
REC-WS1
Clean room
Area
CO-WS1 & 2
SA-WS1 & 2
Cantilever Area CA-WS1
the XFEL Village
Shipment
Area
SH-WS1 & 2
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ORGANISATION WITH ALSYOM
Alsyom has been
subcontracted to assemble
the 100CM under the
supervision of CEA.
For all exchanges, CeaAlsyom shared folders
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C. Madec | SRF13-THIOA02 | 26/09/2013 | PAGE 11
TRAVELER 1/2
XFEL
TRAVELER CLEAN ROOM
Task #
Task identification
GOM Reference
Cryomodule reference:
GOM
Version
Date
Operators
Report File reference
FAQ
NCR
Comments / Main results
Couplers Reception (ISO5-REC-WS)
Other Components Reception (REC-WS)
Cavities Reception (REC-WS + ISO5-REC-WS)
ISO4 Entry
Coupler & Cavity Assembly (ISO4-CC-WS)
ISO4-CC 1
Couplers pumping, leak test, venting
ASS_CR_26_Coupler venting for coupler cold part
assembly
06/01/14
LE GOFF M. / LECUONA T. /
CHATILLON F.
ISO4-CC 2
Cavity positioning on coupler assembly station
ASS_CR_19_Cavity positioning on coupler assembly
station
06/01/14
LE GOFF M. / LECUONA T.
ISO4-CC 4
Cavity pumping and venting
ASS_CR_25_Cavity venting for coupler cold part
assembly, n=[1;8]
06/01/14
LE GOFF M. / LECUONA T. /
CHATILLON F.
QR_LC2_CAV_FE00556_140107.xlsx
ISO4-CC 3
Cleaning of parts ( screw, nuts, washer…)
ASS_CR_28_Cleaning procedure of parts (screw,
nuts, washers)
08/01/14
LE GOFF M. / LECUONA T.
AR_XM4_CCC556_140108.xlsx
ISO4-CC 5
Coupler cavity cold part assembly
ASS_CR_36_Coupler cold part assembly
ISO4-CC 6
Leak check and RGA of the assembly
ASS_CR_27_Leak check and RGA of cavity and
coupler cold part assembly
08/01/14
LECUONA T. / BOULCH C.
QR_LC-RGA_CCC556_140108.xlsx
RGA_CAV556_140108 .png
ISO4-CC 7
Cavity positioning on string assembly station
ASS_CR_18_Cavity positioning on string assembly
station
05/02/14
LECUONA.T / LE GOFF.M
ISO4-CC 27
Couplers pumping, leak test, venting
ASS_CR_26_Coupler venting for coupler cold part
assembly
07/01/14
LECUONA.T / LE GOFF.M /
CHATILLON.F
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QR_LC2_CCP THRI-CP315 - THRICP394_140107.xlsx
QR_LC2_CCP THRI-CP315 - THRICP394_140107.xlsx
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TRAVELER 2/2
XFEL
XM4
Task #
Task identification
Date
Prod.
Control
point
Alsyom
Quality
Control
point
Alsyom
Validation Alsyom
Doc. control
point CEA
Hold point
CEA
Validation CEA
CEA Comments
Couplers Reception (ISO5-REC-WS)
Other Components Reception (REC-WS)
Cavities Reception (REC-WS + ISO5-REC-WS)
ISO4 Entry
Coupler & Cavity Assembly (ISO4-CC-WS)
ISO4-CC 1
Couplers pumping, leak test, venting
06/01/14
ISO4-CC 2
Cavity positioning on coupler assembly station
06/01/14
ISO4-CC 4
Cavity pumping and venting
06/01/14
X
ISO4-CC 3
Cleaning of parts ( screw, nuts, washer…)
08/01/14
X
X
ISO4-CC 5
Coupler cavity cold part assembly
ISO4-CC 6
Leak check and RGA of the assembly
08/01/14
ISO4-CC 7
Cavity positioning on string assembly station
05/02/14
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X
NOK
TRUBLET T.
X
OK
BOULCH C.
OK
TRUBLET T.
OK
BOULCH C.
X
Valeur de pression avant d'ouvrir
la vanne en rouge (TT)
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FAQ (FICHE D’AMÉLIORATION QUALITÉ) /
NCR (NON CONFORMITY REPORT)
All non-conformities are generating a FAQ which is processed internally (Alsyom/CEA).
The CEA area manager decides if it needs to escalate to NCR through EDMS.
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DECISION PROCESS FOR NON CONFORMITY
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QUICK DECISION PROCESS FOR NCR
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NON-CONFORMITY PROCESSED
ON EDMS (1/2)
After the processing of the NCR on EDMS, the corrective and preventive actions should be filled
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NON-CONFORMITY PROCESSED
ON EDMS (2/2)
The NCR document is uploaded on EDMS which is used for coordination, review and approval of the its
content, namely description of the NC, its corrective and preventive actions.
Reference : CEA-XFEL-RNC-13-103-1
Reference : CEA-XFEL-RNC-13-103-1
Page : 1
NON CONFORMANCE REPORT
NON CONFORMANCE REPORT
Date : 17/06/2013
Enter either the "Physical Part EDMS-ID" , or the "Fab. Part Name" + "Fab. Part EDMS-ID" + "Physical Part Serial Number" .
Physical Part EDMS-ID :
Fab. Part Name :
XM-2_CMS: Cold Mass + String
Fab. Part EDMS-ID :
D00000000583027
Physical Part Serial No. XM-2_CMS
Recorded by :
C. CLOUE / P. PLUVY
Location :
CEA XFEL Rollout Area
TITLE :
Dents on cavity bellows between cavities 1/2 and cavities 7/8
During operations in Roll Out WS, some dents have been observed on cavity bellow between cavities in position 1/2 (see Picture 1), and on cavity bellow between cavities in position 7/8 (see
Picture 2).
Reference documents :
TECHNICAL INVESTIGATIONS :
Responsible (s)
Shocks probably generated during string assembly operations (bellows connections on cavities)
S.BERRY
CORRECTIVE ACTIONS (on Physical Part, or Equipment) :
Responsible (s)
NA
S.BERRY
PREVENTIVE ACTIONS (on Fabrication Part, or Equipment) :
Responsible (s)
Change tooling used in SA WS (torque wrench) to prevent to hit bellows during the string assembly
S. BERRY / M. MBELEG3
CATEGORY :
FINAL DECISIONS :
Minor :
Action on Part :
X
Use As Is
Documentation :
Major :
Clearance for actions
Fabrication Engineer (Technical Manager)
Quality Manager
Project Manager (WPL)
C. Cloué
Unit responsible for
involved product :
O. Napoly
Accelerator Consortium
Manager :
1st distribution :
The Coordinator can fill-in the names of reviewers/approver(s), but does not have to because they are listed in the "History", or on the "Reviewer/Approver" tab (names might change there).
Date : 09.10.20xx
Reviewer : A. MATHEISEN, L. LILJE
2nd distribution:
The Coordinator can fill-in the names of reviewers/approver(s), but does not have to because they are listed in the "History", or on the "Reviewer/Approver" tab (names might change there).
Date : xx.xx.20xx
Reviewer :
Closing :
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Date : xx.xx.20xx
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By :
VISA :
Date : 17/06/2013
CONTINUATION SHEET
Picture 1
DESCRIPTION :
Page : 2
Picture 2
HOLD POINTS (1/2)
Time when CEA is inspecting both the documentation and the module and authorized
to proceed to the next assembly steps.
XFEL
Task #
XM4
Task identification
Date
Prod.
Control
point
Alsyom
X
Quality
Control
point
Alsyom
Validation Alsyom
Doc. control
point CEA
Hold point
CEA
Validation CEA
CEA Comments
String Assembly (ISO4-SA-WS)
ISO4-SA 14
Cavity 7 - 8 assembly
26/02/14
ISO4-SA 3
Qpole unit positioning
26/02/14
ISO4-SA 4
Qpole unit alignment
26/02/14
ISO4-SA 15
Qpole unit venting
26/02/14
ISO4-SA 16
Qpôle unit to string cavity assembly
27/02/14
ISO4-SA 17
Final leak check cavity string
28/02/14
ISO4-SA 17
RGA verification
28/02/14
ISO4-SA 18
Distance adjustment
28/02/14
ISO4 CTRL 1 Cavity string outgoing inspection
X FEL
ISO4 CTRL 2 cavity string roll out
X -Ra y Fr e e -Ele ct r on La se r
28/02/14
28/02/14
OK
TRUBLET
TRUBLET
X
OK
TRUBLET
X
X
OK
TRUBLET
X
X
OK
TRUBLET
X
OK
TRUBLET
NOK
TRUBLET
X
X
X
X
OK
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19
TRUBLET
HOLD POINTS (2/2)
Check Report: Mechanical Test on Cavity String before RollOut
Template_QR_MecTest1_XMn_STR_yymmdd_V2
1
2
General Information (for protocol upload)
Project
XFEL_WP03_Alsyom
Document Type:
Team
XFEL_WP03_Alsyom_Team
Team Folder
1_STR
Manufacturer Name
Commissar. À l'énergie atomique
Manufacturer ID
FRA-CEA-SAC
Location
CEA XFEL String Assembly Area in ISO4 Cleanroom
Mecanical Check
Part Information
Part
Part 1
Fabr. Part Name
Fabr. Part EDMS ID
STR: Cavity String
PP Serial No
D00000000572107
XM4
CAVITES
Cavity 1
Cavity 2
Cavity 3
Cavity 4
Cavity 5
Cavity 6
Cavity 7
Cavity 8
CAV_FE00
626
607
556
597
606
621
592
594
THRI-CP-
337
382
394
315
366
399
349
213
077
071
096
052
069
079
067
086
17
Numéro de série des cavités :
18
Numéro de série des coupleurs
19
Numéro de série des soufflets :
20
Vérifier que les cavités sont bien posées sur les posts côté coupleur :
OK
OK
OK
OK
OK
OK
NOK
NOK
21
Vérifier que les cavités sont bien posées sur les posts côté opposé coupleur :
OK
OK
OK
OK
OK
OK
OK
OK
22
Vérifier que le système de maintien du tube He est bien fixé :
OK
OK
OK
OK
OK
OK
OK
OK
23
Vérifier que les tiges filetées ne sont pas débouchantes :
OK
OK
OK
OK
OK
OK
OK
OK
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FEL VB1 000002-
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FURTHERMORE ….. PED :
Welding documents : commments from Lars Hagge
A script extracts the files (conformance report from
manufacturer or WP – already on EDMS) related to the
physical parts that are installed and are parts of the PED
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C. Madec | SRF13-THIOA02 | 26/09/2013 | PAGE 21
Thanks for
your attention
| PAGE 22
Titre | Date
Commissariat à l’énergie atomique et aux énergies alternatives
Centre de Saclay | 91191 Gif-sur-Yvette Cedex
T. +33 (0)1 69 08 69 39
Etablissement public à caractère industriel et commercial | RCS Paris B 775 685 019
DSM
Irfu
SACM
LIDC2
EXAMPLE OF ASSEMBLY PROCEDURES
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