Energy Industries of Ohio (EIO) Team Weekly Status Report

Report covers the NCSX Modular Coil Winding Form Activities Under Production Contract S005242-F

Week ending April 13, 2007

U-5 ops on C-6

Administrative Highlights

Parts in production at MTM continue to progress close to their targets, building momentum towards program completion.   Meanwhile, as the bulk of the NCSX activities shift to PPPL, there are occasional questions that arise.  This week, the matter of the tooling ball fiducials took the spotlight (see QA Highlights).  Once again, we were able to rely on collective memory and documented records, (in this case mostly e-mails), to piece together the necessary history to readily answer the questions.  Such records should serve the NCSX program well even after contract completion.

FTP Postings this week*

(found at:  ftp.atc-inc.org:/PPPL/shared_info)

Location	File Name	Date
\Reports_Weekly-Monthly\Weekly	07-04-06_eio_wk.doc	7/13/07
\Quality-Meeting_notes	PPPLQualityNotes4-9-07.doc	7/13/07
\Quality_Review	Tooling_ball-size-4-9-07.pdf	7/13/07
\Quality­_Review\ Closed_NCR-CA-RFD\NC	Signed_off-NC21296-B6_cntrsnk.zip	7/13/07

Administrative Action Items

1.    (EIO, MTM) Larry Sutton issued Amendment 18 addressing DCAA Audit report on 2/8/07

Status: (Open) Amendment and DCAA findings have been under review at MTM.   EIO received a follow-up letter from PPPL on 4/13 requesting that EIO expedite the review and response to the DCAA Auditor’s findings of MTM’s cost projections and/or signing of Amendment 18 incorporating those findings.  EIO has contacted MTM to keep this moving.

Technical Highlights

C-6

The 5-axis machining on C-6 continued this week. As expected, the 2^nd operation on the casting was started on Monday (4/9) and by Friday (4/13) it was anticipated that the op would be completed and transition to the 3^rd op would commence on Saturday (4/14). Judging from the progress to date and weighing the remaining operations post machining, Mike Griffith continues to project that C-6 will be ready to ship early part of May.

C-6 on U-5

B-6

For B-6, the shop expected to wrap up the initial operation on the 40’ Mitsubishi sometime Friday (4/13). As of early Friday morning, they were finishing the machining on the datum D flange holes.  Setup for the 2^nd (and final) Mitsu operation was scheduled to commence during the 2^nd shift Friday night.   Presuming things progress according to plan, Mike expects this next operation to take approximately 1 ½ weeks, coinciding roughly with the expected U-5 completion time for C-6.

B-6 on 40’ Mitsu

Technical Action Items

1)         (Major Tool) Machining C-6
Status: (Open) On U-5

2)          (Major Tool) Machining B-6
Status: (Open) On 40’ Mitsu

Quality Highlights

On 4/9 Larry Sutton emailed a letter to the team (posted to EIO FTP) regarding a problem noticed during the inspection of the B-4 casting at the lab. They discovered that Major Tool had switched from tooling balls with a 5/16^th center-to-shoulder distance to a 1/2" distance.  The letter noted that this was problematic since the lab was using 5/16” tooling center-to-shoulder distance tooling balls to match those at MTM, along with the corresponding monument holders for the laser tracker. EIO was requested to:

·        Identify the size tooling ball used by MTM on all of the MCWF delivered to date.

·        Direct MTM to use the 5/16” center-to-shoulder distance tooling balls on the remaining 2 MCWFs in process (B-6 & C-6)

In response to the subject correspondence, EIO contacted Major Tool and confirmed that the PPPL findings on B-4 were correct.  Halfway through the inspection of B-4 MTM had inadvertently started using ½” seat to center tooling balls in lieu of the 5/16" and they continued the practice on subsequent castings including B-5, A-5 and A-6.  All previous parts delivered, (possibly excluding C-1, which is where the saga began) had been inspected with the 5/16".  EIO issued our formal e-mail response to PPPL on 4/9, noting that MTM had directed appropriate staff to use the 5/16" on the remaining parts (C-6 and B-6).   

Continued inquiry and investigation during the week revealed that the issue of the tooling balls had first surfaced in October of 2005, during the alignment of C-1 at PPPL.  PPPL had been unable to produce acceptable alignment measurements for C-1 and a dialogue between Steve Raftopoulos of PPPL and Kevin Bowling of MTM was initiated.  A review of their e-mail correspondence indicates that the parties resolved to use the 5/16^th tooling balls; however this was never formally incorporated into the drawings and consequently never was formalized in the MTM inspection process.  

Upcoming QA Activities

Ø        A-6 Doc package

Ø        Update EIO CA 090606

QA Action Items

1         Closed Items:

1.1 NC 21296 for oversized countersink on B-6 was signed off & forwarded to EIO. It has been posted to the FTP site (3.1 below)

2         Pending from EIO:

2.1      (MTM) Provide documentation of completion of corrective action for EIO CA 090606(NCR) for B-3 & B-6 Vacuum Vessel support pads deviations. 
Status: (Open) PPPL directed MTM to tap the 4^th hole on B-6. As documented under QA Highlights this week, this work scope was completed by Friday 4/6 (see additional picture below). The CA will be amended to reflect the final determinations/actions and will be forwarded to PPPL for closure. Pete Djordjevich expects to have the amended CA submitted early next week (w/o 4/16).

2.2       (MTM, EIO) Submit doc package for A-6 casting
Status: (Open) MTM has all documents back from the lab needed to complete package. Mike expects to have MTM portion to EIO next week for EIO review & compilation

3         Pending from PPPL:

3.1      (PPPL) Review corrective actions added to NC 21216 & NC 21296 for root cause & action plan. NOTE NC 21216 will remain open until inspection data for permeability & penetrant for this correction is received.

Status: (Closed) PPPL closed NC 21216 on 3/31.  NC 21219 was closed on 4/9

If you have any questions or need clarification, we welcome your calls and e-mails! 

Nancy Horton

EIO Program Manager for NCSX   

216-296-2314