From: Hutch Neilson
Sent: Tuesday, August 15, 2006 10:25 PM
To: Mike Williams; Lawrence E. Dudek; Ronald L. Strykowsky; Wayne T. Reiersen; James H. Chrzanowski
Subject: Summary of NCSX on-site fabrication meeting of 8/15/06
Summary of NCSX On-Site Fabrication Meeting of Tuesday, August 15, 2006

1.  Cost Trends and Issues  (8/10/06 data)

• Upward cost trends on A1 and C4-C5 continue.
• Cost increase on A1 was attributed to typical first-of-a kind problems: had to modify fixture due to larger size; had to modify clamp hardware due to more turns (11 vs 10).
• Also, A1 has been staffed by new technicians.
• Cost trends on C’s was attributed to various effects which have impacted productivity: shift rotation, vacations, metrology problems.
• Large jump in shop & “other” tech. support hours was attributed to fabrication of the hockey pucks and monuments for the Type A’s in July. Will recur on Type B.
  

2.  Schedule Trends and Issues

• Critical path tasks continue to fall further behind.  C4 and C5 are about 14 and 18 days behind, respectively. A1 about 9 days behind.
• Agreed on Jim’s plan: complete post-VPI on C3 this week, C2 next week. Remove them from rings. Store in NCSX test cell.
• Start casting prep on A2 thereafter, approx. 8/28.
• Decided to repair C2 lead area. Try to get the same person who repaired C1, and not disrupt winding crew. Schedule not critical.
  

3.  Status of measures to improve performance

• New source for chill plates (EDM).  Started with Type A’s. Very good results: rework requirements are eliminated.
• Outside source for autoclave equipment cleanup.  Working out well on steel components. Reduces in-house labor.  Will ask them to try brass components- samples to be provided with next order.
• Inconel studs instead of stainless.  Started with Type A’s. Good results: greatly reduces grinding.
• New staff: on board now and coming up to speed.
• We have started working two shifts on Station 1b
• New fixture fabrication: Could be built in-house or outside. Larry is seeking more bids from outside fabricators. Decide in a few days.
• Facility modification: New fixture will go in Station 3 (clean) and be used for winding. Station 4 will be converted for “dirty” work, nominally casting prep.  Station 1b and 4 will be interchangeable.
  

4.  Follow up actions

• Continue to closely monitor operations to identify opportunities for cost and schedule improvement.  Larry, Jim.
• Move ahead with the new winding fixture ASAP. Larry, Ron.
• We are not ready for additional technician hires at this time. Re-visit in September.  Mike W.
  

5.  Next Meeting:  August 22 at 9:00

Hutch