NuMi Off-Axis Neutrino Appearance - NOVA Document Database ...

• The task manager illustrated high-quality connection to the schedules.
• Manpower appears to be adequate to receive CD-2 approval. The project realizes the
need to hire the first factory manager immediately.
• Structural analysis support appears thin and the project should evaluate the
engineering manpower profile between the R&D and production phases for
continuity.
Time and motion studies for some assembly steps were very well done, but are incomplete.
The routing of the fiber into the manifold is advanced, as is the testing plans for the modules
through their various phases of construction. A similarly thorough assessment for all phases of
module assembly is needed for CD-2. The prototype effort scheduled for this summer should
provide significant insight into the steps necessary to properly assemble and test functional
modules. The prototyping effort should include time and motion definition as one of its
objectives.
Of concern during this review was the handling of the (approximately) 900-pound
extrusion/module. Pushing and pulling these loads overhead on the manual trolley can pose
ergonomic issues, since the loads are relatively high. This process is likely to be repeated at
least twice for each of the (approximately) 21,000 modules. There may be strain related injuries
to personnel due to starting and stopping movement of the half-ton of the module and the lifting
fixture. There is also great potential for collision of the extrusion or lifting fixture with the crane
support structure. Stops at the ends of each cell would eliminate the potential for this event. The
Committee recommended stops and three cranes, for each cell.
Using vacuum fixtures is an acceptable industrial material handling method. However,
with (approximately) 21,000 modules each moved multiple times, special care must be taken of
the vacuum fixtures. The extrusions do not have a uniformly flat surface across its entire width,
owing to the grooves at the webs of the extrusion cells. Further, the vacuum fixtures do not
provide a positive mechanical attachment that can withstand long-term use and abuse. Frequent,
complete maintenance and inspection will be necessary to assure proper function and operation
of the vacuum lifting devices and to minimize the potential for a material handling incident.
The assembly process will primarily be done on “tables” within each assembly cell. The
tables should be low to accommodate manual movement of the cranes, but may be too low to
work on without ergonomic impact. The positioning of the extrusion for assembly should be
evaluated for an ergonomically friendly position.
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