The document discusses the quality assurance and quality control processes used for the HL-LHC Coil Fabrication project. It describes the quality and materials department, quality-related roles, quality systems and tools, and how QA/QC is incorporated throughout acquisition, inspection, process engineering, and documentation control. Key aspects highlighted include the use of traveler documents, discrepancy reporting, and ensuring traceability of parts from receipt to delivery.

1. Adam A. Bracero
QA/QC for HL-LHC Coil Fabrication
31 May 2016
Quality Assurance / Quality Control
Processes

2. • Organization and Project Support
– Quality & Materials Department
– Quality-related Project Roles
• Quality Systems and Tools
– Quality Program/Plans
– Acquisition
– Incoming Inspection
– Process Engineering
• Summary
– Recap QA/QC Points
– Areas to be Completed
Outline
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3. From parts procurement to inspection,
QMD incorporates quality throughout
each group’s processes to support the
project
– Acquisition
– Quality Control
– Component Storage
– Process Engineering
– Design & Drafting
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Quality & Materials Department

4. To supplement Quality Assurance, several engineers provide
support to assure quality.
Steve Krave – Technology Improvements
Carlo Santini – Electrical Quality Assurance
Trey Holik – Coil Quality Assurance (across all labs)
Quality-related Roles for Project
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Quality Systems and Tools

6. • Coordinates all procurement activities; interfacing between the project staff,
procurement, suppliers, and the other functions within QMD
• Turn purchase requests into requisitions or ProCard orders
• Buy “small” fabrications via Task Order
• Coordinate all parts logistics
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Acquisition

7. • Parts are received at IB4, and entered into our “Routing
Form” database (RFLog); assigned an “RF number”
– Maintains traceability from receiving “batch” and PO, tied to
inspection data
• Parts are “routed” for inspection (note on the requisition)
• Parts are inspected in accordance with TD’s procedures
– Project Engineer works with QC to define inspection drawings
• Issues can be tracked either with a “Quality Control Report”
(if not using a traveler), or a “Discrepancy Report” (if using a
traveler)
• Parts are only released for use after a passing inspection or
an approved QCR/DR
Incoming Inspection
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8. • Project Engineers and Techs have all been trained on use of Vector
• Main processes: Winding/Curing, Reaction, and Impregnation have
been revised to a mature level
• Improving Electrical Testing with separate Traveler
• Plans to separate steps for preparation of each major process into
separate Travelers
• Plans to separate and improve the Shipping process into its own
Traveler
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Process Engineering
HL-LHC AUP Traveler Flow Chart

9. Quality Assurance
• DRs for process tracked
• Attachment and Notes
• Document Control
– Revision Tracking
– Serialization
• PPE and handling of parts
• Parts Kit - traceability of parts
• Inspection Number for parts
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Process Engineering

10. All Travelers and Operating
Procedures are under version
control, and any changes to
those documents need to be
reviewed and approved by
Responsible Authorities.
A list of Responsible Authorities
that approves each Traveler is
maintained.
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Process Engineering

11. Quality Control Inspections
• Visual inspection from
Responsible Authority
• Electrical testing
• Serial number of equipment
used
• CMM Measurements of coil
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Process Engineering
Electrical Test Data – Reaction Traveler
Visual inspection from Responsible Authority – Winding Traveler
CMM Coil Measurements – Impregnation Traveler

12. Operating Procedures
• Controlled documents
• Revision change tracking
• Reviewed and approved
Hazard Analysis and
Operational Readiness
Clearances used as needed for
new or changed equipment.
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Process Engineering

13. Discrepancy Report System
• All non-conformances are recorded
• Automated email sent for required
fields: disposition and corrective
action, verification for work completed,
and closeout of DR
• Verification steps ensure action is
taken
• If corrective action is known,
preventive measures are taken and
documented
Process Engineering
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14. Recap of QA/QC in Processes
• Quality Assurance is
supported by policies and
Dept procedures.
• QA/QC is implemented
throughout with traceability
of parts from Acquisition to
QC Inspection to delivery to
floor.
• Document control, revision
tracking, parts kit, QC
inspection steps in
Travelers, Discrepancy
Report System.
Areas to Develop
• Draft Quality Management
Plan needs to be completed.
– Inspection & Procurement
Plans.
• Development of Prep and
Shipping Travelers
• Continuous improvement
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Summary