Philip G. Cutino, P.E. Engineering 10 Presentation April 19, 2012 Chabot College, Hayward CA.
Philip G. Cutino, P.E.
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Transcript of Philip G. Cutino, P.E.
Philip G. Cutino, P.E.
Engineering 10 PresentationApril 19, 2012
Chabot College, Hayward CA
Mr. Phil Cutino • ENGR10 • Sp12
Today’s Agenda SLAC National Accelerator
Laboratory Linac Coherent Light Source (LCLS) My role at SLAC over the years The Mechanical Fabrication
Department
Mr. Phil Cutino • ENGR10 • Sp12
Location: Menlo Park, CA Type: Multi-program Laboratory Contract Operator: Stanford University Website: www.slac.stanford.edu Physical Assets:
426 Acres 145 Buildings 1.8M GSF in Active Operational Buildings
Human Capital Employees: 1,496 FTE as of 4/15/08 Users, Visiting Scientists and Grad Students:
3036 Head Count
Stanford Linear Accelerator Center
Mr. Phil Cutino • ENGR10 • Sp12
SLAC Mission SLAC programs explore the
ultimate structure and dynamics of matter and the properties of energy, space and time - at the smallest and largest scales, in the fastest processes and at the highest energies - through robust scientific programs, excellent accelerator based user facilities and valuable partnerships.
Mr. Phil Cutino • ENGR10 • Sp12
Research at SLAC Accelerator Physics Astrophysics and Cosmology Elementary Particle Physics Materials and Nanoscience Molecular Environmental
Science Structural Biology Ultrafast Science http://
www6.slac.stanford.edu/Research.aspx
Mr. Phil Cutino • ENGR10 • Sp12
LCLSTotal Machine* : ~1750 meters of beam line
1242 DevicesInjector: 28 meters of beam line
& 95 devicesLinac 1003 meters 708 devices
LTU & Dump408 meters 176 Devices
*Electron Beam Line Only Does not include Photon Beam Lines
Mr. Phil Cutino • ENGR10 • Sp12
Linac Coherent Light Source
Ultrafast X-ray science Directly observe the motions of atoms on ultrafast time
scales Investigate dynamics, bonding, heating and melting, at
atomic and nanometer length scales Create and observe extreme new conditions in atoms
and materials Imaging of nonperiodic molecules and nanostructured
materials World’s first X-ray free electron laser
Producing 100 femtosecond pulses of photons in the energy range 800-8,000 eV
10^12 coherent X-ray photons/pulse Potential for sub-femtosecond pulses Lead nanoscale science revolution Master control of energy-relevant complex systems Lead the world in the investigation of dynamics of
atomic transitions, chemical bonding, catalysis and heating
Mr. Phil Cutino • ENGR10 • Sp12
Links to More Information
http://www.slac.stanford.edu http://lcls.slac.stanford.edu http://
www6.slac.stanford.edu/ExploringSLACScience.aspx
https://news.slac.stanford.edu/
Mr. Phil Cutino • ENGR10 • Sp12
Atypical career path
Mechanical Engineer Register Professional Engineer in CA
Returned to school late in life Diverse background . . . ~25 years with the same employer
Four different jobs
Mr. Phil Cutino • ENGR10 • Sp12
My Roles at SLAC Process Control Instrumentation
Technician Facilities Engineer Accelerator Engineer Mechanical Fabrication
Department Head
Mechanical Fabrication Department
Phil CutinoOctober 27, 2010
Mechanical Fabrication DepartmentPage 12
Mission and Vision
• Mission– Provide specialized manufacturing and field support
services necessary for the Lab to achieve it’s stated goals– Provide collaborative and quick turn around manufacturing– Provide services unique to the SLAC mission not available
elsewhere• Vision
– Partner with SLAC organizations to effectively deliver high quality manufacturing services in a safe and cost efficient manner supporting the scientific mission
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Delivering SLAC’s Mission
• Broad capability on site for specialized manufacturing services– High quality, consistency, capacity and unique accelerator research specific processes
developed and delivered safely• Technical know how developed over many years
– Highly trained & experienced staff available for changing needs of an experimental research user facility
• Quick turn around and collaborative manufacturing– Metal Finishing
• Documented processes developed specifically for accelerator research needs– Hydrogen Furnace Brazing– Vacuum Processing and Precision Assembly– Magnet fabrication, refurbishment and repair– Machining
• Special capability such as ability to machine exotic & low-level radioactive materials
• Field work includes installation, installation coordination, accelerator mechanical and vacuum system maintenance and operations
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Organization• 85 Full time staff members
– 6 Engineers– 12 Science & Engineering Associates– 67 technicians and trades
• 9 supervisors• 12 matrixed out
– Formal matrix agreements• 9 are temporary employees• Very experienced workforce
– 16% have 10 to 20 years of service– 19% have 20 to 30 years of service– 9% have more than 30 years of service
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Organization continued• Management (4)
– Mgmt., Admin., ES&H support• Production Planning (6)
– Job inputs, Estimating– Manufacturability Review
• Machine Maintenance (4)• Field Operations (6)• Vacuum Shop (21)
– Vacuum Processing– Precision Assembly
• Braze Shop (7)– Precision Assembly
• Machine Shop (12)• Metal Finishing (8)• Structural Fabrication Shop (7)
– Magnet Coil Shop– Sheet Metal and Welding Shops
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Core Competencies
• Broad range of technical know-how necessary to support the scientific mission– Generally very high quality on site for ongoing and urgent
operational needs as well as collaborative manufacturing• Manufacturing & Field Support Services
– Seamless integration of production planning, machining, metal finishing, magnet fabrication, precision assembly, sheet metal forming, welding operations, quality assurance, vacuum processing with installation, maintenance and repair
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Core Competencies continued
Machine Shop
Clean Machining for UHVQuick Turnaround
Radioactive MaterialsDFM & Prototype Parts
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Core Competencies continued
Hydrogen Furnace BrazingAnd
Heat Treating
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Core Competencies continued
Metal FinishingPlating
and Cleaning for UHV
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Core Competencies continued
Mechanical and Vacuum Processing andField Operations
Precision Assembly
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Performing Work• Customers have access to the manufacturing process
– Scope and technical changes are routinely accommodated– Collaborative manufacturing is facilitated– Problems are solved quickly
• Customer feedback is regularly provided– Cost and schedule estimates are provided as part of the job input
process– Customers can check an online tool for real time updates– Scope and technical changes are not re-estimated unless requested by
the customer• Regular planning meetings are held
– There is a standing weekly meeting for all field work– Larger projects are coordinated in project specific meetings held weekly
or as needed
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Performing Work continued• Quality assurance is integrated and documented on travelers.
– All machined parts are independently quality checked by MET unless the customer requests this step is to be skipped
– Vacuum processing reports are recorded in traveler– Vacuum leak checking is provided in the shop on assemblies and in the
field on systems• Manufacturing process is seamlessly integrated
– Procurement of materials, machining, metal finishing, vacuum processing, precision assembly and installation can be procured from a single request
– In process storage of components and assemblies is provided• Schedule updates are available to project managers
– Schedule reporting is provided to customers or to integrated schedules as requested by customers
• Change control is generally formal
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Performing Work continuedCollaborative Manufacturing Example:Wire Card for combination OTR / Wire Scanner Developed for KEK by Doug McCormick (SLAC)Resolution ~2 microns
Technical Challenge:10 micron Tungsten Wire Soldered to gold plated Macor substrate requiring high positional accuracy
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Concluding Work• Estimate vs. Actual reports are provided for all jobs.
– Actual costs are available online for future use in estimating.– Historical and real time data is searchable by part number,
customer name and job number.– Performance reporting is facilitated using manufacturing
software.– Performance reports are published monthly.
• Scope changes are not typically re-estimated.– Scope changes affect performance.– Recently began tracking jobs with significant changes.
• All Redline drawings are routed back to MED for updating.• An online feedback tool is available.
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Questions and Answers