Industrialization of x-band technology and societal impact of

CLICAnastasiya Magazinik on behalf of the CLIC team

High Gradient Workshop 2019, 10-14 June 2019

OUTLINE

CLIC state

Industrial surveys

Industrialization study

Societal Impact Assessment

Conclusion

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CLIC

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Reports on design, technology, and project implementation plan

Key technologies have been

demonstrated

CLIC is now a mature project, ready to be

built

current

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Discs Halves Full

assembly

(disc

version)

Optional

Production

period

(year)

Production

rate

(discs/day)

at 250

work-

days/yr

Production

rate

(halves/day)

at 250

work-

days/yr

Production

rate

(cavities/day)

at 250 work-

days/yr

627 270 43 260 21 630 5 501.82 34.62 17.3

Accelerating structures for 380 GeV is about 8% of the total cost:

Main Linac Modules is ~ 22.6 % of total CLIC 380 GeV cost (from 2018)

AS structures is ~ 37 % of Two Beam Module (from 2010);

CLIC 380 GeV cost CLIC Timeline

AS quantity for 380 GeV

Examples of production

rates

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Project Numbers of cavities Production sharing # cavity

production

Production period Production rate (cavities/day) (at 250 work-

days/yr)

XFEL 640 50% 640 3 0.43

ILC 16 000 100% 16000 6 (=2*3 (XFEL)) 10.7

SwissFEL 104 (113 caps per structure) 100% 104 2 0.2-0.4 (1-2 per week)/23.5 caps per day

CLIC 380 GeV 21 630 100%

50%

21630

10815

5 17.3 /501.82 caps per day

8.65

Industrial surveys

First survey - Industrialization study:

CLIC needs to check feasibility of going from prototype to

mass production phase:

Many parts to be produced;

Limited amount of qualified suppliers;

Are industries ready for thousands of parts?

When will they be ready?

What kind of investment will they need and how this will

affect costs?

How will the production ramp up and down?

Second survey - Societal impact study:

As a part of societal impact assessment

To highlight all possible benefits of the project for main

stakeholders (public, university, government)

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Industrialization study

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Research & Development

DesignPrototype and

mock-upTesting and Validation

IndustrializationSupplier

managementProduction Logistics

Industrialization in a Process

Chain

Industrialization - the transition from the design phase to the mass

production phase.

From the concept to the design the project, up to the development

and implementation of series production, the entire process chain is

designed and optimized to meet the highest quality standards.

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Industrialization

Industrialization …

is critical and requires the consideration of various

constraints: technical, organizational, economic and

human.

requires well-defined milestones and targets

guarantees the achievement of high-level quality and

production targets at lowest production costs.

takes place through the reviewing and adopting all

processes such as purchases, acceptance, production,

testing and inspections to mass production.

Necessary equipment is also validated and completed

to ensure mass production.

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Industrialization

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Design of the production

process

Risk analysis

Validity of equipment

Operator training

Definition of process controls

Setting of inspections

Choose a production

process, plant layout

It is essential to define

adequate monitoring and

achieve the right balance

between quality and cost

Definition and building of

equipment necessary to

production of components

The assurance of training and

competence of personnel

The monitoring at certain

stages of production

guarantees high quality

standards and compliance

with the requirements

The final validation and

tests for delivering a

product without defects

Industrializationstudy

First survey - Industrialization study:

CLIC needs to check feasibility of going from prototype to

mass production phase

Technical specification (TS) and Technical questionnaire (TQ)

TS and TQ were sent to qualified suppliers

For COMPANIES

An exercise of “imagination”,

Companies are asked to project to the situation where they need

to produce 21 630 accelerating structures in five years,

Technical questionnaire aims to guide companies through critical

questions for preparation to mass production

For CLIC

Evaluate capabilities of the current suppliers,

Take corrective actions if required,

Approximate estimation of time , cost and needed infrastructure

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It is not a price inquire for 21 630 structures!!!

Industrializationstudy

Aim:

To evaluate feasibility and efforts for the manufacturing of one of

the most challenging components of CLIC – 12 GHz accelerating

structures;

Three options: discs, halves and assembly.

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Disc (type A)

Halves (type B)

Optional

Full assembly (disc version)

Optional

Fraction of

total no of

structures

Discs

(type A)

Halves

(type B)

Optional

Full

assembly

(disc version)

Optional

Production

period

(year)

Production

rate

(discs/day) at

250 work-

days/yr

Production

rate

(halves/day) at

250 work-

days/yr

Production rate

(cavities/day) at

250 work-

days/yr

Scenario 1 100% 627 270 43 260 21 630 5 501.82 34.62 17.3

Scenario 2 50% 313 635 21 630 10 815 5 250.91 17.3 8.65

Scenario 3 % proposed by company

Production discs or halves

Capacity

Current;

Required.

Production process (see next

slides)

Process type;

Plant layout;

Level of automation;

Subcontracting operations;

Production strategy.

Quality and Communication

Process capability index;

Quality strategy;

Documentation;

Timely communication.

Recycling policy;

No conform part

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Transport and storage

Raw material supply;

Packing procedure;

Delivery strategy;

Stock capacity

Resources

People, training;

Equipment, building etc

Cost and Time

Evaluated investment;

Evaluated cost of

manufacturing

Potential partnership

Production process

Process type:

Batch (moderate volume and moderate flexibility)

Repetitive (high volume and low flexibility)

Continuous (very high volume and very low flexibility)

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Process type

Batch

Repetitive

Continuous

Layout choice

Functional

Cellular (batch flow)

Line-based layoutInte

rm

itte

nt

pro

ce

ss

Decisions concerning process and layout choices (Production

Development, 4th edition, M. Bellgran, K. Safsten, 2010 )

Production process

Plant layout: A decision can be made on the following basic layouts:

(a) Functional layout (functional/process oriented): equipment of the same

type is collocated;

(b) Cellular layout (batch flow): different equipment and processes

needed for making a product are collocated, comparing to the line-based

flow, handling and moving between stations are still manual and still

intermittent process;

(c) Line-based flow (sequential/product oriented. Workers and equipment

are arranged accordingly to the technological sequence required by the

product or service involved;

A combination of the different layouts

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Various type of plant layout (Fundamentals of modern manufacturing,

4th edition, Mikell P. Groover, 2010 )

Quality and communication

How much to inspect and how often?

When to inspect in the process?

Acceptance from supplier?

Process Capability Index (Cpk =1.33 means 30 parts per million

non within specification): to assess the ability of the process to

meet specification.

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Process capability index (Operations Management, 11th edition, William J. Stevenson, 2012 )

Full assembly

Are you interested to deliver a full assembled structure?

Do you have experienced staff, tooling and facilities for:

Cleaning (procedure to be accepted by CERN);

Assembly of structures;

Brazing/bonding facilities;

RF measurements.

Are you interested in a partnership with other

suppliers?

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Societal impact assessment

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What is an impact? What is a societal impact?

1. What is an impact?

“Measure of the tangible and intangible effects (consequences) of one thing's or

entity's action or influence upon another.” from BusinessDictionary

2. What is social impact?

Social impact indicates the contribution of the research to the social capital of a

nation (e.g., stimulating new approaches to social issues, informed public debate, and

improved policymaking).

3. What is societal impact?

The superior to social and is concerned with is the assessment of social, cultural,

environmental, and economic returns (impact and effects) from results (research

output) or products (research outcome) of publicly funded research.

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20

WHY?

- To help decision

making process;

- To promote a

project;

- To evaluate all

types of benefits.

…and HOW?

WHAT?

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Societal Impact Assessment

Second survey - Societal impact study:

As a part of societal impact assessment

To highlight all possible benefits of the project for main

stakeholders (Public, university, government)

Provide the results to a European Strategy committee in

2020

General Industrial survey – online

https://forms.gle/WAvB86wk1fzmQCaP7

All CLIC suppliers

Questions about environment, people, resources etc.

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Societal Impact Assessment

Company general information to asses societal impact of

CLIC;

There are questions related to social, environmental,

scientific, technological impacts;

Some information about previous business with CERN or

other scientific laboratories;

Questions:

Company size, turnover;

Application of X-band technologies for other business;

Requests from other laboratories;

Attending conferences;

Publications or patents.

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Societal Impact Assessment

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https://forms.gle/WAvB86wk1fzmQCaP7

Societal Impact Assessment

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Japanese Company Visit February 2019

With a great help and perfect “ultra-precise” organisation by Toshi

Higo and Akira Yamamoto

The visit to Japanese company was organised in February 2019;

The idea behind

To get feedback from high-tech companies based on KEK experience

collaboration;

To compare Japanese and European approaches for mass production.

Five companies in UP machining:

MORIKAWA

JUKEN

MHI

K-PRO

U-Corporation

All companies were very welcoming and enthusiastic about further

cooperation.

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Industrial surveys

Summary

The technical questionnaire (Industrialization) was distributed

To five Japanese companies during the visit in February 2019;

Up to now received the feedback from two companies;

To seven European qualified supplier in UP machining (four

companies) and bonding (three companies) in April 2019;

Discussion phase.

General questionnaire (Societal Impact Assessment)

Pilot distribution to a few frequent supplier of RF components (6

companies)

Up to now receive the feedback from four companies.

Planning to contact more than 300 suppliers.

With the assistance of CERN procurement service

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Conclusion

Industrialization study has been launched with

qualified companies. Expecting feedback in

Summer 2019.

Answers expected in three months.

General Industrial Survey is under preparation. The

survey will be distributed in July 2019.

Estimated time to fill in ~1 hour.

Expected feedback from companies:

Technical questionnaire completed as much as

possible;

Comments and suggestions;

Feedback and cooperation.

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EXTRA

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CLIC cost

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380 GeV: ~5.9 BCHF

Upgrade to 1.5 TeV: ∼ 5.1 billion CHF

For klystron 1.5 TeV: 25% more expensive

Upgrade to 3TeV: ∼ 7.3 billion CHF Project Implementation Plan 2018

Maintenance cost 116 MCHF per year.

Reference: CLICTechnology

Graph: Company

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Reference:Company

Graph: CLICTechnology

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Reference: orders

Technogram

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Laboratories (collaborators)

FERMI FEL

VALENCIA S-BAND

X-BAND TEST STAND TSINGHUA

AWA FACILITY

EUPRAXIA@SPARC_LAB

COMPACT LIGHT AT LNF-INFN

LANL

SXFEL

PSI

CLARA

SMART*LIGHT

DESY

VHEE

LANL

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38

Clic costs

380 GeV: ~5.9 BCHF

Upgrade to 1.5 TeV: ∼ 5.1 billion CHF

For klystron 1.5 TeV: 25% more expensive

Upgrade to 3TeV: ∼ 7.3 billion CHFProject Implementation Plan 2018

Maintenance cost 116 MCHF per year.

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39Accelerators in the world

Based on the review from 2014 (Florio, M.,

Bastianin, A., Castelnovo, P., 2018):

27 000 accelerators in industry

14 000 for medical purposes

1200 for basic research

(Florio, M., Bastianin, A., Castelnovo, P., 2018)

Industry

64%

Medical

33%

Basic

research

3%

Number of accelerators 2014

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Accelerators only at CERN

LHC is the world’s largest and most powerful particle accelerator (27 km ring) successfully operated

for the first run 2009-2013 and for the second run 2015-2018.

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Stopped for two years for major upgrade and

renovation works, restart in 2021.

From 2025 The High-Luminosity LHC (HL-LHC)

increase luminosity by a factor 10 beyond LHC

design value.

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