Philip G. Cutino, P.E. Engineering 10 Presentation April 19,
2012 Chabot College, Hayward CA
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Mr. Phil Cutino ENGR10 Sp12 Todays Agenda SLAC National
Accelerator Laboratory SLAC National Accelerator Laboratory Linac
Coherent Light Source (LCLS) Linac Coherent Light Source (LCLS) My
role at SLAC over the years My role at SLAC over the years The
Mechanical Fabrication Department The Mechanical Fabrication
Department
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Mr. Phil Cutino ENGR10 Sp12 Location: Menlo Park, CA Location:
Menlo Park, CA Type: Multi-program Laboratory Type: Multi-program
Laboratory Contract Operator: Stanford University Contract
Operator: Stanford University Website: www.slac.stanford.edu
Website: www.slac.stanford.edu Physical Assets: Physical Assets:
426 Acres 426 Acres 145 Buildings 145 Buildings 1.8M GSF in Active
Operational Buildings 1.8M GSF in Active Operational Buildings
Human Capital Human Capital Employees: 1,496 FTE as of 4/15/08
Employees: 1,496 FTE as of 4/15/08 Users, Visiting Scientists and
Grad Students: 3036 Head Count Users, Visiting Scientists and Grad
Students: 3036 Head Count Stanford Linear Accelerator Center
Slide 4
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. 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.
Slide 5
Mr. Phil Cutino ENGR10 Sp12 Research at SLAC Accelerator
Physics Accelerator Physics Astrophysics and Cosmology Astrophysics
and Cosmology Elementary Particle Physics Elementary Particle
Physics Materials and Nanoscience Materials and Nanoscience
Molecular Environmental Science Molecular Environmental Science
Structural Biology Structural Biology Ultrafast Science Ultrafast
Science http://www6.slac.stanford.edu/Research.aspx
http://www6.slac.stanford.edu/Research.aspx
http://www6.slac.stanford.edu/Research.aspx
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Mr. Phil Cutino ENGR10 Sp12 LCLS Total Machine* : ~1750 meters
of beam line 1242 Devices Injector: 28 meters of beam line & 95
devices Linac 1003 meters 708 devices 708 devices LTU & Dump
408 meters 176 Devices *Electron Beam Line Only Does not include
Photon Beam Lines Does not include Photon Beam Lines
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Mr. Phil Cutino ENGR10 Sp12 Linac Coherent Light Source
Ultrafast X-ray science Ultrafast X-ray science Directly observe
the motions of atoms on ultrafast time scales Directly observe the
motions of atoms on ultrafast time scales Investigate dynamics,
bonding, heating and melting, at atomic and nanometer length scales
Investigate dynamics, bonding, heating and melting, at atomic and
nanometer length scales Create and observe extreme new conditions
in atoms and materials Create and observe extreme new conditions in
atoms and materials Imaging of nonperiodic molecules and
nanostructured materials Imaging of nonperiodic molecules and
nanostructured materials Worlds first X-ray free electron laser
Worlds first X-ray free electron laser Producing 100 femtosecond
pulses of photons in the energy range 800- 8,000 eV Producing 100
femtosecond pulses of photons in the energy range 800- 8,000 eV 10^
12 coherent X-ray photons/pulse 10^ 12 coherent X-ray photons/pulse
Potential for sub-femtosecond pulses Potential for sub-femtosecond
pulses Lead nanoscale science revolution Lead nanoscale science
revolution Master control of energy-relevant complex systems Master
control of energy-relevant complex systems Lead the world in the
investigation of dynamics of atomic transitions, chemical bonding,
catalysis and heating Lead the world in the investigation of
dynamics of atomic transitions, chemical bonding, catalysis and
heating
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Mr. Phil Cutino ENGR10 Sp12 Links to More Information
http://www.slac.stanford.edu http://www.slac.stanford.edu
http://www.slac.stanford.edu http://lcls.slac.stanford.edu
http://lcls.slac.stanford.edu http://lcls.slac.stanford.edu
http://www6.slac.stanford.edu/ExploringSLACScie nce.aspx
http://www6.slac.stanford.edu/ExploringSLACScie nce.aspx
http://www6.slac.stanford.edu/ExploringSLACScie nce.aspx
http://www6.slac.stanford.edu/ExploringSLACScie nce.aspx
https://news.slac.stanford.edu/ https://news.slac.stanford.edu/
https://news.slac.stanford.edu/
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Mr. Phil Cutino ENGR10 Sp12 Atypical career path Mechanical
Engineer Mechanical Engineer Register Professional Engineer in CA
Register Professional Engineer in CA Returned to school late in
life Returned to school late in life Diverse background... Diverse
background... ~25 years with the same employer ~25 years with the
same employer Four different jobs Four different jobs
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Mr. Phil Cutino ENGR10 Sp12 My Roles at SLAC Process Control
Instrumentation Technician Process Control Instrumentation
Technician Facilities Engineer Facilities Engineer Accelerator
Engineer Accelerator Engineer Mechanical Fabrication Department
Head Mechanical Fabrication Department Head
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Mechanical Fabrication Department Phil Cutino October 27,
2010
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Mechanical Fabrication Department Page 12 Mission and Vision
Mission Provide specialized manufacturing and field support
services necessary for the Lab to achieve its 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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Mechanical Fabrication Department Page 13 Delivering SLACs
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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Mechanical Fabrication Department Page 14 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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Mechanical Fabrication Department Page 15 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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Mechanical Fabrication Department Page 16 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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Mechanical Fabrication Department Page 17 Core Competencies
continued Machine Shop Clean Machining for UHV Quick Turnaround
Radioactive Materials DFM & Prototype Parts
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Mechanical Fabrication Department Page 18 Core Competencies
continued Hydrogen Furnace Brazing And Heat Treating
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Mechanical Fabrication Department Page 19 Core Competencies
continued Metal Finishing Plating and Cleaning for UHV
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Mechanical Fabrication Department Page 20 Core Competencies
continued Mechanical and Vacuum Processing and Field Operations
Precision Assembly
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Mechanical Fabrication Department Page 21 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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Mechanical Fabrication Department Page 22 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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Mechanical Fabrication Department Page 23 Performing Work
continued Collaborative 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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Mechanical Fabrication Department Page 24 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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Mechanical Fabrication Department Page 25 Questions and
Answers