Design Process and Control

DESIGN PROCESS AND
CONTROL
ATLAS Project Document. No. Institute Document No. Created Page

Project - System - Institute - Type - Sequential No. 15-Nov-1996 1 of 10
Modified Rev. No.
ATC-OQ-QA-5110 CERN / QAP / 5110 04-Dec-1998 1.1
DESIGN PROCESS AND

CONTROL
Abstract
This document describes the design process applicable to the ATLAS Project from
conceptual design to the release for procurement and during manufacturing. It defines the
design control and documentation and assigns the relevant responsibilities
Prepared by : Checked by : Approved by :

Marcel MOTTIER Bertrand NICQUEVERT Gérard BACHY
Revised by :
Kathy POMMES
for information, Tel. Fax. E-Mail

you can contact : Gérard BACHY
+41 22 767 +41 22 767 95 gerard.bachy@cern.ch
4739 50
Distribution List
History of Changes
DESIGN PROCESS AND
CONTROL

Modified Rev. No.
Rev. No. Date Pages Description of Changes

draft May-96
releases — Draft Reviews by QA Authors
Oct-96
1.0 15-Nov-96 — First issue - for EB approval
1.1 4-Dec-98 — Revision

DESIGN PROCESS AND
CONTROL

Modified Rev. No.
Table of Contents
1. NORMS & REFERENCES...........................................................................................................................................4
2. PURPOSE AND SCOPE................................................................................................................................................4
3. POLICY...........................................................................................................................................................................4
4. RESPONSIBILITIES.....................................................................................................................................................5
5. DESIGN PROCESS & RELATED DOCUMENTATION.........................................................................................6

5.1 CONCEPTUAL, BASIC AND DETAILED DESIGN....................................................................................................................6
5.2 STATUTORY AND REGULATORY REQUIREMENTS..................................................................................................................6
5.3 SAFETY REQUIREMENTS...............................................................................................................................................6
5.4 DOCUMENTATION REQUIREMENTS...................................................................................................................................6
5.4.1 Engineering specifications.............................................................................................................................................6
5.4.2 technical description of market survey..........................................................................................................................7
5.4.3 technical specification of invitation to tender...............................................................................................................7
5.4.4 engineering drawings.....................................................................................................................................................7
6. DRAWING REVIEW AND APPROVAL.....................................................................................................................7
7. DESIGN CONTROL......................................................................................................................................................9
7.1 PRELIMINARY DESIGN REVIEW .....................................................................................................................................9
7.2 DESIGN REVIEW........................................................................................................................................................9
7.3 PRODUCTION READINESS REVIEW ...................................................................................................................................9
7.4 SPECIFICATION REVIEW................................................................................................................................................9
8. DESIGN CHANGES....................................................................................................................................................10
9. CHANGES DURING PRODUCTION.......................................................................................................................10

DESIGN PROCESS AND
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Modified Rev. No.
1.NORMS & REFERENCES

[1]ATC-OQ-QA-1010 Quality Assurance Policy
[2]ATC-OQ-QA-2020 Document Writing Standards
[3]ATC-OQ-QA-2034 Document Types
[4]ATC-OQ-QA-2035 Documents Process & Control
[5]ATC-OQ-QA-2050 Quality Assurance Categories
[6]ATC-OQ-QA-3060 Configuration Management Process & Control
[7]ATC-OQ-QA-5120 Design Standards - Mechanical Engineering and Installations
[8]ATC-OQ-QA-5121 Design Standards - Electrical Schematics
[9]ATC-OQ-QA-5122 Design Standards - Fluids Schematics
[10]ATC-OQ-QA-5130 Drawing Management and Control
[11]CERN's Technical Inspection & Safety Commission : TIS directives
[12]http://atlasinfo.cern.ch/Atlas/GROUPS/notes.html : ATLAS notes/publications/TDR
[13]http://atlasinfo.cern.ch/Atlas/TCOORD/TechCoord/reviews/ : ATLAS reviews
2.PURPOSE AND SCOPE

This procedure applies to the engineering design of ATLAS systems, sub-systems, assemblies,
sub-assemblies and parts from the conceptual design to the release for procurement and
manufacturing.
It establishes design control policy and defines responsibilities and procedures for preparing
and verifying engineering design documents.
It applies to design teams at CERN, in Institutes and at Contractors.
3.POLICY
To implement uniform methods of design and drafting in all engineering groups involved in the
construction to ensure that it meets the specified requirements.
To define the checks and verifications applied to the design and development activity.
To control and verify the design, assign design function responsibilities, define technical
interfaces and verify that the design output meets the design input requirements.
To expose the design to persons with viewpoints and opinion other than those of the design
and development teams.
To maximise protection against oversight that might adversely affect the ATLAS quality, safety
and performance.
To ensure through proper documentation that the design decision process is recorded for
reference in the production, commissioning, operation and maintenance of ATLAS Project.
To ensure that the design change history is properly documented.
To ensure that all technical documents, drawings and specifications will be merged into the
CERN EDMS system.
To ensure the Quality Assurance database also becomes part of EDMS.
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Modified Rev. No.
4.RESPONSIBILITIES
Project Leaders, Project Engineers (PE) and Designers at CERN, Institutes, and Contractors
are responsible for:
 Making all participants aware in performing good engineering and management practices
to meet Project cost, schedule, safety and technical objectives.
 Ensuring that all engineering calculations but specially those related to safety are carried
out by suitably qualified personnel.
 Ensuring that non-staff personnel assigned to design and drafting activity is suitably trained
in the use of Computer Aided Design tools (CAD) and has been informed of CERN
practices before starting work
 Ensuring that detailed designs are consistent with the approved ATLAS configuration.
Approval Groups and dedicated reviews provide additional checks, through reviews, that
detailed designs are consistent with the ATLAS approved configuration.
The ATLAS Project organisation chart assigns responsibilities for the development, design,
manufacturing and commissioning of the systems, sub-systems, assemblies and parts to the
Divisions and Groups, in collaborating Institutes including CERN, that are participating in the
Project.
The ATLAS collaboration is allocating work packages corresponding to the main systems,
sub-systems, assemblies and parts of the ATLAS Project.
A Project Engineer is assigned to each work package.
The Project Engineer of a work package has the responsibility to:
 Assure that prior to starting the design all requirement boundary conditions and functional
specifications and constraints on choice of materials of the desired object are clearly
defined.
 Plan and supervise the design of the products included in the work package.
 Supervise the production of specifications, drawings and layouts.
 Assess the safety requirements of the products and co-ordinate the review of those
requirements with CERN's Technical Inspection & Safety Commission (TIS) 1.
 Supervise the building and testing of models and prototypes.
 Supervise the collection and recording of test data.
 Define the quality assurance category of the product and its sub-assemblies and parts as
described in "Quality Assurance Categories" 1.
 Supervise the processing of modifications in accordance to "Configuration Management
Process and Control" 1.
 Make sure that the EDMS database is kept up to date.
DESIGN PROCESS AND
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Modified Rev. No.
5.DESIGN PROCESS & RELATED DOCUMENTATION
5.1CONCEPTUAL, BASIC AND DETAILED DESIGN

The Technical Design Reports 1 contains the initial functional and technical requirements of the
ATLAS Project.
The requirements given in the Technical Design Report are updated when necessary.
The design process begins with the translation of the conceptual requirements into a functional
specification. Once reviewed, the functional specification requirements are further refined into
basic and detailed design resulting in production and assembly drawings, technical
specifications, procurement documents, manufacturing and tests instructions.
The detailed design activity is carried out at CERN, in Institutes, or at Contractors.
When the design process is completed, the design is released for procurement or for fabrication.
5.2STATUTORY AND REGULATORY REQUIREMENTS

The codes, standards, and practices used for dimensioning the product, selecting materials,
defining manufacturing, assembly, testing and operation procedures shall be defined in the design
documentation. Whenever possible, International Organization for Standardization (ISO) and
International Electrotechnical Commission (IEC) standards and practices shall be used. When
ISO or IEC documents fall short of defining the requirements, they are to be complemented or
replaced by Deutsches Institut für Normung (DIN) documents or by a national code or standard
approved by CERN.
These rules are independent of any national codes and standards applicable in the country of
manufacture of the product.
5.3SAFETY REQUIREMENTS
In application of CERN's TIS directives 1, the PE shall establish whether the product being
designed requires a safety assessment to be carried out by TIS. If required, the TIS safety
assessment should be carried out early enough in the design for its conclusions to be
incorporated in the final design.
5.4DOCUMENTATION REQUIREMENTS
Documents shall be stored in the Engineering Data Management System.
The following documents shall be prepared in accordance with "Document Writing Standards"
1 and managed as described in "Documents Process and Control" 1.
The Engineering specifications (5.4.1) are input, the (5.4.2) through (5.4.4) are output but not
all of them might be required for procurement. The technical description and the technical
specification are needed for procurement from industry.
5.4.1ENGINEERING SPECIFICATIONS
The documentation of the design of a system, sub-system, assembly or part describing how to
manufacture, install and operate that system, sub-system, assembly or part must be done with
Engineering Specifications document type.
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Modified Rev. No.
The Engineering Specifications must contain the Functional Specification, the Interface
Specification and Engineering Requirements to allow an unperturbed design process. 1
5.4.2TECHNICAL DESCRIPTION OF MARKET SURVEY
The purpose of the document is to provide the basic technical description of products for
which a Market Survey is carried out. Market Survey shall also include the qualification
criteria and a questionnaire. 1
The Market Survey tells what the market can offer and which firms could qualify to receive an
Invitation To Tender.
5.4.3TECHNICAL SPECIFICATION OF INVITATION TO TENDER
The Technical Specification provides the detailed technical description of products for which
an Invitation to Tender, a Price Inquiry or a Contract is carried out. 1
The Invitation to Tender, also referred Calls for Tender, are used to obtain price quotations
from Industry with the final objective of purchase.
5.4.4ENGINEERING DRAWINGS
The Project Engineer shall provide the design office with all the necessary information to
prepare engineering drawings. Design criteria approved by the PE should include as
appropriate: performance objectives, operating conditions, requirements for reliability,
availability, maintainability and safety, and the definition of technical interfaces.
The PE shall provide the CDD manager with the information necessary to enable drawing
registration and drawing review and approval. This includes the equipment codes to be used
and their description, the QAC of the products, the names of designers, drawing controllers
and approvers, the applicable drawing release procedure and the CAD software used.
Engineering Drawings shall be prepared in accordance with the appropriate Design Standards:
"Design Standards - Mechanical Engineering and Installations" 1, "Design Standards -
Electrical Schematics" 1, "Design Standards - Fluids Schematics" 1.
6.DRAWING REVIEW AND APPROVAL

Drawings shall be managed as described in "Drawing Management and Control" 1. As a
minimal requirement, checks should be carried out by design office, by project engineers, by
project leader and by project leaders of "neighbouring" subsystems prior to release for reviews
and for production.
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Modified Rev. No.
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7.DESIGN CONTROL
Formal design control is secured by conducting at appropriate stages of the development
Preliminary Design Reviews and Design Reviews. (see Figure 1)
Based on the Design Review, the design can then be finalised to lead to the last internal review,
the Production Readiness Review (PRR) or a Specification Review.
The proposed sequence of reviews are then: (more details in 1)
 Preliminary Design Review, …
 Design Review,
 Production Readiness Review or Specification Review.
7.1 PRELIMINARY DESIGN REVIEW

The Preliminary Design Review shall be carried out by the Project Engineer and his design team.
The reviewers shall be internal and external to the system. Its purpose is to ensure that the basic
design description is complete and unambiguous and corresponds to the conceptual design
requirements.
7.2 DESIGN REVIEW

The Design Review shall be carried out with the Project Engineer and his design team. Its
purpose is to ensure that the basic and detailed design correspond to the basic design description
and that the design is optimised and fullfils all requirements and the documentation is complete
and ready for approval. The review panel shall be composed of external reviewers.
They are usually carried out in parallel with Module zero construction.
All engineering drawings are subject to a Review and Approval process before they are ready for
distribution. (see chap 5.4.4)
7.3PRODUCTION READINESS REVIEW

Before launching the construction of major parts of the systems and engaging major
expenditures, engineering reviews will be organised to confirm the soundness and completeness
of the final design options including all interfaces to neighbouring parts of ATLAS to minimise
the risks (cost, function, schedule).
The Production Readiness Reviews (PRR) are organised by the technical co-ordination and are
intended as final cross-check before production.
7.4SPECIFICATION REVIEW
The Specification Review is performed for components and objects contained in a single
specification before release for fabrication. Similarly to the Production Readiness Review, it
shall ascertain that design requirements are met by the proposed design in respect of
Engineering and Functional considerations, Quality Assurance requirements, Statutory and
regulatory requirements, Safety requirements, Cost and Schedule.
DESIGN PROCESS AND
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Modified Rev. No.
8.DESIGN CHANGES
A formal Engineering Change Request (ECR) is required to initiate a revision of a design when
this design has been released for procurement/production and is included in the ATLAS baseline.
Engineering Change Request shall be prepared and processed as described in "Configuration
Management - Change Process and Control" 1
When a design document, such as a drawing, has been released but has not yet been placed
under Configuration Control, that document can be modified at the initiative of the Project
Engineer. A new revision of the document shall be created and this revision must be submitted to
the same release procedure than the original document.
9.CHANGES DURING PRODUCTION

The Engineering Change Request procedure must also be applied. The final and last version of
the production document must be integrated into EDMS and clearly marked as the real, final,
executed version of an object. 1
The project engineer and project leader must agree on proposed changes.

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DESIGN PROCESS AND

ATLAS Project Document. No. Institute Document No. Created Page