126 Ridge Road Tel: (607) PO Box 187 Fax: (607) Manufacturing Capabilities

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1 Manufacturing Capabilities ADC consists of different departments to make up the framework of our operations. This includes; Engineering Design and Analysis, Manufacturing and Planning, Temperature Control/Clean Room Assembly/Testing Facility, Ultra-High Vacuum (UHV) Facility, Metrology Laboratory, Magnetic Measurement Facility (Undulator Testing Facility), and Electronics and Instrumentation. Each department plays an important role in the capabilities we offer our customers. It is rare to find this myriad of capabilities in one company. At ADC, each large long-term contract is assigned dedicated space in our machine shop, assembly area, or both, depending on the size and nature of the contract. ADC will make sure from the beginning that there will be sufficient resources available for manufacturing, assembly and testing. ADC has built a solid relationship with its material suppliers. Since we have also started to implement ISO 9001, all of our suppliers have been, or will be, certified by our QC department. Every part is thoroughly inspected on arrival. Our personnel are trained and experienced in ADC s strict quality control program. Material certifications are examined and properly filed. Machine Shop Our Manufacturing department is dedicated to fabricating, installing, and servicing systems to satisfy our customers' needs fully. State-of-the-art technology is used to build a wide variety of equipment square feet of floor space was added to our manufacturing department and includes a welding room, shown below, (TIG, MIG, and other types), EDM machining, CNC machining including a MG 840 Gantry Bridge CNC Vertical Machining Center, and precision grinding. Forklifts allow us to move the most massive structures among the work areas during the fabrication process. Welding Room

2 We have most recently acquired three machining centers from HASS, shown below, and a Lucas Table Type Horizontal Boring Mill, shown on the following page. We have also set up a computer station with the appropriate program packages so that we can feed our CAD drawings directly into our machining centers. HAAS Machining Centers

3 Lucas Horizontal Boring Mill Mastercam X6 CAD/CAM Software has been certified for Autodesk Inventor D mechanical design software under the Autodesk Inventor Certified Applications Program. Digital Prototyping with Autodesk Inventor software gives ADC the ability to digitally design, visualize, and simulate how a product will work under real world conditions before it is built, which helps reduce cost and increase efficiency.. This will reduce our cost, improve our quality (allows more complicated shapes for fabrication) and improve manufacturing schedules. Mastercam Software Station

4 We also have an 8,000 lb and 16,000 lb Toyota industrial forklift available for moving parts throughout the shop. Toyota Forklift One change that we applied over the last 5 years that has greatly improved our scheduling is to farm out fabrication. Even though we maintain a state-of-the-art machine shop, we have removed the process bottle-neck by using a small group of highly qualified fabrication suppliers within a 2 hour drive from ADC. We keep our shop for emergency machining and to maintain the skill which is necessary to construct complex mechanical machines. Below and on the following pages are machines in which ADC utilizes at local machine shops. MG 840 Gantry Bridge CNC Vertical Machining Center built by WELE Local Shop for Large Machining Projects

5 Large Travel CNC Vertical Machining Center Local Shop for Large Machining Projects Large Travel CNC Vertical Machining Center Local Shop for Large Machining Projects

6 Large Travel CNC Vertical Machining Center Local Shop for Large Machining Projects Quality Control Room for Large Machining Projects Quality Control Room for Large Machining Projects

7 ADC Quality Control Room (Temp Control) Factory Acceptance Test (FAT) ADC Large Surface Plate For Precision Assemblies

8 Examples of Manufacturing Jobs Cavity Parts for Spallation Neutron Source ADC fabricated 24 sets of the space frame and thermal shield assemblies for the U.S. Department of Energy Spallation Neutron Source program. This work involved sheet metal rolling, bending, ASME certified brazing operation, precision machining, ASME certified welding, vacuum cleaning, and vacuum testing. Each system underwent complete testing and inspection which included thermal shock, leak checking, and precise physical measurements.

9 Jefferson Lab 12GeV Upgrade ADC fabricated and is assembled ten sets of C100 Cryomodule Space frame Assemblies for the Jefferson Lab 12GeV cryomodule upgrade. The project required fabricating jigs and simple fixtures to ensure important components are maintained to specified tolerances. This work involved; precision machining, ASME certified welding, and vacuum cleaning. Each space frame has a 13 page test report provide to JLab detailing dimensions and welding. Travellers are provided on each space frame. Each space frame is verified by a third party source. For additional information regarding this project, please visit: /Space-Frame-for-Jefferson-Laboratories

10 H-Steel for Jefferson Laboratories Magnet Upgrades ADC fabricated all of the H-Steel for Jefferson Laboratories 12GeV Upgrade dipole magnets. This work contained various sizes of A1006 steel bars/plates to be used in the rebuild of the 12GeV upgrade dipole magnets. All the metals had to come from the same heat, parts then had to be heat treated with very strict quality control, the project required precision machining with tight tolerances and extremely tight quality control keeping track of each parts and its history/specifications. For additional information regarding this project, please visit: /H-Steel-for-Jefferson-Laboratories-Magnet-Upgrades

11 Secure Web-Data Storage Development and Project Communication Online Reviewing of the Project A secured web site is the most important part of the multiple channels needed to ensure adequate communication among ADC personnel and the client general oversight community. ADC s web site ( has a location that the customer can login and review critical data that contains sections detailing the progress and planning parts of the process for on-demand review. The web site will be a searchable index of literature, design updates, FEA calculations, progress reports, pictures, comments, and recommendations. GoTo Meeting ADC uses online video conferencing and real time computer screen sharing using GoTo Meeting. GoTo Meeting is an online services division of Citrix Systems, Inc. is based in Santa Barbara, California, with satellite offices and data centers around the world. GoToMeeting allows ADC to host online meetings with up to 25 people so we can do more and travel less. Using our web conferencing tool, you can share any application on your computer in real time. Attendees join meetings in seconds. Sample GotoMeeting Screen with CAD in the background

12 Monthly Reporting At the beginning of each month a monthly progress (below) is given out to the customer. This report reviews the past months progress and will state any issues or problems that may have come up. Sample Monthly Report

13 Documentation Complete documentation, manuals and instructions, all in English, are provided before final acceptance tests are approved. Documentation covers all components and include the following: part and assembly travelers (below) data sheets, test protocols, and instructions for service. Drawings of the mechanical assemblies and diagrams of all electrical wiring will be included. Operating manuals contain instructions for all functions of the equipment, control and alignment procedures. Sample Part Traveler

14 ADC s IT Infrastructure and Backup System ADC s Server Hardware Backup System ADC has a hi-end computer network system using the latest hi-tech equipment. This infrastructure of computers helps ADC to continue on its path to being a leader in the array of high-precision components and instruments. ADC Internal Computer Network ADC is running a Gigabit network backbone; Each dedicated workstation is connected to a 3Com SuperStack 3 Baseline Switch, and; All computers at ADC are running a Windows XP or Windows 7 Operating System or better. Backup Synopsis The minimization of recovery time in the event electronic files need to be restored is considered paramount in the electronic file backup procedures at ADC. Hardware and software comprising the electronic file backup system are to be approved by the IT manager, and are to be installed, configured, and maintained per specifications. Only media approved for digital data storage are used with the backup system. Recovery time from server downtime and/or file loss, should files need to be restored. Backup of File Server(s) A full backup of all electronic data files is performed daily Monday through Friday each week, at which time an end-of-the-month copy is maintained in an off-site storage area for at least five years; the daily Monday through Friday copies are overwritten throughout the next month. To recover space on the file server(s), or to "consolidate" data after completion of a project, electronic data files are archived on an as-needed basis. Two copies of all data files to be removed from the file server(s) are made. One copy is stored on-site and a second copy is stored in an off-site storage area for at least five years. The backup of electronic files is verified by the software to be accurate after each copy is made. Any errors occurring during the backup are documented. Backup of User WorkStations All dedicated user workstations are equipped to be backed up via mirroring to a data server. The following directories an automatically backed up every 4 hours Mon Sat. All Outlook setting and folders My Documents directory per user