Splice Machine Management

Transcription

1 Splice Machine Management Care, Cleaning, Inspections and Accountability OTI Splice Machine Management 1 of 14 10/5/11

2 Table of Contents 3 Splice Machine Assets 3 Expectations on Project Managers 3 Expectations on Lead Techs and Technicians 4 Splicer Cleaning Tools and Supplies 5 Splice Machine Inspection and Reporting Process 5 Daily General Inspection and Arc Check (Technician) 6 Weekly Inspection and Standard Cleaning (Technician) 7 Supervised Monthly Inspection/Deep Cleaning (Tech + LT/PM) 9 Splice Machine Monthly Report (PM) 10 Quarterly Splicer Inspection and Photo Record (PM) 11 Splice Machine Damages and Repairs 11 Damage Reporting 11 Follow Up Instructions 12 Down Time and Loaners 12 Charge Backs for Slice Machine Issues OTI Splice Machine Management 2 of 14 10/5/11

3 Splicer Assets Second only to fleet vehicles, fusion splice machines account for the most expensive technical tools and equipment in the On Trac inventory. This equipment is VERY expensive to purchase AND quite costly to repair. However, proper maintenance of splice machines is fairly SIMPLE and CHEAP. Good asset management for On Trac means a close eye on fusion splicers and more diligent management of those responsible for their use and care. For this reason, On Trac dictates diligent attention to this management document and future edits. Expectations on Project Managers On Trac system Project Managers (PM) bear the responsibility of assuring that all fusion splicers assigned to their local operation are well accounted for, well maintained, and daily active in production use by competent technicians. Corporate expectations in this area include the following: Fusion splice machines will be assigned by Issue Agreements to TRAINED and CERTIFIED On Trac Technicians only. Fusion splice machines will undergo diligent and regular inspections and reporting. Lead Technicians and Drop/Splice Technicians will be held accountable for splicer/equipment condition, as well as for securing splice machines against theft or loss. Project Managers will communicate immediately to the Director of Technical Operations concerning any splicer problems or malfunctions. Establish an area in the shop or office to serve as a cleaning station with good lighting, clean surfaces, and storage for cleaning tools and supplies. Expectations on Lead Techs and Technicians Technicians, as well as Lead Technicians who train and assist, bear the responsibility of careful daily maintenance and careful handling/use of fusion splice machines. Corporate expectations in this area include the following: Splice machines will be inspected each day (including an Arc Check) before production work begins. Splice machines will undergo a general cleaning each week. Technicians will conduct a monthly deep cleaning of the Electrodes and Prism while under supervision of a Lead Technician or PM. Technicians will handle and operate fusion splice machines with great respect and care in the field- including proper storage and carrying. Technicians will bear financial responsibility for splicer abuse, misuse, or professional cleaning services. Technicians will communicate IMMEDIATELY to LT and/or PM concerning any problems or issues with their assigned splice machine OTI Splice Machine Management 3 of 14 10/5/11

4 Splicer Cleaning Tools and Consumables Each system is issued a beginning Splicer Cleaning/Inspection Tool Kit containing the required tools along with initial supplies necessary to perform the weekly, monthly and quarterly inspections and cleanings. Project Managers are required to maintain the tools and supplies related to these tasks and to report to the Director of Technical Operations (DTO) should any tools need replacing. The Splicer Cleaning/Inspection Tool Kit and all related supplies should be kept at a general cleaning station accessible to Techs and Lead Techs. This area should be well lighted, clean, and free of draft/breezes. The cleaning area should also be located to minimize distractions to allow anyone working on splice machines to be as focused and attentive as possible. The area should have access to a shop vac. Whenever cleaning supplies run low, the technicians should notify the PM so these materials can be purchased and stocked. AT NO TIME SHOULD THE TOOL KIT OR SUPPLIES BE USED FOR ANY OTHER PURPOSE THAN SPLICER MAINTENANCE! Questions related to splicer cleaning tools and materials should be addressed to the DTO. Dedicated Tools for Splicer Cleaning 1. Small screwdriver set 2. Small scale Allen Wrench set 3. Soft bristle cleaning brush 4. Magnifying glass 5. Tweezers set 6. Electrode cleaning disk 7. Alcohol dish Dedicated Consumable Supplies for Splicer Cleaning 1. 32oz bottle of 99% alcohol 2. Standard Q-Tips 3. Kim Wipes 4. Chemtronics Foam Swabs 5. Fusion Splice mirror cleaning swab 6. Can of Compressed Air (for cleaver & accessories only) 7. General Purpose cleaner/wipes 8. Fiber strands (system/customer specs) OTI Splice Machine Management 4 of 14 10/5/11

5 Splice Machine Inspection and Reporting Process The regularity and routine built into the following processes are designed to minimize costs and frustrations with splicer issues which have grown in number over the past few years. On Trac is convinced that a dedicated process with splicer machines similar to fleet vehicles/trucks will enhance our effectiveness and provide more efficient tools for technicians. More specifically, this process will meet three important objectives: 1. The first objective is to instruct Project Managers, Lead Technicians, and Splice Technicians in the proper way to maintain splice equipment. 2. The second objective is to diligently track the condition of each splice machine in order to proactively schedule repairs/updates and minimize lost production. 3. The third objective is to establish firm accountability to underscore the critical responsibility related to these expensive and delicate machines. Daily General Inspection and Arc Check Any/all Technicians assigned a fusion splice machine MUST follow this inspection/check routine at the beginning of EVERY production day. This routine will not take long and includes both a general condition inspection and an Arc Check. The Arc Check is important because fibers melt or fuse at different temperatures, so it is necessary to adjust the arc power to ensure optimum splicing results. NOTE: Arc Check function is not available on EFS-150 machines. For ANY discrepancies found through the general inspection or Arc Check, notify your supervisor immediately. Daily General Inspection 1. Take an overall inventory of splice machine kit that has been assigned to you. Make sure that all fiber holders, cleavers, chargers, carrying bag, accessories and any tools that may have been assigned to you are in your possession and in working condition. 2. Look for any damage that you may not have noticed from the previous day of work. 3. Check the splicer and cleaver for any loose screws. Check for any loose or missing pieces and parts such as heat oven cover, rubber pads, and magnets. 4. Inspect soft carrying bag for any screws or pieces that may have become detached from your splicer or cleaver. Remove any debris or trash from the carrying case or soft bag. Remove any tools from the carrying case that do not belong. 5. Inspect all carrying straps. Insure that all latches and straps are secure and that there is no chance of them malfunctioning. Inspect the general condition of the bag- note any tears or seams coming undone. 6. Perform the daily Arc Check: OTI Splice Machine Management 5 of 14 10/5/11

6 Daily Arc Check 1. Strip, clean, and cleave fibers just as you would when performing a splice and load fibers into the machine. Select MENU on your screen and then select Arc Check and press Enter. 2. The splicer will automatically feed the fibers and discharge an arc. 3. During the arc discharge, the fiber feeding motors remain idle, preventing the fiber ends from butting. As a result the fiber ends melt back. 4. The arc check function measures how far the fibers melt back and the centered position of the fiber. If the arc check results are good, the message RESULT: OK is displayed in the pop-up window. Press OK or Cancel to return to the MENU screen. 5. If the message RESULT: NG Try again is displayed, press RETRY and the machine will automatically adjust the arc power, and then return to the menu screen. Once this occurs you will need to begin the check process again from Step 1 with freshly cleaned and cleaved fibers. 6. If after four (4) attempts the arc check does not display RESULT: OK, then you need to consult your supervisor and perform a full inspection and deep cleaning of the splicer machine (see Monthly Inspection process). Weekly Inspection and Standard Cleaning Any/all Technicians assigned a fusion splice machine MUST follow a detailed cleaning of the splice machine, cleaver and all accessories at the end of each week, or weekly as assigned by the PM. MOST field problems with splicers can be traced to DIRTY machines and failure to clean machines with the proper technique. Do not skip ANY of the following steps: 1. Clean the outside of the splice machine. Use general purpose cleaner to wipe down the entire outside of the machine. Scrub off all d-gel, dirt, dust and built-up grime from the exterior of the machine. Use Q-tips for getting into small crevasses. Remember- grime on the OUTSIDE eventually gets into the INSIDE! 2. Use alcohol and a soft bristle brush to carefully clean fiber holders. 3. Use alcohol and Q-tips to carefully clean all magnets and magnet contacts. 4. Use alcohol to clean all rubber pads. 5. Clean the top of the fiber clamps with Q-tips and alcohol. The fiber clamps are located in the windshield and help press the fiber into the V-grooves. 6. Use Q-tips and alcohol to CAREFULLY clean v-grooves and also use a properly prepared fiber to run thru v-grooves to remove dust and dirt build up. NOTE: The V-grooves are made of a brittle ceramic material. Clean carefully. DO NOT use any abrasive tools such as metal to clean V-grooves. 7. Look for signs of moisture around screws and metal parts, clean with alcohol as needed. 8. Use Q-tips and alcohol to clean inside of heat oven. 9. Use alcohol and Q-tips to clean all around the cleaver (compressed air can also be used on cleaver to remove dust from crevasses) OTI Splice Machine Management 6 of 14 10/5/11

7 10. Use compressed air on battery charger and battery to remove dust and dirt from contacts. NOTE: BE CAREFUL WITH COMPRESSED AIR CANS.. NEVER use compressed air near the mirrors or the cameras inside the splice machine. Compressed air should be used ONLY on the cleaver, fiber holders, heat oven, and accessories. 11. Use Shop Vac to remove dust and trash from soft carrying bag. 12. Perform a standard Daily General Inspection. Supervised Monthly Inspection/Deep Cleaning Any/all Technicians assigned a fusion splice machine MUST perform a detailed cleaning of the splice machine, cleaver and all accessories at the end of each month, or monthly as assigned by the PM. This monthly process is in ADDITION to the normal weekly cleaning. The monthly check MUST be conducted under the supervision/observation of a Lead Tech and/or Project Manager. Following this monthly inspection, the Project Manager will evaluate, conduct a visual check, make notes, and submit a standard Splice Machine Monthly Report to corporate officers validating that the machine is in good working condition and that the assigned checks and cleanings are performed. The supervised monthly inspection and deep cleaning includes the following four areas: 1. Perform a Weekly Inspection and Standard Cleaning. 2. Cleaning Electrodes During the course of normal operations, the electrodes can be cleaned and maintained for up to 5000 splices. However, over time the electrode tips become rounded and a combination of melted glass particles and dust form a thin layer of grime on the electrodes themselves which must be removed to produce optimum results. Perform the following steps to properly clean the electrodes. a. Loosen the screws of the Holding Plates, and raise the plates. Be careful not to drop the electrodes into the machine. Use tweezers to hold the electrode while loosening the Holding plate. b. Carefully remove the electrode making sure nothing touches or bumps the electrode. c. Use the electrode sharpener to sharpen and clean the electrode tip. Firmly stick the electrode into the electrode sharpener and turn/twist the electrode 3 to 4 times. You can use all faces of the electrode sharpener. NOTE: Do NOT grasp the electrode knob; instead, grasp a section of the electrode rod while twisting. d. Wipe the electrode tip with a Kim Wipe dampened with alcohol. Wipe in a direction from the knob to the point being careful not to damage the tip of the electrode. e. When loading the electrode into the splicer, push the electrode knob flush with the holding plate to ensure correct position. f. Tighten the screws of the Holding Plates uniformly. NOTE: Do not over-tighten the screws! g. Close the windshield and press the ARC button at least 5 times to burn off any residue remaining. h. 3. Cleaning the Prism If the prism (some people say the mirror ) becomes dirty, the splicer will encounter difficulties inspecting/reading the fiber and can give you false error messages such as fiber OTI Splice Machine Management 7 of 14 10/5/11

8 not present or not aligned properly. Splice machines have two prisms for reflecting the LED light and these are located in the windshield. Perform the following steps to properly clean the prisms. a. First, open the windshield and visually inspect the prisms for dust and particles noticeable to the naked eye. If dust or dirt can be seen visually, take care to wipe with a moistened swap in one direction to remove these particles. b. Once all noticeable dust and dirt is removed, wipe with a second swab moistened in alcohol, applying slight pressure and in a circular motion. NOTE: Never use compressed air on mirrors or camera lens AND never use acetone to clean mirrors or camera lens. 4. Cleaning the Cleaver The S325a Cleaver is a high precision one-step cutting instrument. The blade has 16 positions printed on the side of the blade itself. Each individual position can process up to 2,000 cleaves cleanly. However, the number of doable cleaves is decreased drastically by dust, oil and grime. So, if the cleaver is properly cared for and cleaned REGULARLY, the blade will only have to be replaced after approximately 30,000 cleaves or splices. Which computes to never, with the amount of splices a technician generally perform with these cleavers. Perform the following steps to properly clean the cleaver. a. Wipe down the exterior of the cleaver with a paper towel and general purpose cleaner. b. Use Q-tip and alcohol to clean all rubber pads, magnets, and fiber holder carriage. c. Use swab and alcohol to clean the blade. Take extra CARE while wiping the blade, touching the actual cutting edge with your fingers or swabs can dull the blade. Compressed air may be used on and around the blade to remove dust and to dry excess alcohol. d. Remove waste box and empty fiber shards into an appropriate trash container for raw fiber. Do not stick your finger into the waste box because fiber shards may still be present. e. Consult your supervisor for direction on how to make adjustments to the cleaver. NO adjustments will be made without prior authorization! f. Any advancement of cleaver blade position MUST be made with approval of Project Manager and MUST be noted on the Monthly Splicer Report OTI Splice Machine Management 8 of 14 10/5/11

9 Splice Machine Monthly Report Project Managers will visibly inspect each splice machine DURING and following the Supervised Monthly Inspection and Deep Cleaning. From these inspections, the PM will produce a report using the Splice Machine Monthly Report form available from the On Trac SharePoint website (sample below). Completed forms will be part of standard paperwork forwarded to corporate via packets. Again, a separate form is required for EACH splice machine. Splice Machine Monthly Report Date: System: Splicer Model & serial# Splice Count Assigned to (Tech name): Please respond to these four areas based on your PERSONAL review and supervision of the Monthly Inspection and Deep Cleaning process on this particular splice machine: 1. From your observations and notes, give your estimation of the EXTERIOR CONDITION. Specifically, note exterior cleanliness and loose or missing parts and/or screws. Report on any signs of damage such as broken heat oven cover or for any roughed up corners or scratches to plastic or rubber parts: 2. From your observations and notes, give your estimation of the condition of the ELECTRODES and PRISM. Note overall cleanliness, operational function, and record any observed problems. 3. From your observations and notes, give your estimation of the CLEAVER CONDITION. Note overall cleaver cleanliness, operational function, and record any lose or missing parts or screws. Note any dust and/or glass shards accumulated in corners and crevasses. Note if blade position has been advanced. 4. Inspect thoroughly the Carrying Case and Accessories for cleanliness and wear. Inspect for dust/dirt or trash. Note condition of all straps/clasps for wear and cleanliness. Inspect all fiber holders, power supplies, and chargers for cleanliness and proper operation. Give estimation of CASE/EQUIPMENT CONDITION. I attest to the care/condition of this splice machine as noted above. In addition, I confirm by my signature that the full process of daily, weekly, and monthly inspections/checks have indeed occurred under my leadership. Project Manager Signature OTI Splice Machine Management 9 of 14 10/5/11

10 Quarterly Splicer Inspection & Photo Record At the close of each quarter through the year, the Project Manager will add to the normal monthly inspection an additional step of creating a photographic record documenting the condition and status of each machine. This particular form of inspection and documentation will also be repeated whenever a splicer is transferred from one system to another, or is re-issued to a different technician. The Quarterly inspection includes ALL of the same checks as the Monthly Inspection/Deep Cleaning, but with the important addition of digital photo files. This process requires a total of 12 specific images (min. 5 mega-pixels) for each splice machine. Each digital image MUST include the date stamp digital function and saved/named by the serial # and photo title. The exact model/order for the 12-image photo documentation is as follows: Kit Holders Open Splice Table Splicer Closed Cleaver Closed Bag Outside Splicer Open Cleaver Open Bag Inside Holders Closed Charger Cleaver Bag OTI Splice Machine Management 10 of 14 10/5/11

11 Splice Machine Damages and Repairs In the past, damages and cleaning charges have mostly been borne by On Trac. These costs are now excessive and MOSTLY result from mismanagement and mishandling of splicer machines. Beginning in 2011, this dynamic is reversed where Project Managers, Lead Technicians, and Technicians themselves will bear the greater share of accountability and responsibility for conditions and costs related to splice machines. The protocol outlined in this section are designed to better identify the condition of the splice machine and alert On Trac to issues that need attention or repair. Keep in mind that any and all discrepancies are required to be documented. The correct manner of reporting, repairing and determining cause of breakage/damage begins with the Project Manager. Damage Reporting Discovering a Problem At ANY time during a daily, weekly, monthly, or quarterly inspection some damage or discrepancy is discovered, please STOP and record the problem. This might include anything like cleaver not cleaving properly, missing parts, electrodes worn, battery weak, or general signs of damage. This is also the obvious step if a splice machine is reported not functioning by a technician. Report the Problem. Immediately the details of the problem to the Director of Technical Operations (bradslipher@ontracinc.net). This report should include the discrepancy/damage as observed, the serial # of the machine/equipment, the assigned, the circumstances in which the discrepancy/damaged occurred or was discovered, and if the equipment is still operational and able to perform its function properly. Also include any relative information since the last inspection. Follow Up Instructions Following the damage reporting , you will receive instructions from the DTO. Common follow up to a damage report will likely be a resolution call with the DTO, or a Purchase Request to replace missing or damaged parts, or a full Repair Order. Potential Action Resolution Call. If the DTO believes the problem may be resolved over the phone, or if he has questions or concerns about a repair or incident, he will call you with specific instruction. When receiving telephone support, the technician and the equipment in need of support will need to be present and ready to perform specific tasks and test splices. This type of telephone support may need to be scheduled at a time that fits the need of the system and the DTO depending on the severity of the problem. If necessary the DTO may put you in contact with the service center for more detailed technical phone support. Potential Action Purchase Request.. Fill out the Purchase Request Form for the specific part and description. If you are unsure of the price then leave that section blank. the purchase OTI Splice Machine Management 11 of 14 10/5/11

12 request to the DTO. The DTO will determine price and vendor as well as obtaining approval from the proper authority for the purchase. Potential Action Repair Order. Complete the excel format Splice Machine/Equipment Repair Order (sample attached). Make sure all fields are completed with accurate information- especially the splicer serial # and splice count. Include a very detailed description of the problem. If any error messages are displayed on the splicer screen then list those messages specifically. The Repair Order form also serves as a packing slip, so make sure that all items being sent are listed on the form with an accurate serial number. Before packing/shipping, a copy of the Repair Order BOTH to the appropriate Repair Center and the DTO. The Repair Center will reply back with a Repair Order number or Ticket number along with a questionnaire. Insert that ticket number into the RMA # line on the On Trac Repair Order and reply to the repair centers questionnaire. Once you have received an RMA or ticket number from the repair center, than you are authorized to pack/ship the machine. INCLUDE A SAMPLE length of fiber from YOUR SYSTEM (long enough for several test splices). Make sure to properly insure shipment with the correct declared values. Declare a value of $7, for all handheld splicers. Print off the Repair Order, insert into the box with the machine, and ship the machine standard overnight to the repair center. Note: Currently all Future EFS-150 machines are being repaired at Corporate so ship those units to the DTO in Morristown. Fitel machines are to be repaired at OFS/Fitel and shipped to the following: OFS Fitel, LLC David Harrison / Tom Stafford 2000 Northeast Expressway Mail Drop: 1W02 Norcross, GA Should follow-up with OFS/Fitel be necessary, contact Karen Slade (Inside Sales/Customer Care) at or kslade@ofsoptics.com. Following shipment, please note the machine as being in repair in your system inventory. After receiving the splice machine and/or equipment back from repair, immediately confirm that all problems are fixed and that the machine is functioning properly. Then notify Brad Slipher of completed repair, and indicate on your system inventory that the unit is returned from repair and back in production. Down Time and Loaners On the Repair Order form, there is a line to specify if you need a temporary splice machine ( loaner ) to use while the original machine is in repair. If a loaner is needed and one is available, it will be sent to you the same day that your machine is shipped to the Repair Center. However, please note that temporary loaners are not always available. In this case, Project Managers will have to resolve down time with technicians whose assigned machine is under repair. Recommendations for down time are as follows: You may decide not to give that tech work for the time being until the machine is repaired- this would include sending the tech home instead of issuing hourly (non-production) work. You may decide to have that technician ride with another tech and share the workload OTI Splice Machine Management 12 of 14 10/5/11

13 You may decide to have that technician perform other types of production (billable) work that do not require a splice machine. Charge Back for Splice Machine Issues When a problem is discovered with a splice machine, cleaver, or any machine accessories, the Project Manager has the task at that time to determine WHO is responsible for the problem. We understand that there are costs associated with maintaining such delicate equipment and we expect a certain amount of wear with this type of equipment. However, splice machines don t just break or malfunction by themselves! The system personnel assigned to the splice machine are responsible for quality care, cleaning, and careful handling AND WILL BE HELD RESPONSIBLE. Given diligent care, cleaning, and handling it is HIGHLY possible for a splice machine to be returned to the company in as good a shape or better as it was originally assigned. While it is true that accidents occur, accidents occurring because of a Technician s negligence or carelessness are never acceptable or excusable. Technicians should be WARNED that should a splice machine or cleaver be sent in for repair and all evidence points to abuse or neglect, then the technician will ALSO be charged back for the cost of the repair evaluation. Just to BEGIN a repair inspection, the cost on a splicer is $450 and the cost on a cleaver is $250. Below are some splice machine accidents reported to On Trac which are actually examples of true NEGLIGENCE and CARELESSNESS: There was ice on my splicing table, and the cleaver slid off and landed on the splice machine damaging the screen. THIS REPAIR IS A CHARGE BACK! Why would anyone set a cleaver on an icy surface, or any unstable surface that may result in a slip? My splicer was setting in the front seat of my truck and I had to slam on my brakes. The splicer hit the floor board and was damaged. THIS REPAIR IS A CHARGE BACK! A splice machine should always be secured in a safe and secure location, whether driving down the road, going up in your bucket, or just setting at the office. It is YOUR responsibility to protect this splicer at all times. I forgot and left the splicer sitting on the tail gate of my truck, when I drove off it tumbled down the road. THIS REPAIR IS A CHARGE BACK! A tailgate is NEVER a safe place for a splice machine. Always designate a safe location to store the splicer, where it is protected from the elements. As soon as all splices are complete for the job, place the splicer back in its designated safe spot. DO THIS EVERYTIME and EVERYDAY- make it a critical habit. NEVER park a splice machine on the tailgate, or on top of the utility bed, or lying in the floor of the bucket. NEVER settle on ANY temporarily setting for a splicer- always return it back to the designated safe place. The blade on my cleaver is corroded and will have to be replaced. I had to get the job done even though it was raining. THIS REPAIR IS A CHARGE BACK! Splicing in the rain should be avoided. However, if you are in a bucket and it starts raining unexpectedly, OTI Splice Machine Management 13 of 14 10/5/11

14 your machine may be exposed to excessive moisture while trying to get under cover. If your machine is exposed to moisture, take the time to clean the machine thoroughly to remove any dampness and prevent corrosion. This cleaning may have to be done multiple times over the next few days to completely eliminate moisture. Always keep a small compact waterproof poncho with you to use as a cover for both you and the splicer. The neck strap broke because it was worn out and the splicer fell and broke. THIS REPAIR IS A CHARGE BACK! It is your responsibility to inspect all accessories and to catch worn pieces and parts before they fail. Would you use a worn out safety harness that you thought could break? Technicians are just as accountable for the case and equipment as for the actual splice machine. Once Project Managers, Lead Technicians, and Technicians implement and follow closely the routines of inspection and cleanings outlined in this document, On Trac will realize more efficient management of splice machine assets with fewer repairs and less down-time to the system production. Again, for any questions related to the information in this document, contact the Director of Technical Operations: Brad Slipher Director of Technical Operations Cell# Office# bradslipher@ontracinc.net OTI Splice Machine Management 14 of 14 10/5/11