1st Edition

Advanced Manufacturing for Optical Fibers and Integrated Photonic Devices

By Abdul Al-Azzawi Copyright 2016
    220 Pages 166 B/W Illustrations
    by CRC Press

    Advanced Manufacturing for Optical Fibers and Integrated Photonic Devices explores the theoretical principles and industrial practices of high-technology manufacturing. Focusing on fiber optic, semiconductor, and laser products, this book:

    • Explains the fundamentals of standard, high-tech, rapid, and additive manufacturing workshops
    • Examines the production lines, processes, and clean rooms needed for the manufacturing of products
    • Discusses the high-technology manufacturing and installation of fiber optic cables, connectors, and active/passive devices
    • Describes continuous improvement, waste reduction through 5S application, and management’s responsibilities in supporting production
    • Covers Lean Manufacturing processes, product improvement, and workplace safety, as well as internal/external and ISO auditing
    • Offers a step-by-step approach complete with numerous figures and tables, detailed references, and a glossary of terms
    • Employs the international system of units (SI) throughout the text

    Advanced Manufacturing for Optical Fibers and Integrated Photonic Devices presents the latest manufacturing achievements and their applications in the high-tech sector. Inspired by the author’s extensive industrial experience, the book provides a comprehensive overview of contemporary manufacturing technologies.

    Preface

    About the Author

    Acknowledgments

    Workshops

    Introduction

    Standard Workshops

    High-Tech Workshops

    Rapid Manufacturing Workshops

    Additive Manufacturing Workshops

    An Example of Workshop Modifications

    Production Lines

    Introduction

    Why Build Production Lines?

    Producing Economical Products

    Requirements to Build and Design a Production Line

    Categories of Manufacturing Lines

    Manufacturing Processes

    Types of Assembly Lines

    Single Production Lines

    Parallel Production Lines

    Feed in Production Lines

    Cross-Production Lines

    Partially Automated Lines

    Fully Automated Lines

    Pilot Production Lines

    Standard Workstations

    Principles of Building Successful Production Lines

    Consequences of Building Unsuccessful Production Lines

    Causes of Day-to-Day Problems

    Steps in Long-Term Planning to Solve the Production Line Problems

    Objectives for Long-Term Planning to Improve the Production Line

    Reduced Labor

    Improved Machine Utilization

    Improved Operational Control

    Reduced Inventory

    Procedures

    Manufacturing Procedures

    Types of Manufacturing Procedures

    Samples of Manufacturing Procedures

    Sample 1: Temperature Test (Manual Oven) for Hybrid Devices

    Sample 2: AP and PC Connector Assembly

    Appendix A: PDL Test Procedure

    Appendix B: Troubleshooting and Possible Fixes

    Clean Rooms

    Introduction

    Bunny Suit

    Clean Room Standards

    High Manufacturing Technology

    Introduction

    Fiber Optic Cables

    Fiber Optic Cable Construction

    Plastic Fiber Cables

    Light Propagation in Fiber Optic Cables

    Types of Fiber Optic Cables

    Single-Mode Step-Index Fiber Cable

    Multimode Step-Index Fiber Cable (Multimode Fiber Cable)

    Multimode Graded-Index (GRIN) Fiber Cable

    Polarization-Maintaining Fiber Cables

    Specialty Fiber Cables

    Fiber Cable Fabrication Techniques

    Double Crucible Method

    Chemical Vapor Deposition (CVD) Processes

    Outside Vapor Deposition (OVD)

    Vapor Axial Deposition (VAD)

    Modified Chemical Vapor Deposition (MCVD)

    Plasma Chemical Vapor Deposition (PCVD)

    Fiber Drawing

    Photonic Crystal Fiber Cables

    Microstructure Fiber Cables

    Polymer Holey-Fiber Cables

    Fiber Cable Inspection and Handling

    Case a: Fiber Cable Inspection and Handling

    Case b: Fiber Cable Ends Preparation

    Manufacturing Fiber Cable Assembly

    Light Source Coupling to a Fiber Cable

    Launching Light Conditions into Fiber Cables

    Applications of Connectors and Splices

    Requirements of Connectors and Splices

    Fiber Connectors

    Fiber Optic Connector Types

    Adapters for Different Fiber Optic Connector Types

    Fiber Optic Connector Structures

    Fiber Optic Connector Assembly Techniques

    Building FSMA Connectors

    Hot-Melt Connectors

    Epoxyless Connectors

    Automated Polishing

    Fluid Jet Polishing

    Fiber Optic Connector Cleaning

    Connector Testing

    Fiber Splicing

    Mechanical Splicing

    Key Lock Mechanical Fiber Optic Splices

    Table Type Mechanical Fiber Optic Splices

    Fusion Splices

    Splice Testing

    Fiber Optic Cable Types and Installations

    Introduction

    Fiber Optic Cable Types and Applications

    Indoor Fiber Optic Cable Types and Applications

    Outdoor Fiber Optic Cable Types and Applications

    Indoor/Outdoor Fiber Optic Cable Types and Applications

    Other Fiber Optic Cable Types and Applications

    Fiber Optic Cable Installation Methods

    Indoor Fiber Optic Cable Installation

    Cable Installation in Tray and Duct Systems

    Conduit Installation

    Pulling Fiber Optic Cable Installation

    Fiber Optic Cables Direct Burial Installation

    Fiber Optic Cable Aerial Installation

    Air-Blown Fiber Cable Installation

    Other Fiber Cable Installation Methods

    Standard Hardware for Fiber Optic Cables

    Fiber Splice Closures

    Rack with Panels

    Connector Housings

    Patch Panels

    Splice Housings

    Wall Outlets

    Fiber Optic Testing Equipment

    Fiber Optic Cable Test Requirements

    How to Install a Fiber Optic Cable

    Technique and Apparatus

    Fiber Optic Cable Installation Procedure

    Manufacturing of Passive Fiber Optic Devices

    Introduction

    2 × 2 Couplers

    3 dB Couplers

    Y-Couplers

    Star Couplers

    Coupler Construction

    Fused Taper Couplers

    Polishing D-Section Couplers

    Twin Core Fiber Couplers

    Manufacturing of Active Fiber Optic Devices

    Introduction

    Optomechanical Switches

    Electro-Optic Switches

    A High-Speed Optical Switch Using a Fiber Optic Coupler

    Acousto-Optic Switches

    Microelectromechanical Systems (MEMS)

    3D MEMS-Based Optical Switches

    Micro-Optomechanical Systems (MOMS)

    Continuous Improvement in a Production Line

    Introduction

    Understand the Need for Changes

    Preparing for the Change

    Handling Time

    Reducing Packaging and Shipping Times

    Packaging

    Process

    Shipping Labels and Tags

    Sealing the Shipping Box

    5S Implementation

    Modifications of a Production Line and Product

    Reducing Waste

    Solving Problems in Manufacturing Lines

    Jigs Usage in Production Lines

    Continuous Improvement Schedule

    Standard Work Improvement Process

    Continuous Flow Production (CFP)

    Basic Elements of Continuous Flow Production

    Just in Time (JIT)

    Characteristics of the Flow Production

    Implementation of Continuous Flow Production (CFP)

    Benefits of Continuous Flow Production

    Types of Waste

    Introduction

    Types of Waste

    Waste of Inventory

    Waste of Overproduction

    Waste of Defect

    Waste of Inefficient Process

    Waste of Waiting

    Waste of Materials Transportation/Movement

    Waste of Motion

    Waste of Rejects

    Waste of Person

    Other Types of Waste

    Waste Reduction Techniques

    Waste of Products

    Eliminating Waste

    Waste Reduction

    Product Design and Manufacturing

    Materials Reuse and Recycling

    Packaging Reduction

    Purchasing

    Office Paper Use

    Cafeterias and Restrooms

    Waste Reduction by Training

    Enhance Your Waste Reduction Program

    Remarks

    Application of the 5S’s in Manufacturing Lines

    Introduction

    The 5S’s

    Sort

    Set in Order

    Shine

    Standardize

    Sustain

    Implementation of the 5S’s in a Manufacturing Line

    Plan

    Start

    Put Plan into Action

    Analyses

    Future Plan

    Management and Employee Responsibilities

    Introduction

    Structural Needs of a Company

    Responsibilities of Employees

    Employee Rights

    Responsibilities of Managers

    Safety Ethics

    Laws and Regulations

    Management and Ethnics

    Occupational Safety and Health Administration

    Society and Ethics

    Human Society: Family and Person

    Professional Societies

    Fundamental Standards in Professional Engineering Societies

    Lean Manufacturing

    Introduction

    History of Lean Manufacturing

    Key Elements of Lean Manufacturing

    Just in Time (JIT)

    Jidoka

    Standardized Work

    Understanding the Application of Flow Processing Techniques

    Applying Lean Principles (Poka-Yoke)

    Key Tools of Lean Manufacturing

    Differences between Lean and Conventional Manufacturing

    Leadership in Lean Manufacturing

    Lean Manufacturing and Waste

    Lean Manufacturing Implementation Program

    Characteristics of Lean Manufacturing

    Application of Lean Manufacturing

    Lean Software Engineering

    Lean on Healthcare

    Lean Manufacturing Strategy

    Benefits Make Lean Manufacturing Succeed

    Advantages of Lean Manufacturing

    Disadvantages of Lean Manufacturing

    Product Improvement

    Introduction

    Purpose of Product Improvement

    Process of Producing Economical Products

    Modify Floor Plan

    Floor Plan Design

    Modifying a Floor Plan

    Improving and Optimizing Handling and Process Times

    Reduce the Waste of Inventory

    Reduce Overproduction

    Reduce Defects

    Inspection of Incoming Materials

    Employee Training

    Inspection of Inventory

    Reduce Rejects

    Using Alternative Materials

    Using New Jigs, Devices, and Tools

    Using Automation

    Time Management in a Professional Environment

    Introduction

    Time Management Best Practices

    Adopt a Positive Attitude

    Blame

    Self-Assessment

    Responsibility

    Developing Specific Skills

    Prioritization Skills

    Planning Skills

    Delegation Skills

    Organization Skills

    Establishing Daily Priorities

    Identifying Goals from Objectives

    Identify Activities

    Determine High- and Low-Return Activities

    Consider Objectives

    Determine Urgency vs. Importance

    Rank Priorities (1-2-3 System)

    Decide What to Do (ABC System)

    The Myths

    Hard Work Leads to Success

    Keep Working and You Will Get More Done

    Efficiency Leads to Effectiveness

    Dedication and Commitment Are Essential to Success

    You Are the Best Person to Do the Job

    He or She Who Runs Away Lives to Fight Another Day

    Work Is Its Own Reward

    Work Was Never Intended to Be Fun

    It’s My Way or the Highway

    Work Best under Pressure

    Time Wasters

    Interruptions

    Correspondence

    Meetings

    Meeting Rules

    Communications

    Top 10 Time Management Tips

    Time Management Strategies

    Internal, External, and ISO Auditing

    Introduction

    Internal Auditing

    External Auditing

    Auditing Activities

    Management’s and Engineers’ Roles

    Auditing Annual Planning

    Execution of Auditing Activities

    Audit Reports

    Quality of the Audit Report

    Audit Report Strategic Plans

    The Difference between Internal and External Audits

    The Role of the Internal Auditor

    The Role of the External Auditor

    International Organization for Standardization (ISO)

    Benefits of ISO 9000 Standards

    Benchmarking for ISO 9000

    Responsibilities of Management

    ISO 9000 Employee Expectations

    Tips for a Successful ISO 9000 Process

    Impact of Technology Changes and ISO 9000

    High-Tech Manufacturing Safety

    Introduction

    Personal Protective Safety Equipment (PPSE)

    Electrical Safety

    Fuses/Circuit Breakers

    ON/OFF Switches

    Plugs

    Wall Outlets

    Cords

    Ground Fault Circuit Interrupters

    Light Sources

    Devices and Equipment

    Audiovisual and Computer Peripherals

    Handling of Fiber Optic Cables

    Epoxy Adhesives and Sealants

    Cleaning Optical Components

    Optic/Optical Fiber Devices and Systems

    Cleaning Chemicals

    Warning Labels

    Laser Safety

    Laser Safety Tips

    Indoor Air Quality

    Other Considerations

    References

    Glossary

    Index

    Biography

    Abdul Al-Azzawi earned his Ph.D from the University of Strathclyde, Glasgow, Scotland. He has more than 30 years of experience in research, academia, and the photonics manufacturing industry. Currently, he is a professor, coordinator, and researcher at Algonquin College, Ottawa, Ontario, Canada, teaching in the joint Bachelor of Information Technology – Photonics and Laser Technology Program between Algonquin College and Carleton University, Ottawa, Ontario, Canada. Dr. Al-Azzawi is a senior member of SMIEEE, as well as a member of Canadian professional photonics societies. He has published several books and papers, participated in numerous workshops and conferences around the world, and been the recipient of the National Institute for Staff and Organizational Development (NISOD) Excellence Award from the University of Texas at Austin, USA. His areas of research include optic/optical fiber devices, fiber optic lighting, and fiber optic devices.

    "I’ve known Dr. Abdul Al-Azzawi since the early days of college level Photonics Education in Ontario. The world of Photonics manufacturing is critical to the functioning of our modern society. It’s great to see such an exhaustive range of topics taken on in his latest book!"
    —Alexander McGlashan, Niagara College

    "Dr. Al-Azzawi draws on his vast industrial experiences to provide a comprehensive look at the essential technologies for manufacturing high-quality fiber optic cables, connectors, couplers, and active switching devices. The fundamentals of industrial production are described in detail and modern methods for continuous improvement are discussed. Dr. Al-Azzawi moves beyond traditional manufacturing textbooks by stressing practical solutions and time management skills in a competitive high-tech manufacturing environment. The book serves as an introduction to the practical aspects of fiber optic manufacturing and a guidebook for evaluating other high-tech manufacturing enterprises."
    —George Knopf, The University of Western Ontario