Advanced Manufacturing for Optical Fibers and Integrated Photonic Devices

Advanced Manufacturing for Optical Fibers and Integrated Photonic Devices

by Abdul Al-Azzawi
Released December 2017
Publisher(s): CRC Press
ISBN: 9781351830058

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Book description

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.

Table of contents

  1. Cover
  2. Half Title
  3. Title Page
  4. Copyright Page
  5. Table of Contents
  6. Preface
  7. Acknowledgments
  8. About the Author
  9. Chapter 1 Workshops
    1. 1.1 Introduction
    2. 1.2 Standard Workshops
    3. 1.3 High-Tech Workshops
    4. 1.4 Rapid Manufacturing Workshops
    5. 1.5 Additive Manufacturing Workshops
    6. 1.6 An Example of Workshop Modifications
  10. Chapter 2 Production Lines
    1. 2.1 Introduction
    2. 2.2 Why Build Production Lines?
    3. 2.3 Producing Economical Products
    4. 2.4 Requirements to Build and Design a Production Line
    5. 2.5 Categories of Manufacturing Lines
    6. 2.6 Manufacturing Processes
    7. 2.7 Types of Assembly Lines
      1. 2.7.1 Single Production Lines
      2. 2.7.2 Parallel Production Lines
      3. 2.7.3 Feed in Production Lines
      4. 2.7.4 Cross-Production Lines
      5. 2.7.5 Partially Automated Lines
      6. 2.7.6 Fully Automated Lines
      7. 2.7.7 Pilot Production Lines
    8. 2.8 Standard Workstations
    9. 2.9 Principles of Building Successful Production Lines
    10. 2.10 Consequences of Building Unsuccessful Production Lines
    11. 2.11 Causes of Day-to-Day Problems
    12. 2.12 Steps in Long-Term Planning to Solve Production Line Problems
    13. 2.13 Objectives for Long-Term Planning to Improve the Production Line
      1. 2.13.1 Reduced Labor
      2. 2.13.2 Improved Machine Utilization
      3. 2.13.3 Improved Operational Control
      4. 2.13.4 Reduced Inventory
      5. 2.13.5 Procedures
  11. Chapter 3 Manufacturing Procedures
    1. 3.1 Types of Manufacturing Procedures
    2. 3.2 Samples of Manufacturing Procedures
      1. 3.2.1 Sample 1: Temperature Test (Manual Oven) for Hybrid Devices
      2. 3.2.2 Sample 2: AP and PC Connector Assembly
    3. Appendix 3A: PDL Test Procedure
    4. Appendix 3B: Troubleshooting and Possible Fixes
  12. Chapter 4 Clean Rooms
    1. 4.1 Introduction
    2. 4.2 Bunny Suit
    3. 4.3 Clean Room Standards
  13. Chapter 5 High Manufacturing Technology
    1. 5.1 Introduction
    2. 5.2 Fiber Optic Cables
    3. 5.3 Fiber Optic Cable Construction
    4. 5.4 Plastic Fiber Cables
    5. 5.5 Light Propagation in Fiber Optic Cables
    6. 5.6 Types of Fiber Optic Cables
      1. 5.6.1 Single-Mode Step-Index Fiber Cable
      2. 5.6.2 Multimode Step-Index Fiber Cable (Multimode Fiber Cable)
      3. 5.6.3 Multimode Graded-Index (GRIN) Fiber Cable
    7. 5.7 Polarization-Maintaining Fiber Cables
    8. 5.8 Specialty Fiber Cables
    9. 5.9 Fiber Cable Fabrication Techniques
    10. 5.10 Double Crucible Method
    11. 5.11 Chemical Vapor Deposition (CVD) Processes
    12. 5.12 Outside Vapor Deposition (OVD)
    13. 5.13 Vapor Axial Deposition (VAD)
    14. 5.14 Modified Chemical Vapor Deposition (MCVD)
    15. 5.15 Plasma Chemical Vapor Deposition (PCVD)
    16. 5.16 Fiber Drawing
    17. 5.17 Photonic Crystal Fiber Cables
    18. 5.18 Microstructure Fiber Cables
    19. 5.19 Polymer Holey-Fiber Cables
    20. 5.20 Fiber Cable Inspection and Handling
      1. 5.20.1 Case A: Fiber Cable Inspection and Handling
        1. 5.20.1.1 Fiber Optic Cable Defect Types
        2. 5.20.1.2 Fiber Optic Cable Inspection
        3. 5.20.1.3 Fiber Optic Cable Cleaning
        4. 5.20.1.4 Fiber Optic Cable Handling
      2. 5.20.2 Case B: Fiber Cable Ends Preparation
        1. 5.20.2.1 Manual Stripping Procedure
        2. 5.20.2.2 Thermal Stripping Procedure
        3. 5.20.2.3 Cleaning Procedure after Stripping
        4. 5.20.2.4 Manual Cleaving Procedure
        5. 5.20.2.5 Mechanical Cleaving Procedure
    21. 5.21 Manufacturing Fiber Cable Assembly
    22. 5.22 Light Source Coupling to a Fiber Cable
    23. 5.23 Launching Light Conditions into Fiber Cables
    24. 5.24 Applications of Connectors and Splices
    25. 5.25 Requirements of Connectors and Splices
    26. 5.26 Fiber Connectors
    27. 5.27 Fiber Optic Connector Types
    28. 5.28 Adapters for Different Fiber Optic Connector Types
    29. 5.29 Fiber Optic Connector Structures
    30. 5.30 Fiber Optic Connector Assembly Techniques
      1. 5.30.1 Building FSMA Connectors
        1. 5.30.1.1 Connector Body
        2. 5.30.1.2 Epoxy and Polish
        3. 5.30.1.3 Strain Relief Boot
      2. 5.30.2 Hot-Melt Connectors
      3. 5.30.3 Epoxyless Connectors
      4. 5.30.4 Automated Polishing
      5. 5.30.5 Fluid Jet Polishing
      6. 5.30.6 Fiber Optic Connector Cleaning
      7. 5.30.7 Connector Testing
    31. 5.31 Fiber Splicing
      1. 5.31.1 Mechanical Splicing
      2. 5.31.2 Key Lock Mechanical Fiber Optic Splices
      3. 5.31.3 Table Type Mechanical Fiber Optic Splices
      4. 5.31.4 Fusion Splices
      5. 5.31.5 Splice Testing
        1. 5.31.5.1 Testing Connection Loss Using a Key Lock Mechanical Splice
        2. 5.31.5.2 Testing Connection Loss in a Table Type Mechanical Splice
  14. Chapter 6 Fiber Optic Cable Types and Installations
    1. 6.1 Introduction
    2. 6.2 Fiber Optic Cable Types and Applications
      1. 6.2.1 Indoor Fiber Optic Cable Types and Applications
      2. 6.2.2 Outdoor Fiber Optic Cable Types and Applications
      3. 6.2.3 Indoor/Outdoor Fiber Optic Cable Types and Applications
      4. 6.2.4 Other Fiber Optic Cable Types and Applications
    3. 6.3 Fiber Optic Cable Installation Methods
      1. 6.3.1 Indoor Fiber Optic Cable Installation
      2. 6.3.2 Cable Installation in Tray and Duct Systems
      3. 6.3.3 Conduit Installation
      4. 6.3.4 Pulling Fiber Optic Cable Installation
      5. 6.3.5 Fiber Optic Cables Direct Burial Installation
      6. 6.3.6 Fiber Optic Cable Aerial Installation
      7. 6.3.7 Air-Blown Fiber Cable Installation
      8. 6.3.8 Other Fiber Cable Installation Methods
    4. 6.4 Standard Hardware for Fiber Optic Cables
      1. 6.4.1 Fiber Splice Closures
      2. 6.4.2 Rack with Panels
      3. 6.4.3 Connector Housings
      4. 6.4.4 Patch Panels
      5. 6.4.5 Splice Housings
      6. 6.4.6 Wall Outlets
      7. 6.4.7 Fiber Optic Testing Equipment
    5. 6.5 Fiber Optic Cable Test Requirements
    6. 6.6 How to Install a Fiber Optic Cable
    7. 6.7 Technique and Apparatus
    8. 6.8 Fiber Optic Cable Installation Procedure
  15. Chapter 7 Manufacturing of Passive Fiber Optic Devices
    1. 7.1 Introduction
    2. 7.2 2 × 2 Couplers
    3. 7.3 3 dB Couplers
    4. 7.4 Y-Couplers
    5. 7.5 Star Couplers
    6. 7.6 Coupler Construction
      1. 7.6.1 Fused Taper Couplers
      2. 7.6.2 Polishing D-Section Couplers
      3. 7.6.3 Twin Core Fiber Couplers
  16. Chapter 8 Manufacturing of Active Fiber Optic Devices
    1. 8.1 Introduction
    2. 8.2 Optomechanical Switches
    3. 8.3 Electro-Optic Switches
    4. 8.4 High-Speed Optical Switch Using a Fiber Optic Coupler
    5. 8.5 Acousto-Optic Switches
    6. 8.6 Microelectromechanical Systems (MEMS)
    7. 8.7 3D MEMS-Based Optical Switches
    8. 8.8 Micro-Optomechanical Systems (MOMS)
  17. Chapter 9 Continuous Improvement in a Production Line
    1. 9.1 Introduction
    2. 9.2 Understand the Need for Changes
    3. 9.3 Preparing for the Change
    4. 9.4 Handling Time
    5. 9.5 Reducing Packaging and Shipping Times
      1. 9.5.1 Packaging Process
      2. 9.5.2 Shipping Labels and Tags
      3. 9.5.3 Sealing the Shipping Box
    6. 9.6 5S Implementation
    7. 9.7 Modifications of a Production Line and Product
    8. 9.8 Reducing Waste
    9. 9.9 Solving Problems in Manufacturing Lines
    10. 9.10 Jig Usage in Production Lines
    11. 9.11 Continuous Improvement Schedule
    12. 9.12 Standard Work Improvement Process
    13. 9.13 Continuous Flow Production (CFP)
    14. 9.14 Basic Elements of Continuous Flow Production
    15. 9.15 Just-in-Time (JIT)
    16. 9.16 Characteristics of the Flow Production
    17. 9.17 Implementation of Continuous Flow Production (CFP)
    18. 9.18 Benefits of Continuous Flow Production
  18. Chapter 10 Types of Waste
    1. 10.1 Introduction
    2. 10.2 Types of Waste
    3. 10.3 Waste of Inventory
    4. 10.4 Waste of Overproduction
    5. 10.5 Waste of Defect
    6. 10.6 Waste of Inefficient Process
    7. 10.7 Waste of Waiting
    8. 10.8 Waste of Materials Transportation/Movement
    9. 10.9 Waste of Motion
    10. 10.10 Waste of Rejects
    11. 10.11 Waste of Person
    12. 10.12 Other Types of Waste
    13. 10.13 Waste Reduction Techniques
    14. 10.14 Waste of Products
    15. 10.15 Eliminating Waste
    16. 10.16 Waste Reduction
      1. 10.16.1 Product Design and Manufacturing
      2. 10.16.2 Materials Reuse and Recycling
      3. 10.16.3 Packaging Reduction
      4. 10.16.4 Purchasing
      5. 10.16.5 Office Paper Use
      6. 10.16.6 Cafeterias and Restrooms
      7. 10.16.7 Waste Reduction by Training
    17. 10.17 Enhance Your Waste Reduction Program
    18. 10.18 Remarks
  19. Chapter 11 Application of the 5Ss in Manufacturing Lines
    1. 11.1 Introduction
    2. 11.2 The 5Ss
      1. 11.2.1 Sort
      2. 11.2.2 Set in Order
      3. 11.2.3 Shine
      4. 11.2.4 Standardize
      5. 11.2.5 Sustain
    3. 11.3 Implementation of the 5Ss in a Manufacturing Line
      1. 11.3.1 Plan
      2. 11.3.2 Start
      3. 11.3.3 Put Plan into Action
        1. 11.3.3.1 Light Actions (Simple Jobs)
        2. 11.3.3.2 Heavy Actions (Complicated Jobs)
      4. 11.3.4 Analyses
      5. 11.3.5 Future Plan
  20. Chapter 12 Management and Employee Responsibilities
    1. 12.1 Introduction
    2. 12.2 Structural Needs of a Company
    3. 12.3 Responsibilities of Employees
    4. 12.4 Employee Rights
    5. 12.5 Responsibilities of Managers
    6. 12.6 Safety Ethics
      1. 12.6.1 Laws and Regulations
      2. 12.6.2 Management and Ethnics
      3. 12.6.3 Occupational Safety and Health Administration
    7. 12.7 Society and Ethics
      1. 12.7.1 Human Society: Family and Person
      2. 12.7.2 Professional Societies
    8. 12.8 Fundamental Standards in Professional Engineering Societies
  21. Chapter 13 Lean Manufacturing
    1. 13.1 Introduction
    2. 13.2 History of Lean Manufacturing
    3. 13.3 Key Elements of Lean Manufacturing
      1. 13.3.1 Just-in-Time (JIT)
      2. 13.3.2 Jidoka
      3. 13.3.3 Standardized Work
      4. 13.3.4 Understanding the Application of Flow Processing Techniques
    4. 13.4 Applying Lean Principles (Poka-Yoke)
    5. 13.5 Key Tools of Lean Manufacturing
    6. 13.6 Differences between Lean and Conventional Manufacturing
    7. 13.7 Leadership in Lean Manufacturing
    8. 13.8 Lean Manufacturing and Waste
    9. 13.9 Lean Manufacturing Implementation Program
    10. 13.10 Characteristics of Lean Manufacturing
    11. 13.11 Application of Lean Manufacturing
      1. 13.11.1 Lean Software Engineering
      2. 13.11.2 Lean on Healthcare
      3. 13.11.3 Lean Manufacturing Strategy
    12. 13.12 Benefits Make Lean Manufacturing Succeed
    13. 13.13 Advantages of Lean Manufacturing
    14. 13.14 Disadvantages of Lean Manufacturing
  22. Chapter 14 Product Improvement
    1. 14.1 Introduction
    2. 14.2 Purpose of Product Improvement
    3. 14.3 Process of Producing Economical Products
    4. 14.4 Modify Floor Plan
      1. 14.4.1 Floor Plan Design
      2. 14.4.2 Modifying a Floor Plan
    5. 14.5 Improving and Optimizing Handling and Process Times
    6. 14.6 Reduce the Waste of Inventory
    7. 14.7 Reduce Overproduction
    8. 14.8 Reduce Defects
    9. 14.9 Inspection of Incoming Materials
    10. 14.10 Employee Training
    11. 14.11 Inspection of Inventory
    12. 14.12 Reduce Rejects
    13. 14.13 Using Alternative Materials
    14. 14.14 Using New Jigs, Devices, and Tools
    15. 14.15 Using Automation
  23. Chapter 15 Time Management in a Professional Environment
    1. 15.1 Introduction
    2. 15.2 Time Management Best Practices
      1. 15.2.1 Adopt a Positive Attitude
      2. 15.2.2 Blame
      3. 15.2.3 Self-Assessment
      4. 15.2.4 Responsibility
      5. 15.2.5 Developing Specific Skills
      6. 15.2.6 Prioritization Skills
      7. 15.2.7 Planning Skills
      8. 15.2.8 Delegation Skills
      9. 15.2.9 Organization Skills
    3. 15.3 Establishing Daily Priorities
      1. 15.3.1 Identifying Goals from Objectives
      2. 15.3.2 Identify Activities
      3. 15.3.3 Determine High- and Low-Return Activities
      4. 15.3.4 Consider Objectives
      5. 15.3.5 Determine Urgency vs. Importance
      6. 15.3.6 Rank Priorities (1-2-3 System)
      7. 15.3.7 Decide What to Do (ABC System)
    4. 15.4 The Myths
      1. 15.4.1 Hard Work Leads to Success
      2. 15.4.2 Keep Working and You Will Get More Done
      3. 15.4.3 Efficiency Leads to Effectiveness
      4. 15.4.4 Dedication and Commitment Are Essential to Success
      5. 15.4.5 You Are the Best Person to Do the Job
      6. 15.4.6 He or She Who Runs Away Lives to Fight Another Day
      7. 15.4.7 Work Is Its Own Reward
      8. 15.4.8 Work Was Never Intended to Be Fun
      9. 15.4.9 It’s My Way or the Highway
      10. 15.4.10 People Work Best under Pressure
    5. 15.5 Time Wasters
      1. 15.5.1 Interruptions
      2. 15.5.2 Correspondence
      3. 15.5.3 Meetings
      4. 15.5.4 Meeting Rules
      5. 15.5.5 Communications
      6. 15.5.6 Top 10 Time Management Tips
    6. 15.6 Time Management Strategies
  24. Chapter 16 Internal, External, and ISO Auditing
    1. 16.1 Introduction
    2. 16.2 Internal Auditing
    3. 16.3 External Auditing
    4. 16.4 Auditing Activities
    5. 16.5 Management’s and Engineers’ Roles
    6. 16.6 Auditing Annual Planning
    7. 16.7 Execution of Auditing Activities
    8. 16.8 Audit Reports
    9. 16.9 Quality of the Audit Report
    10. 16.10 Audit Report Strategic Plans
    11. 16.11 The Difference between Internal and External Audits
    12. 16.12 The Role of the Internal Auditor
    13. 16.13 The Role of the External Auditor
    14. 16.14 International Organization for Standardization (ISO)
    15. 16.15 Benefits of ISO 9000 Standards
    16. 16.16 Benchmarking for ISO 9000
    17. 16.17 Responsibilities of Management
    18. 16.18 ISO 9000 Employee Expectations
    19. 16.19 Tips for a Successful ISO 9000 Process
    20. 16.20 Impact of Technology Changes and ISO 9000
  25. Chapter 17 High-Tech Manufacturing Safety
    1. 17.1 Introduction
    2. 17.2 Personal Protective Safety Equipment (PPSE)
    3. 17.3 Electrical Safety
      1. 17.3.1 Fuses/Circuit Breakers
      2. 17.3.2 ON/OFF Switches
      3. 17.3.3 Plugs
      4. 17.3.4 Wall Outlets
      5. 17.3.5 Cords
      6. 17.3.6 Ground Fault Circuit Interrupters
    4. 17.4 Light Sources
    5. 17.5 Devices and Equipment
    6. 17.6 Audiovisual and Computer Peripherals
    7. 17.7 Handling of Fiber Optic Cables
    8. 17.8 Epoxy Adhesives and Sealants
    9. 17.9 Cleaning Optical Components
    10. 17.10 Optic/Optical Fiber Devices and Systems
    11. 17.11 Cleaning Chemicals
    12. 17.12 Warning Labels
    13. 17.13 Laser Safety
    14. 17.14 Laser Safety Tips
    15. 17.15 Indoor Air Quality
    16. 17.16 Other Considerations
  26. Glossary
  27. References
  28. Index

Product information

  • Title: Advanced Manufacturing for Optical Fibers and Integrated Photonic Devices
  • Author(s): Abdul Al-Azzawi
  • Release date: December 2017
  • Publisher(s): CRC Press
  • ISBN: 9781351830058