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SAIL-SWP-CMS-001
Operation of 3SAE Combiner Manufacturing System (CMS)
Status: Draft Version 1.0 Issued: January 2026 šŸ“„ Download PDF
Risk Assessment - 3SAE CMS Manufacturer Product Information
SAFE WORK PROCEDURE

āš ļø CRITICAL SAFETY INFORMATION āš ļø

BEFORE OPERATING THIS EQUIPMENT:

SWP Title

Operation of 3SAE Combiner Manufacturing System (CMS) for Fibre Optic Glass Processing

Prepared by: Chris Responsible supervisor/s: [To be completed]

List the Hazards and Risk Controls as per Risk Assessment

Associated risk assessment reference: SAIL-RA-CMS-001

Hazards

Risk Controls

List Resources Required

Personal Protective Equipment (PPE)

Equipment and Materials

Safety Equipment (must be present in laboratory)

Environmental Requirements

Step by Step Instructions for Undertaking the Task

BEFORE STARTING - CRITICAL SAFETY REQUIREMENTS

STOP - Verify your authorisation:

Supervision requirements for new users:

1. PRE-OPERATION SAFETY CHECKS (MANDATORY - DO NOT SKIP)

Complete these checks EVERY TIME before operation. If ANY check fails, DO NOT USE - lock out and report to supervisor immediately.

  1. Sign in to equipment logbook:
    • Record: Your name, date, time, type of operation planned
    • Review previous entries for any reported issues
    • Check that no maintenance or repair is scheduled
  2. Visual inspection of equipment exterior:
    • Check for any visible damage to equipment housing or enclosures
    • Verify no cables or hoses are damaged, frayed, or kinked
    • Check that all cable connections are secure
    • Ensure no liquid spills or contamination on or near equipment
    • Verify work area is clean and free of clutter
    • If ANY damage found: DO NOT USE - lock out and report to supervisor
  3. Check exclusion zone and clearances:
    • Verify 500mm exclusion zone around equipment is clear
    • Remove any flammable materials from 1-metre radius
    • Ensure no obstructions to emergency stop button or exit routes
    • Confirm adequate lighting for operation
    • Check that fire extinguisher is accessible
  4. Compressed air system checks:
    • Verify compressed air supply is connected and secure
    • Check pressure gauge reads approximately 6.2 bar (90 psi)
    • Listen for any unusual hissing or air leaks
    • Inspect visible air lines for damage or kinks
    • Test emergency air shut-off valve (close and reopen to verify function)
    • If pressure is incorrect or leaks detected: DO NOT USE - contact facilities/supervisor
  5. Electrical system checks:
    • Verify mains power is connected and RCD is functional (test RCD button)
    • Check that no electrical cables show damage or exposed conductors
    • Verify all equipment indicators show normal status
    • Ensure emergency power isolation switch is accessible and functional
    • If any electrical issues detected: DO NOT USE - contact supervisor/electrician
  6. Emergency stop button test:
    • CRITICAL: Press emergency stop button to verify it functions
    • System should immediately cease all operations
    • Reset emergency stop and verify system can restart normally
    • If emergency stop does not function correctly: DO NOT USE - lock out and report immediately
  7. Safety interlock verification:
    • Verify that opening chamber door during operation triggers automatic shutdown (test with system in safe idle state)
    • Check that all safety interlocks appear intact and functional
    • If any interlock appears bypassed or faulty: DO NOT USE - report immediately
  8. Software and control system check:
    • Power on PC and CMS control system
    • Verify software loads without errors
    • Check that both camera views display correctly
    • Verify all system status indicators show ā€œreadyā€ or normal state
    • If software errors or camera failures: DO NOT USE - contact IT/supervisor
  9. Vision system verification:
    • Check both orthogonal camera views are clear and focused
    • Verify telecentric lenses are clean (clean gently with lens tissue if needed)
    • Test that monitor displays both camera feeds clearly
    • Adjust monitor brightness/contrast if needed for viewing comfort
    • If vision system not functioning: DO NOT USE - operation requires visual monitoring
  10. Check sharps disposal and first aid readiness:
    • Verify sharps disposal container is available and not full
    • Confirm first aid kit location and check it contains splinter removal tools
    • Note location of emergency eyewash station
    • If safety equipment not available: Obtain before proceeding
  11. Personal protective equipment (PPE) verification:
    • Put on safety glasses (close-fitting type)
    • Confirm laboratory coat/protective clothing is worn
    • Verify closed-toe shoes are being worn
    • Have nitrile gloves and heat-resistant gloves readily available
    • Never proceed without appropriate PPE
  12. Final pre-operation check:
    • All pre-operation checks completed satisfactorily? YES/NO
    • Any safety concerns or unusual observations? Record in logbook
    • If any concerns: Consult with supervisor before proceeding
    • If all checks passed: Proceed to operation

2. EQUIPMENT STARTUP AND INITIALISATION

  1. Power-up sequence:
    • Ensure PC and CMS software are running
    • Verify compressed air supply is open and at correct pressure
    • Allow system to complete initialisation sequence (typically 2-3 minutes)
    • Watch for any error messages during startup
    • Verify all system diagnostics show normal operation
  2. Electrode inspection and installation (if required):
    • Put on nitrile gloves before handling electrodes
    • Open electrode chamber following software prompts or manual procedures
    • Visually inspect electrodes for wear, damage, or excessive contamination
    • If electrodes appear worn (consult manufacturer guidelines for wear limits): Replace with spare set
    • Ensure electrodes are correctly positioned and secured
    • Close electrode chamber and verify secure closure
    • Remove nitrile gloves after electrode handling (do not contaminate other surfaces)
  3. Cooling system verification:
    • Verify embedded electrode cooling system is functioning (check for coolant flow indicators if present)
    • Listen for coolant pump operation (should be quiet and steady)
    • Check for any coolant leaks around electrode assembly
    • If cooling system not functioning: DO NOT proceed - contact supervisor/manufacturer
  4. Calibration and alignment check (if required by procedure):
    • Some processes may require alignment calibration
    • Follow software prompts for automatic alignment procedures
    • Verify pitch and yaw alignment systems are functioning correctly
    • If manual alignment needed: Use provided alignment fixtures and follow manufacturer procedures

3. FIBRE PREPARATION AND LOADING

  1. Select appropriate fibre holders:
    • Choose fibre holders matching the diameter of fibres to be processed:
      • 250Ī¼m holders for standard single-mode fibres
      • 400Ī¼m, 700Ī¼m, 1000Ī¼m, 1500Ī¼m, 2000Ī¼m, 2500Ī¼m for larger diameter fibres
    • Install fibre holders in both left and right positioning stages
    • Ensure holders are clean and properly seated
  2. Prepare optical fibres:
    • Ensure safety glasses are on before handling fibres
    • Strip fibre coating if required using appropriate stripping tool (not while in CMS)
    • Clean fibre ends with isopropanol and lint-free wipes
    • If cleaving externally before loading: Use proper cleaving technique to achieve clean end face
    • Handle fibres only by coated sections when possible
    • Use tweezers or fibre handling tools - avoid direct hand contact with glass sections
  3. Load fibres into holders:
    • Carefully position fibre in left holder first
    • Secure fibre gently (avoid over-tightening which can damage fibre)
    • Load second fibre into right holder (for splicing operations)
    • For tapering operations: Load single fibre as per procedure
    • Verify fibres are properly seated and secured
    • Check alignment visually through camera system
  4. Position fibres using software control:
    • Use X-Y-Z positioning controls to align fibres
    • Bring fibre ends into view of both camera systems
    • For fusion splicing: Align fibre cores using automatic or manual alignment
    • Achieve alignment resolution of <50nm in X and Y axes
    • Verify alignment on both orthogonal camera views before proceeding
    • Never attempt to adjust fibre position manually while system is powered

4. OPERATION - FUSION SPLICING

This section covers standard fusion splicing operations. For tapering or cleaving, see sections 5 and 6.

  1. Configure splice parameters:
    • Select appropriate splice program from software library OR
    • Create custom splice program specifying:
      • Arc power settings (based on fibre type and diameter)
      • Arc duration
      • Pre-splice cleaning arc (if required)
      • Overlap distance
      • Push distance during splice
    • Save custom programs for repeatability
    • Test new programs on scrap fibres before using on valuable components
  2. Pre-splice arc cleaning (if required):
    • Some fibre types benefit from pre-splice cleaning arc
    • Software will prompt for this step if programmed
    • Verify fibres remain aligned during cleaning arc
    • Visual inspection via camera for any debris or contamination
  3. Final pre-splice verification:
    • STOP - Safety verification before plasma activation:
      • Hands clear of equipment? YES
      • Exclusion zone clear? YES
      • Fibre alignment correct? YES
      • Splice parameters confirmed? YES
      • Emergency stop accessible? YES
    • If any NO answers: Correct before proceeding
  4. Initiate fusion splice:
    • Click ā€œStart Spliceā€ or equivalent command in software
    • PLASMA WILL NOW ACTIVATE - Stand clear
    • Monitor splice progress on both camera views
    • Watch for:
      • Smooth approach of fibre ends
      • Uniform heating and melting of glass
      • Proper fusion at interface
      • Absence of bubbles or voids
    • Do NOT reach towards equipment during plasma operation
  5. Post-splice monitoring:
    • Software will automatically control:
      • Plasma power and timing
      • Fibre positioning and overlap
      • Push force during fusion
      • Cool-down period
    • Process typically completes in 10-60 seconds depending on fibre size
    • Wait for ā€œSplice Completeā€ confirmation before proceeding
  6. Splice quality assessment:
    • System automatically captures before/during/after images
    • Visually inspect splice on monitor for:
      • Smooth, symmetrical splice junction
      • Proper alignment (minimal core offset)
      • Absence of bubbles, voids, or cracks
      • Appropriate splice geometry
    • Use scanning function to measure splice diameter profile if needed
    • Record splice quality in logbook (accept/reject decision)
  7. Cool-down period (MANDATORY):
    • DO NOT touch fibres or components for minimum 15 minutes after splice
    • Software may display temperature information
    • Use thermal inspection camera to verify components have cooled if immediate handling required
    • Heat-resistant gloves do not provide complete protection immediately after >3000Ā°C plasma
    • Plan work to allow proper cooling time between splices
  8. Remove spliced component:
    • After confirmed cool-down:
      • Carefully release fibre from holders
      • Use fibre handling tools (tweezers) to grip coated sections only
      • Transfer to appropriate storage or testing fixture
    • Dispose of any cleaved scrap fibres in sharps container immediately
  9. If splice is rejected:
    • Cleave out the failed splice section
    • Prepare new fibre ends
    • Repeat alignment and splicing process
    • Document failure mode in logbook for quality tracking

5. OPERATION - FIBRE TAPERING

Tapering operations use plasma to elongate fibre while reducing diameter. Available modes: bidirectional, single-direction, or custom table-based tapering.

  1. Select tapering mode and parameters:
    • Bidirectional tapering: For symmetric tapers up to 150mm length
    • Single-direction tapering: For asymmetric tapers up to 90mm length
    • Table-based tapering: For custom taper profiles using syntax-based programming
    • Define critical parameters:
      • Taper ratio (input diameter / output diameter)
      • Taper length
      • Pulling speed profile
      • Arc power profile
      • Hot zone width (can be expanded in partial vacuum mode)
  2. Load fibre for tapering:
    • Secure fibre in both left and right holders with adequate length for taper
    • Ensure sufficient fibre extends beyond holders to achieve desired taper length
    • Position initial heat zone at correct starting location
    • Verify load cell feedback system is functional (shows fibre tension)
  3. Partial vacuum mode (if required):
    • For adiabatic tapers or wide heat zone processing:
      • Verify vacuum chamber seals and O-rings are in good condition
      • Close chamber and verify seal integrity
      • Initiate vacuum pump following software procedure
      • Monitor pressure gauge during evacuation
      • Target pressure: [specify based on process requirements]
    • Never open chamber while under vacuum
    • Vacuum mode expands plasma heat zone up to 10x along fibre axis
    • If unusual sounds or pressure readings: Immediately abort and vent to atmosphere
  4. Configure taper program:
    • Use simplified LabVIEW GUI for standard tapers OR
    • Create custom program using table-based tapering interface OR
    • Import program from MATLAB/Excel if custom algorithm developed
    • Software allows 20 adjustments per second for:
      • Fibre platform positions (left and right)
      • Heat zone location
      • Arc power settings
    • Validate program with simulation or test run before using on valuable fibre
  5. Initiate tapering process:
    • STOP - Final safety check:
      • Fibre secured properly? YES
      • Taper parameters confirmed? YES
      • If using vacuum: Chamber sealed and pressure correct? YES
      • Exclusion zone clear? YES
    • Click ā€œStart Taperā€ command
    • PLASMA WILL ACTIVATE - Stand clear of equipment
  6. Monitor tapering process:
    • Watch ā€œHot Imagingā€ live view of molten glass during tapering
    • Monitor load cell feedback showing fibre tension
    • Verify smooth, controlled pulling motion
    • Watch for taper formation via camera views
    • Typical taper time: Several minutes depending on length and profile
    • Do NOT interfere with process once started
    • If any abnormal behaviour observed: Use emergency stop immediately
  7. Post-taper procedures:
    • Process completes automatically when programmed taper profile achieved
    • Software captures images and process data
    • Cooling period MANDATORY: Minimum 15 minutes before handling
    • If in vacuum mode:
      • Software will prompt for controlled venting
      • Allow chamber to return to atmospheric pressure
      • Verify pressure equalised before opening chamber
    • Use thermal camera to verify taper has cooled sufficiently
  8. Taper quality verification:
    • Use scanning function to measure taper diameter profile
    • Compare measured profile to target specification
    • Visual inspection for:
      • Smooth taper transition
      • Absence of modulations or stress concentrations
      • Symmetry (for bidirectional tapers)
      • Proper taper length
    • Record taper quality data in logbook
    • If taper meets specifications: Proceed to removal
    • If taper is defective: Document failure mode and repeat process
  9. Remove tapered fibre:
    • After confirmed cool-down and quality verification
    • Carefully release fibre from holders using fibre handling tools
    • Support taper along entire length to prevent breakage
    • Transfer to appropriate storage or next processing step
    • Clean work area and dispose of scrap in sharps container

6. OPERATION - PRECISION CLEAVING

The CMS includes in situ ultrasonic diamond-tipped cleaving capability for production of end caps, tapers, and accurate length components.

  1. Prepare fibre for cleaving:
    • Load fibre to be cleaved in appropriate holder
    • Position fibre so desired cleave location is in field of view
    • Use real-time scanning to identify exact cleave position
    • Achieve cleave location precision of Ā±12.5Ī¼m using reference marks
  2. Configure cleaving parameters:
    • Diamond-tipped blade with piezo-based frequency and amplitude control
    • Set ultrasonic frequency and amplitude based on fibre diameter:
      • Larger fibres (up to 500Ī¼m): May require higher amplitude
      • Smaller fibres: Lower amplitude prevents shattering
    • Position semi-automated backstop for blade travel limit
    • Verify blade is sharp and undamaged (inspect through camera if possible)
  3. Execute cleave:
    • STOP - Safety check before cleaving:
      • Safety glasses on? YES
      • Hands clear of cleaving zone? YES
      • Fibre properly positioned? YES
    • Initiate cleave command in software
    • Ultrasonic blade will advance to fibre, vibrate, and create cleave
    • Process typically completes in <1 second
    • Do NOT manually interfere with cleave process
  4. Cleave quality assessment:
    • High-resolution camera inspection of cleaved end face
    • Good cleave characteristics:
      • Flat, perpendicular end face
      • Minimal chipping or fracture
      • Clean separation
    • If cleave is poor quality:
      • Adjust cleave parameters (frequency, amplitude, blade position)
      • May need to cleave back further and repeat
    • Software captures images for documentation
  5. Post-cleave handling:
    • Cleaved fibre end is VERY SHARP
    • Use extreme care when removing cleaved component
    • Use tweezers or fibre handling tools only
    • Place cleaved scrap immediately in sharps container
    • Never allow cleaved fibres to fall on floor or work surface
  6. Cleaving blade maintenance:
    • Diamond blade requires periodic replacement based on usage
    • Signs blade needs replacement:
      • Poor cleave quality despite parameter adjustments
      • Visible damage to blade tip
      • Inconsistent cleave results
    • Blade replacement procedure:
      • LOCK OUT EQUIPMENT before accessing blade
      • Use nitrile gloves when handling blade
      • Follow manufacturer procedure for safe blade removal and installation
      • Dispose of used blade in sharps container (extremely sharp)
      • Test new blade on scrap fibre before critical cleaves

7. EQUIPMENT SHUTDOWN AND POST-OPERATION PROCEDURES

  1. Prepare for shutdown:
    • Complete any in-progress operations
    • Remove all fibres from holders
    • Collect all cleaved scrap and dispose in sharps container
    • Remove any fibre holders or fixtures that are not permanent
  2. Software shutdown sequence:
    • Save any custom programs or process data
    • Backup critical data if required
    • Close processing software following proper exit procedure
    • Do NOT force-quit software - may cause data loss or system errors
  3. Plasma system shutdown:
    • System will automatically cool down electrodes using embedded cooling
    • Allow cooling cycle to complete (typically 5-10 minutes)
    • Do NOT power off during cooling cycle
    • System will indicate when safe to power down
  4. Vacuum system shutdown (if used):
    • Ensure chamber is fully vented to atmosphere
    • Verify pressure gauge shows atmospheric pressure
    • Safe to power off vacuum pump
    • Leave chamber slightly open to prevent seal damage during storage
  5. Compressed air shutdown:
    • Close compressed air supply valve (optional - can be left on if equipment used regularly)
    • If closing air supply:
      • Allow system to depressurise naturally
      • Verify pressure gauge drops to zero
      • Do NOT disconnect pressurised lines
  6. Power down sequence:
    • Shut down PC in normal manner
    • Switch off CMS main power
    • Verify all indicator lights are off
    • Do NOT disconnect power cables while system is energised
  7. Post-operation inspection:
    • Visual check for any damage or issues that developed during session
    • Note any unusual behaviour in equipment logbook
    • Check work area for any dropped fibres or glass debris
    • Verify all sharps have been disposed of properly
  8. Work area cleanup:
    • Clean all work surfaces using damp cloth (captures glass fragments)
    • Do NOT use compressed air to clean - will disperse glass particles
    • Dispose of cleaning materials in general waste (not sharps unless glass embedded)
    • Return all tools and accessories to designated storage
    • Ensure fire extinguisher and emergency equipment are accessible
    • Leave work area clean and ready for next user
  9. Sign out from equipment logbook:
    • Record: End time, operations completed, component count, any issues
    • Note any maintenance needs or concerns
    • If any problems occurred:
      • Complete incident report if safety-related
      • Tag equipment if not safe to use
      • Inform supervisor immediately of serious issues
  10. PPE removal and hand washing:
    • Remove and dispose of nitrile gloves if worn
    • Remove safety glasses and store properly
    • Remove laboratory coat
    • Wash hands thoroughly after handling fibres, electrodes, or chemicals
    • Inspect hands for any glass fragments (use magnification if needed)

Emergency Shutdown Procedures

EMERGENCY STOP - Use in ANY of these situations:

EMERGENCY SHUTDOWN PROCEDURE:

  1. IMMEDIATELY PRESS EMERGENCY STOP BUTTON
    • Large red button on equipment front panel
    • Pressing will immediately shut down:
      • Plasma generation
      • All motion systems
      • Processing functions
    • Emergency stop does NOT remove electrical power (use main isolator for electrical emergencies)
  2. If emergency stop button fails or is inaccessible:
    • Turn off main power at mains isolator switch
    • Close compressed air supply at emergency shut-off valve
    • Evacuate area if situation is worsening
  3. Assess the situation:
    • Fire: Follow fire emergency procedures (see below)
    • Electrical issue: Do not approach equipment - call electrician
    • Compressed air failure: Evacuate and call facilities/supervisor
    • Personal injury: Provide first aid and call emergency services if serious
    • Equipment malfunction: Assess damage and determine if area is safe
  4. DO NOT attempt to restart equipment until:
    • Emergency condition has been completely resolved
    • Equipment has been thoroughly inspected by competent person or supervisor
    • Root cause of emergency has been identified and corrected
    • Supervisor has authorised restart in writing
    • Any necessary repairs have been completed and tested
    • All safety systems verified functional
  5. Complete incident documentation:
    • Fill out incident report form immediately while details are fresh
    • Include: Date, time, personnel present, exact circumstances, actions taken
    • Attach photos if equipment damage occurred
    • Submit to supervisor and safety officer
    • Complete RiskWare report if required by university policy
    • Equipment may need to be locked out pending investigation
  6. Lock out and tag equipment:
    • If equipment is not safe to use, attach lockout tag
    • Tag must state: Date, reason for lockout, who locked out, contact details
    • Only supervisor or authorised maintenance can remove lockout

RESETTING EMERGENCY STOP (only after emergency fully resolved and authorisation obtained):

  1. Verify that emergency condition has been completely addressed
  2. Obtain supervisor approval to reset (document in logbook)
  3. Rotate emergency stop button clockwise to release (or follow equipment-specific reset procedure)
  4. System will require re-initialisation
  5. Perform complete pre-operation safety checks before resuming any work
  6. Test emergency stop button again to verify it functions correctly
  7. Proceed with caution and monitor equipment closely for any recurring issues

Emergency Procedures for Fires, Spills or Exposure to Hazardous Substances

FIRE EMERGENCY:

  1. ACTIVATE EMERGENCY STOP to shut down all CMS systems

  2. CLOSE COMPRESSED AIR SUPPLY immediately at emergency shut-off valve

  3. If fire is SMALL (smaller than a wastebasket) and CONTAINED:
    • Use appropriate fire extinguisher:
      • COā‚‚ or Dry Powder for electrical fires
      • DO NOT use water on electrical equipment
    • Aim at base of fire, sweep side to side
    • Ensure you have clear escape route behind you
    • If fire does not extinguish immediately or grows: Evacuate
  4. If fire is LARGE, SPREADING, or involves compressed gas:
    • Evacuate area immediately
    • Close door behind you (do not lock)
    • Activate building fire alarm (break glass at alarm point)
    • Call 000 (Emergency Services) from safe location
    • Provide: Location, type of fire, any hazardous materials involved
    • Evacuate to designated assembly point
    • Do not re-enter for any reason
  5. If clothing is on fire:
    • STOP, DROP, and ROLL to smother flames
    • Use fire blanket or safety shower if available
    • Once flames out, cool burned area with water
    • Seek immediate medical attention
  6. After fire is extinguished:
    • Do not re-enter area until declared safe by emergency services or supervisor
    • Equipment must be thoroughly inspected before any restart attempt
    • Complete incident report with detailed description of fire cause and damage
    • Review fire safety procedures and identify any improvements needed

THERMAL BURN INJURY:

  1. Immediately move away from heat source

  2. Cool affected area under running cold water for at least 20 minutes
    • Use cool tap water, not ice
    • Start cooling as quickly as possible
    • Continue cooling even if pain subsides
    • Remove jewellery or constricting items before swelling occurs
  3. Do NOT:
    • Apply ice directly to burn
    • Apply butter, oil, ointments, or ā€œhome remediesā€
    • Break any blisters that form
    • Touch burn with dirty hands or materials
  4. After cooling, cover burn with:
    • Sterile non-stick dressing from first aid kit
    • Clean plastic wrap as alternative
    • Do NOT use fluffy materials (cotton wool) that may stick
  5. Seek immediate medical attention for:
    • Burns larger than a 20-cent coin (5cm diameter)
    • Burns to face, hands, feet, genitals, or major joints
    • Burns that appear deep (white, waxy, charred, or painless)
    • Burns causing severe pain or extensive blistering
    • Burns from electrical source
    • Burns from chemical contact
    • Any uncertainty about burn severity
    • Call 000 for severe burns
  6. For minor burns (small, superficial, not on sensitive areas):
    • Continue cooling for 20 minutes
    • Apply sterile dressing
    • May use over-the-counter pain relief if needed
    • Monitor for signs of infection (increased pain, redness, swelling, pus)
    • Seek medical review if any concerns
  7. Complete incident documentation:
    • Record details in equipment logbook
    • Fill out incident report form
    • Notify supervisor immediately
    • Complete RiskWare report
    • Investigate how burn occurred to prevent recurrence

ELECTRIC SHOCK:

  1. DO NOT touch the person if they are still in contact with electrical source
    • You may also be shocked
  2. Break the circuit:
    • Switch off power at mains isolator, or
    • Use non-conductive material (dry wood, plastic) to move person away from source
    • Only if safe to do so
  3. Call 000 immediately if person is:
    • Unconscious or not breathing
    • Showing signs of serious shock (pale, clammy, rapid pulse)
    • Burned from electrical contact
  4. If person is unconscious:
    • Check for breathing
    • If trained in CPR and person not breathing: Commence CPR
    • Continue CPR until emergency services arrive or person recovers
  5. If person is conscious but shocked:
    • Have them lie down and remain still
    • Keep warm with blanket if available
    • Treat any burns (see thermal burn procedure above)
    • Seek medical attention even if person feels ā€œfineā€ - electrical shock can cause internal injuries
  6. LOCK OUT AND TAG EQUIPMENT:
    • Equipment that delivered shock must be locked out immediately
    • Attach tag stating: ā€œElectrical hazard - Do not useā€
    • Only qualified electrician can inspect and clear equipment for use
  7. Complete incident documentation:
    • Document exact circumstances of shock
    • Identify electrical fault that caused shock
    • Ensure equipment is repaired before any future use
    • Review electrical safety procedures

GLASS INJURY (Cuts or Embedded Fragments):

  1. For minor cuts:
    • Rinse wound gently with clean water
    • Apply pressure with clean cloth if bleeding
    • Once bleeding stopped: Apply sterile adhesive dressing
    • Monitor for signs of infection
  2. For EMBEDDED glass fragments:
    • DO NOT attempt to remove large or deep embedded glass
    • Cover area with sterile dressing
    • Seek medical attention for professional removal
    • DO NOT apply pressure over embedded glass
  3. For deep cuts or severe bleeding:
    • Apply direct pressure with clean cloth
    • Elevate injured area above heart level if possible
    • Do NOT remove cloth if blood soaks through - add more layers on top
    • Call 000 if bleeding is severe or does not stop within 5-10 minutes
    • Keep person calm and lying down
    • Monitor for signs of shock (pale, clammy, weak pulse)
  4. For EYE injuries involving glass:
    • DO NOT rub eye
    • DO NOT attempt to remove any object from eye
    • DO NOT apply pressure to eye
    • Cover eye gently with sterile dressing (no pressure)
    • Seek IMMEDIATE medical attention at emergency department
    • Call 000 if object embedded in eye or severe pain
    • Cover both eyes to prevent movement (injured eye will track with healthy eye)
  5. After treatment:
    • All glass injuries, even minor, must be reported to supervisor
    • Complete incident report
    • Investigate how glass injury occurred
    • Review handling procedures to prevent recurrence
    • Ensure sharps disposal procedures are being followed
  6. First aid supplies for glass injuries:
    • Sterile dressings in various sizes
    • Adhesive bandages
    • Splinter removal tweezers (for tiny superficial fragments only)
    • Eye wash and eye pads
    • Clean water for rinsing wounds

COMPRESSED AIR SYSTEM FAILURE / AIR BLAST:

  1. ACTIVATE EMERGENCY STOP

  2. CLOSE COMPRESSED AIR SUPPLY at emergency shut-off valve

  3. EVACUATE AREA if loud hissing, visible high-pressure air leaks, or flying debris

  4. DO NOT approach failed air lines or fittings - high-pressure air can cause serious injury

  5. If injury from air blast:
    • Move to safe area away from air stream
    • Seek IMMEDIATE medical attention for suspected air embolism:
      • Signs: Chest pain, difficulty breathing, confusion, loss of consciousness
      • Call 000 - air embolism is life-threatening
    • Do NOT allow casualty to move excessively - may worsen embolism
    • Treat any projectile injuries (embedded objects, cuts, bruises)
  6. Never use compressed air to:
    • Clean clothing or body
    • Direct at another person
    • Blow dust or debris (creates airborne hazards)
  7. After system failure:
    • LOCK OUT AND TAG equipment
    • Contact facilities/maintenance for pressure system inspection
    • Only qualified technician can repair and re-certify compressed air system
    • Complete incident report documenting failure mode

VACUUM SYSTEM FAILURE:

  1. ACTIVATE EMERGENCY STOP

  2. If catastrophic failure (implosion, explosion, or violent air inrush):
    • Evacuate area immediately
    • Call 000 if injuries present
    • Do not re-enter until area declared safe by supervisor or emergency services
  3. If controlled venting or slow leak:
    • Allow system to vent to atmosphere naturally
    • Monitor pressure gauge
    • Once at atmospheric pressure: Open chamber slowly
    • Inspect for damage before any further use
  4. Injuries from vacuum failure:
    • Flying glass or debris: Treat as cuts/embedded fragments (see above)
    • Noise trauma: Seek medical review if hearing affected
    • Crush injuries: Seek immediate medical attention
  5. After vacuum system failure:
    • LOCK OUT AND TAG equipment
    • Only qualified technician can inspect vacuum chamber and seals
    • Pressure testing may be required before return to service
    • Document failure mode in incident report

CHEMICAL EXPOSURE (Electrode Materials or Cleaning Chemicals):

  1. Skin contact:
    • Immediately remove contaminated clothing
    • Rinse affected area with copious running water for at least 15 minutes
    • Do NOT use neutralising agents unless specifically directed by SDS
    • If irritation persists: Seek medical attention
    • Bring SDS with you to medical facility
  2. Eye contact:
    • Immediately flush eye with water or eyewash for at least 15 minutes
    • Hold eyelids open to ensure thorough rinsing
    • Remove contact lenses if present and easy to remove
    • Seek immediate medical attention after flushing
    • Bring SDS to medical facility
  3. Inhalation:
    • Move to fresh air immediately
    • Loosen tight clothing
    • If breathing difficulty: Seek immediate medical attention
    • Call 000 if severe respiratory distress
    • Bring SDS to medical facility
  4. Ingestion (unlikely but possible):
    • Do NOT induce vomiting unless directed by Poisons Information
    • Rinse mouth with water
    • Call Poisons Information Centre: 13 11 26
    • Follow their advice
    • Seek medical attention
    • Bring chemical container or SDS
  5. After chemical exposure:
    • Complete incident report
    • Review SDS and handling procedures
    • Identify how exposure occurred and implement prevention

SOFTWARE / CONTROL SYSTEM FAILURE:

  1. Attempt emergency stop via software interface (if responsive)

  2. If software unresponsive:
    • Press physical emergency stop button
    • If both fail: Turn off power at mains isolator
  3. Record any error messages or system state:
    • Take photo of screen if possible and safe
    • Note exact sequence of events leading to failure
    • Do NOT attempt to troubleshoot during active emergency
  4. After system is stopped:
    • DO NOT attempt to restart
    • LOCK OUT AND TAG equipment
    • Contact IT support or manufacturer technical support
    • Only qualified technician can diagnose and repair software/control issues
  5. Data preservation:
    • If safe to do so, attempt to save any critical process data before complete shutdown
    • System logs may help diagnose software failure
  6. Complete incident report documenting software failure and any equipment impact

EMERGENCY CONTACTS:

Clean Up and Waste Disposal Requirements

AFTER EACH USE - CLEANING PROCEDURES:

Processing Chamber and Fibre Holders:

Electrode Cleaning (Periodic - follow manufacturer schedule):

Camera Lenses and Optics:

Work Area and Benchtop:

WASTE DISPOSAL:

Glass Waste (Fibre Scraps, Cleaved Ends, Broken Components):

Electrode Waste:

Chemical Waste (Cleaning Agents, Isopropanol, etc.):

General Waste:

Recycling:

PERIODIC MAINTENANCE CLEANING:

Weekly:

Monthly:

Annually (or per manufacturer schedule):

MAINTENANCE LOG:

References Used in the Development of This SWP

Competency Required

MANDATORY TRAINING (Must be completed before authorisation):

All training must be documented and records maintained by supervisor.

1. Manufacturer Training Course

2. Laboratory Safety Induction

3. Fibre Optic Handling and Safety

4. Electrical Safety Awareness

5. High-Temperature Process Safety

6. Compressed Air and Vacuum Systems Safety

COMPETENCY ASSESSMENT:

Competency must be formally assessed and documented before independent operation.

Theory Assessment:

Written test or oral examination covering:

  1. Safety-Critical Knowledge (Must achieve 100% on these questions):
    • Emergency stop procedure and location
    • Emergency shutdown for different emergency types
    • Thermal burn first aid procedures
    • Glass injury prevention and first aid
    • Electrical safety and when to evacuate
    • Compressed air system hazards
    • When operation must stop (red flags)
    • PPE requirements for different tasks
  2. Equipment Knowledge (Minimum 80% pass mark):
    • CMS capabilities and specifications
    • Fusion splicing principles and parameters
    • Tapering methods and applications
    • Cleaving operation and quality assessment
    • Software interface and control functions
    • Electrode function and maintenance
    • Cooling system purpose
    • Vision system operation
  3. Procedure Knowledge (Minimum 80% pass mark):
    • Pre-operation safety checks
    • Fibre preparation and loading
    • Splice parameter selection
    • Taper program configuration
    • Cleave positioning and execution
    • Shutdown procedures
    • Cleaning and waste disposal
    • Documentation requirements

Failed assessment: Review training materials, additional instruction, retest

Practical Assessment:

Supervised practical demonstration of competency in:

  1. Pre-Operation Procedures:
    • Complete all safety checks correctly
    • Identify and test emergency stop
    • Verify safety equipment presence
    • Set up work area appropriately
    • Don proper PPE
  2. Basic Operation:
    • Power up system correctly
    • Inspect and install electrodes
    • Load fibres into holders safely
    • Achieve proper fibre alignment
    • Execute a simple fusion splice
    • Assess splice quality
    • Properly shutdown system
  3. Advanced Operation (as applicable to userā€™s role):
    • Configure and execute taper program
    • Perform precision cleave
    • Use scanning functions
    • Operate vacuum system (if required)
    • Create custom splice/taper parameters
  4. Emergency Response:
    • Demonstrate emergency stop activation
    • Describe appropriate response to different emergency scenarios
    • Locate and identify use of emergency equipment
    • Demonstrate understanding of when to evacuate vs. respond
  5. Housekeeping:
    • Proper cleanup procedures
    • Correct waste disposal
    • Appropriate documentation in logbook

Assessment Requirements:

ONGOING REQUIREMENTS:

Refresher Training:

Retraining Required When:

Supervision Requirements:

Based on experience level:

Medical Monitoring:

RECORD KEEPING:

Documentation required for competency management:

  1. Training Records:
    • Manufacturer training certificate (keep copy)
    • Laboratory safety induction completion
    • All supplementary training courses
    • Refresher training attendance
    • Maintained by supervisor, copies in personnel files
  2. Competency Assessments:
    • Theory assessment results (written test or oral exam notes)
    • Practical assessment checklist (signed by assessor)
    • Date competency achieved
    • Any remedial training and reassessment
    • Maintained by supervisor
  3. Authorised Users List:
    • Current list of all authorised users
    • Date authorised, authorisation level
    • Displayed prominently near equipment
    • Updated when users added or removed
    • Reviewed annually, remove inactive users
  4. Individual Operation Logs:
    • Each userā€™s operation count tracked in logbook
    • Helps determine supervision requirements
    • Identifies when refresher training may be beneficial
    • Reviewed during annual competency review
  5. Incident and Near-Miss Records:
    • Any safety incidents involving specific users
    • May trigger retraining requirements
    • Pattern analysis for systemic issues
    • Maintained by safety officer

COMPETENCY RENEWAL:

Staff Approved to Assess Competence for This SWP

Authorised Assessors:

The following staff members are authorised to assess competency for this procedure:

Assessor Requirements:

To be authorised as an assessor, staff must:

Assessment Process:

  1. Trainee completes all mandatory training modules
    • Manufacturer training (TRN-01-0012)
    • Laboratory safety induction
    • Supplementary safety training (electrical, high-temp, compressed air, etc.)
    • Trainee reviews this SWP and associated Risk Assessment thoroughly
  2. Assessor conducts theory assessment
    • Written test or structured oral examination
    • Safety-critical questions must achieve 100%
    • General knowledge questions minimum 80%
    • If failed: Review materials, additional instruction, retest
  3. Assessor supervises practical demonstration
    • Trainee demonstrates all required practical skills
    • Assessor uses practical assessment checklist
    • Any safety-critical errors result in immediate fail
    • Corrective instruction provided for minor errors
  4. Assessor verifies competency in all required areas
    • Reviews theory and practical assessment results
    • Confirms all elements demonstrated satisfactorily
    • Ensures trainee understands limitations and when to seek help
    • Verifies trainee can respond appropriately to emergencies
  5. If competent: Assessor signs trainee off on sign-off sheet
    • Assessor signature authorises trainee for operation
    • Date of authorisation recorded
    • Supervision requirements specified (based on experience level)
    • Trainee added to authorised users list
  6. If not yet competent:
    • Specific deficiencies identified and communicated
    • Additional training and supervised practice required
    • Reassessment scheduled once trainee ready
    • May be partial reassessment (only areas that were deficient)
  7. Once signed off: Trainee added to authorised users list
    • Name added to list displayed near equipment
    • Date authorised and authorisation level recorded
    • Supervision requirements clearly noted
    • Laboratory manager notified

Authorised Users List Maintenance:

Name Date Authorised Authorisation Level Supervision Required Authorised By Notes
[Name] [DD/MM/YYYY] [Novice/Intermediate/Experienced] [Direct/Oversight/Independent] [Assessor Name] [Any special conditions]

SWP Sign Off Sheet

SWP name and version: Operation of 3SAE Combiner Manufacturing System (CMS)
Version: 1.0 - January 2026
Reference: SAIL-SWP-CMS-001

In signing this section the assessor agrees that the following persons are competent in following this SWP.

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Authorisation Levels:

Document Review Schedule

This SWP must be reviewed:

Review Process:

  1. Collect feedback from all users
  2. Review incident reports and near-miss records
  3. Check for equipment modifications or updates
  4. Verify all safety controls remain effective
  5. Update procedures as needed
  6. Re-train all users on significant changes
  7. Document review completion in equipment logbook

Version Control:

End of Safe Work Procedure

Document Control:

Related Documents

Document Control

Version Date Author Changes
1.0 January 2026 Chris Betters Initial release