TELDOR CABLES TELECOM LTD

Quality Assurance Plan - Optical Fiber Cables

Document No. 02-001E Revision F Date 01/02/2015 Page 1 of 6

Written: Eran Reizner Approved: Zeev Mazal Signature:

1. Scope
This document describes the quality assurance plan for optical fiber cables at Teldor Cables Telecom
Ltd. It pertains to both single-mode fiber cables as well as to multi-mode fiber cables. The plan covers
all quality assurance activities: materials purchasing control, quality assurance during manufacturing
and final testing and packaging.

2. Applicable Documents
Quality System Procedures 00-0XX
Operators quality inspection procedures 09-0XX
Inspection and testing instructions for Fiber- 10-005
Optic cables
New Product Qualification Specification - 10-026
Optical fiber Cables
Materials Incoming Inspection Procedures 10-003
Test Equipment Calibration Procedures 11-000
Packing, Marking and Shipping instructions 15-00X

In addition, the quality assurance plan of optical fiber cables is derived from the following documents:

 For standard cables - the standard cable specification

 For non-standard cables - the customer specifications as approved in the contract review
 The purchase order
 Applicable national and international standards.

The quality assurance plan for optical fiber cables is described schematically in Figure 1.

3. Purchasing Control
The purchasing control is carried out according to the Quality System procedure 00-704 “Purchasing
Control and Verification”.

The purchasing department issues purchasing order requirement according to the manufacturing plan
and material availability. The requirements are submitted to the Quality Assurance Manager and the
Company manager for approval. A signed requirement is the basis for issuing a material purchase
order. Materials are ordered only from qualified vendors who are listed in the Qualified Vendor List.

The materials are usually ordered according to Material Specifications issued by the Engineering
department and approved by the Quality Assurance Manager. The QA manager may decide to adopt a
supplier material specification as the official Teldor material specification.

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Quality Assurance Plan - Optical Fiber Cables

Document No. 02-001E Revision F Date 01/02/2015 Page 2 of 6

All materials arriving to the plant are subjected to incoming inspection or testing according to a pre-
defined testing program No. 10-003. The material specifications and the incoming inspection
procedures are listed in Table 1.

Following material approval, it is placed in the company stores and identified either by a suitable
label as “Approved” or located in a pre-determined space identified as devoted only to approved
materials.

Table 1: Materials Used in Producing Optical Fiber Cables

Material Type Material Type Material

Specification
Central member Steel MW-001
FRP MD-001
Loose tube PBT MP-005
In-tube gel MJ-001
Between tube gel MJ-002
Optical fibers Single Mode MF-001
Multi Mode MF-002, MF-003
Fiber colors UV-cured Acrylate Supplier Spec
Dummy elements Polyethylene MP-002
Binding tape Binder MB-001
Wrapping tape Polyester MM-001
Moisture absorbing MM-003
tape
Jacket material Polyethylene MD MP-002
HFFR Supplier Spec
PVC MP-006
Tape armor Steel tape MS-001
Aluminum MA-001
moisture barrier
Between jackets gel MJ-003
Strengthening yarn Aramid Yarn Supplier Spec
Fiberglass MD-002
Suspension strand Galvanized Steel MW-002

4. Manufacturing Quality Assurance

The quality assurance during manufacturing is based on four types of activities:

 Operator inspection and testing.

 Automatic on-line measuring and controlling equipment
 Product inspection and testing by quality assurance personnel
 Continuous process audit by quality assurance personnel.

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Quality Assurance Plan - Optical Fiber Cables

Document No. 02-001E Revision F Date 01/02/2015 Page 3 of 6

The operators are responsible for the quality of their product. They perform specified tests and
measurements on the product during and after performing their manufacturing tasks. The operator
quality inspection tasks are defined in appropriate procedures. The operators are authorized to reject a
product if it fails to meet the product specifications.

Teldor Cables maintains a sophisticated computer control of the production floor. Computer terminals
are located near each manufacturing facility and all the information pertaining to the manufacturing is
stored in the computer. The operators are responsible for:

 Logging all their measurement results in the computer

 Inform the system of the quantity of raw materials used in each process
 Request maintenance operations
 Approve the product conformity to spec

Tolerances and other requirements are stored in the computer so that a warning is issued
automatically if a measurement result is out of spec.

As the cabling step is crucial for the product conformance, all cabling operation approved by the
department supervisor after every set-up.

Quality assurance personnel carry out optical and geometrical tests during the manufacturing process
and on the final product. The tests are carried out in the quality assurance laboratory using carefully
calibrated equipment. The test results are logged into a computer for future analysis and serve to issue
certificate of test for each optical fiber cable.

The quality assurance personnel are authorized to stop a manufacturing process and to reject a
product.

Quality assurance personnel carry out process inspection. Conformance of the process parameters to
appropriate documents is checked, and measurements are carried out on the products during
manufacturing.

The tests carried out by the operators at each manufacturing stage are given in Table 2. The tests
carried out by the quality assurance personnel at each stage are given in Table 3. Consult Figure 1 for
reference.

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Quality Assurance Plan - Optical Fiber Cables

Document No. 02-001E Revision F Date 01/02/2015 Page 4 of 6

Table 2: Operator Inspection

Process Procedure Code Inspections and Tests

Fiber dying 09-007 Visual and line inspection
Color stability
Color conformance
Tube manufacture 09-003 Visual and line inspection:
Fiber color conformance
Tube color conformance
Tube outer diameter
Tube wall thickness
Tube concentricity
Fiber excess length
Proper gel filling
Attenuation by OTDR

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Quality Assurance Plan - Optical Fiber Cables

Document No. 02-001E Revision F Date 01/02/2015 Page 5 of 6

Table 2: Operator Inspection (continued)

Process Procedure Code Inspections and Tests

Cabling 09-005 Visual and line inspection
Cable components and structure
Polyester/swelling tape overlap
Pitch
For gel-filled cores – gel filling
Outer diameter
Jackets 09-002 Visual and line inspection
Outer diameter and ovality
Jacket thickness and concentricity
Jacket color
Cable components and structure
(including geometrical conformance in
non-circular cables)
Cable elements separation in zip cables
Metallic/non-metallic tape overlap
Jacket integrity (spark testing)
Printing text and quality
Length marking accuracy

Table 3: Quality Assurance: Product Inspection and Test

Process Specification Inspections and Tests

Cabling 10-005 Central member type and diameter
Tube/tight buffer geometry
Stranding order, pitch and colors. Core integrity
Attenuation at 1550 nm (SM) or 850 nm (MM) - OTDR
Optical length
Cabling set-up is approved by department supervisor
Final jacket 10-005 Outer diameter and ovality
Jacket thickness and concentricity
Jacket color and quality
Core covering overlap
Core structure and colors on both cable ends
Twist for armored cables
Cable elements separation in zip cables
Water penetration
Attenuation at 1310, 1550 and 1625 nm (if needed) (SM)
or 850 and 1300 nm (MM) - OTDR
Printing text and quality
Length marking accuracy
Packaging quality
All other required Product Inspections and Testing as
required in the contract review

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Quality Assurance Plan - Optical Fiber Cables

Document No. 02-001E Revision F Date 01/02/2015 Page 6 of 6

5. Documentation
Identification tags accompany each product through all the manufacturing stages. All authorizations
are marked on the tags.

All the measurements and inspection results carried out by the quality assurance personnel are
recorded in the company computer:

 All geometrical and structural measurement results. Tolerances are built into the system so that
deviations from spec are automatically pointed out.
 Manual cable approval by the testing quality person
 OTDR measurements results are automatically logged into the system. Each fiber is
individually marked as conforming or not, and a cable is automatically marked as conforming
only if all the fibers conform to the spec.
 All OTDR traces are maintained and identified by cable serial number and customer. The traces
are stored in such a way that they can be later analyzed by a supervisor.

Standard certificates of test (COT) are issued for all optical fiber cables by a supervisor based on the
data stored in the computer. The COT includes OTDR measurement results at 1310, 1550, 1625 nm
(for SM fibers – as needed) or at 850 and 1300 nm (for MM fibers).

Periodic conformity and statistical reports are issued by the QA manager for quality assessment and
reporting to the company management.

Figure 1: Quality Assurance Flow Chart for Optical Fiber Cables

Figure 1.A: Quality Activities – Preparation for manufacturing

Material Purchasing Material

Customer PO
Purchase Req Control Purchase Order

Operation Inspection Material Material to

Instructions Results Incoming Incoming
Inspection Stores

Approved
material to
Stores

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Quality Assurance Plan - Optical Fiber Cables

Document No. 02-001E Revision F Date 01/02/2015 Page 7 of 6

Figure 1.B: Quality Activities During Manufacturing

Tubing/
Fiber Operator Operator Operator QC
Inspection/
Tight Inspection/
Cabling Inspection/ Inspection
Dying
Documentation Buffering Documentation Documentation

Rework or No Documen-
Pass/Fail tation
Scrap
Yes

Packaging Yes Final QC Operator

Labeling
Pass/Fail
Inspection Inspection/ Jacketing
Documentation
No

Packaging Rework or Documen-

Inspection Scrap tation

Shipped
Cable
All reworked cables undergo again full inspection

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Quality Assurance Plan - Optical Fiber Cables

Document No. 02-001E Revision F Date 01/02/2015 Page 8 of 6

6. Changes

Revision Date Change details

C 29/4/01
D 29/1/04
E 01/10/05
F 18.4.2007
Updated referenced documents numbers.
Updated logo and referenced documents numbers.
Add ”All other required Product Inspections and Testing as
approved in the contract review” at table 3
Redraw schematics; add computerized documentation,
additional tests. Logo and company name change

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