This document is a standard operating procedure for safely handling large glass blocks in a continuous polishing department. It details the equipment used, including articulated jib cranes and vacuum cups, and outlines both setup and removal processes to minimize risks of injury and damage to workpieces. Responsibilities of technicians and management in maintaining safety and equipment are also highlighted.

1. For change control: Reviewers: Approved by: For info:
Paul F. Geer
Author: Paul F. Geer
Pages Incl. cover : 12
© LOGOS 2008. All rights reserved.
Reproduction in whole or in part is prohibited without the prior written consent of LOGOS.
Doc. ID / Version: XXXXXX / A
Doc. Owner: YYYYY
DOC. TYPE: Standard Operating Procedure
Program:
TEST
Project:
Materials Handling
Glass Block Handling for Processing
DOCUMENT CHANGE & HISTORY RECORD
Name
Last
Update
Status Version Comment
Paul F. Geer 3-Aug-2008 CO A Initial release.
Applicable Documents
Ref. Title Doc. Id
[1.1]
[1.2]
Tooling Required
Description 12NC
ONE 6 – INCH VACUUM CUP N / A
TWO 3 X 6 – INCH VACUUM HAND GRIPS N / A
ONE 35 LB WEIGHT BALANCER N / A
LIFTING CHAINS N / A
Digitally signed by Paul F. Geer
DN: cn=Paul F. Geer, o, ou,
email=pfgeer@sbcglobal.net, c=US
Date: 2017.04.10 17:58:11 -04'00'

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TABLE OF CONTENTS
1 GENERAL ...........................................................................................................................3
1.1 PURPOSE.....................................................................................................................3
1.2 SCOPE .........................................................................................................................3
2 RESPONSIBILITIES............................................................................................................4
2.1 TECHNICIAN ................................................................................................................4
2.2 MANAGEMENT.............................................................................................................4
3 PROCESS DEFINITION ......................................................................................................5
3.1 EQUIPMENT.................................................................................................................5
3.2 PROCESS OVERVIEW.................................................................................................7
4 HANDLING LARGE BLOCKS FOR LAP PROCESSING....................................................8
4.1 SETUP PROCESS........................................................................................................8
4.2 REMOVAL PROCESS ................................................................................................10
APPENDIX A PROCEDURE CHECKLIST ..........................................................................12
LIST OF FIGURES
Figure 3.1 Articulated Jib Crane: Example...............................................................................................5
Figure 3.2 Jib Crane Setup for a Continuous Polisher Workstation ........................................................6
Figure 3.3 Six – Inch Vacuum Cup ..........................................................................................................6
Figure 3.4 3 X 6 – Inch Vacuum Hand – Grip ..........................................................................................7
Figure 4.1 The Weight Balancer and 6” Vacuum Cup Assembly ............................................................8
Figure 4.2 6” Vacuum Cup Attached to Work piece.................................................................................9
Figure 4.3 Hand Grips Attached to Workpiece ........................................................................................9
Figure 4.4 Arrangement for Lifting the Carrier Ring...............................................................................10

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1 GENERAL
1.1 PURPOSE
1.1.1 The Continuous Polishing Department frequently processes workpieces in sizes that are
difficult to handle without mechanical assistance. The 40-pound Encoder Block in
particular presents a risk of serious injury to technicians with limited physical capabilities
for lifting and moving, especially when loading the block into fabrication equipment.
1.1.2 To ensure safe handling, and prevent costly damage to workpieces like the Encoder Block,
the CP Department uses articulated jib cranes equipped with weight balancers for moving
heavy materials as required for operations. The weight balancer generates an upward
pull, against the force of gravity, that significantly reduces the effort needed for moving the
workpiece. The weight balancer creates an 80% reduction in the apparent weight of the
workpiece, while the swiveling action of the crane’s arm assembly enables the lateral
movement.
1.1.3 Once the technician prepares the jib crane as directed in this standard, he or she then can
manipulate with ease a heavy workpiece like the Encoder Block with a pair of hand grips
attached to the smooth surface (see Chapter 3).
1.1.4 The standards described in this document will show:
1) The precise movement and positioning at workstations.
2) The enhancements necessary to prevent injury.
3) The steps necessary for protection against damage or total loss due to accidents.
1.1.5 This document outlines the most effective means and tools necessary for consistently
maintaining optimal production quality, while also placing emphasis on safety.
1.2 SCOPE
1.2.1 The procedure discussed below shall mainly apply to materials having a rectangular form,
e.g., blocks having six (6) flat faces. The blocks should have at least two mutually parallel
blanched or ground faces, as is typical of many flat optics processed in the department.
1.2.2 The Encoder Blocks, which weigh approximately 40 pounds apiece, are the primary
examples of optics included within this document’s scope.

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2 RESPONSIBILITIES
2.1 TECHNICIAN
2.1.1 This procedure requires that technicians observe the following precautions, to prevent
injury to themselves and/or damage to workpieces:
1) Technicians must ensure that the environment does not disturb the vacuum cups in
Figure 3.3, in the next chapter. In particular, they must prevent anything from
disturbing the plungers or release tabs, as this can break the suction.
2) They must ensure the vacuum cups are clean prior to use. Any contaminants on the
rubber pads can disrupt the suction, since the pads directly contact the workpiece
surfaces. Whenever cleaning is necessary, technicians are to use WATER ONLY;
other cleaning solvents, such as Methanol, can degrade and weaken the rubber.
3) Besides making sure vacuum cups are clean, technicians must also ensure optical
surfaces of materials are free of contaminants. A dirty surface can interfere with the
contact of the vacuum cup, disrupting the suction as a dirty vacuum cup could while
in contact with a clean surface.
4) A vacuum cup is not to be used if the rubber pad appears damaged or worn, or if the
cup otherwise fails to hold onto surfaces after attachment.
5) When operating a jib crane, technicians must NEVER attempt lifting materials
exceeding the crane’s load capacity. Most cranes in Continuous Polishing are
capable of lifting up to 240 lbs maximum.
WARNING: Not following the above precautions significantly increases the risk of
optics detaching from the vacuum cups.
2.1.2 Whenever a problem arises with the jib crane and/or the associated tools, the technician
is responsible for notifying the supervisor or engineer responsible for this equipment.
WARNING:The technician is not to perform any handling operations with damaged
or defective equipment, until qualified servicing specialists complete the necessary
repairs.
2.1.3 The technician must fill a checklist, to certify that he or she has completed the required
steps of the procedure. The form for this checklist can be found in Appendix A of this
document.
2.2 MANAGEMENT
2.2.1 The area supervisor or manager must ensure all equipment at CP workstations is in
working order, and is safe for use. This includes ensuring the availability of spare parts
for cranes, vacuum cups, etc., through regular contact with suppliers.
2.2.2 The management must ensure that technicians carefully observe all work instructions as
stated in this document. He or she must regularly review checklists submitted for
processing jobs, to ensure the procedure has been completed as instructed herein.

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3 PROCESS DEFINITION
3.1 EQUIPMENT
3.1.1 Continuous Polishing operates jib cranes similar to those manufactured by the American
Industrial Manipulator Company (a.k.a. AIMCO). Figure 3.1 provides a photographic view
of one example.
Figure 3.1 Articulated Jib Crane: Example
3.1.2 A weight balancer, which is essentially a drum containing a recoiling hook line, is mounted
to a hoist at the end of a swiveling arm assembly with two rotating members. The arm
assembly, in turn, carries the attached balancer in rotation about the top of a pedestal. The
crane is generally placed next to the lapping plate of a CP machine for raising or lowering
heavy materials with the hook line.

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3.1.3 In Figure 3.2, an illustration shows the basic layout of a typical CP workstation, which
includes a drawing of a jib crane for lifting and moving heavy flat optics, like the TEST
Encoder Blocks. The elements illustrated are somewhat approximate in scale.
CP WORKSTATION COMPONENTS (AS NUMBERED ABOVE)
1. CRANE PEDESTAL 6. BLANCHARD / GRINDING MACHINE
2. SWIVELING ARM ASSEMBLY 7. CARRIER RING
3. HOIST 8. TRANSPORTER CART
4. WEIGHT BALANCER 9. STYROFOAM CUSHION
5. VACUUM CUP 10. BLOCK (WORKPIECE)
Figure 3.2 Jib Crane Setup for a Continuous Polisher Workstation
3.1.4 Component No. 5, the vacuum cup, is the critical element needed for attaching a workpiece
to the jib crane. A 6-inch vacuum cup, like the one diagrammed in Figure 3.3, is the tool
commonly used for this purpose.
Figure 3.3 Six – Inch Vacuum Cup
PLUNGER
RELEASE
TABS
VACUUM PAD
FLIP HANDLE

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3.1.5 Two other vacuum cups (not shown in Figure 3.2) are used for the physical maneuvering
of a workpiece between the CP machine (No. 6) and the transporter cart (No. 8). These
cups function as grips the technician can use for handling the workpiece. The grips are
mounted on either side of the above 6-inch vacuum cup. Figure 3.4 provides a diagram.
Figure 3.4 3 X 6 – Inch Vacuum Hand – Grip
3.2 PROCESS OVERVIEW
3.2.1 Chapter 4 details the method for handling flat optics with the above equipment. This
description covers both the setup and removal processes.
3.2.2 In the CP Department, each jib crane is generally capable of extending across the entire
footprint of the CP machine. This enables technicians to raise or lower workpieces at any
point on the surface of the lapping plate, wherever needed. However, for safety, the
technician mostly performs the material handling as close as possible to his or her standing
position, near the machine.
3.2.3 In the usual application of a crane, the technician transfers a heavy workpiece from a
transporter cart to the lapping plate of a CP machine, for setup. After processing, the
technician uses the crane to return the workpiece to the cart, resting it on the Styrofoam
cushion. After the work piece is covered with a Plexiglas shield, the cart is then moved to
another production workstation.
3.2.4 The setup and removal procedures both use the same tooling discussed in Section 3.1.
PLUNGER
RELEASE
TABS
VACUUM PAD
HANDLE

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4 HANDLING LARGE BLOCKS FOR LAP PROCESSING
4.1 SETUP PROCESS
4.1.1 Attach the 35 lb weight balancer to the hoist, and then attach the 6-inch vacuum cup to the
balancer, inserting the balancer flip handle into the hook. Figure 4.1 provides an illustration.
Make sure the hook latches of the hoist and weight balancer are properly secured.
Figure 4.1 The Weight Balancer and 6” Vacuum Cup Assembly
4.1.2 Wheel the transporter cart, and the block, to a position near the CP machine. The block
should be on a Styrofoam cushion, and enclosed under a Plexiglas cover, for protection.
Remove the Plexiglas cover to expose the block.
4.1.3 Clean the top surface of the block, to ensure a dust – free surface for secure attachment
of the vacuum cup. Use tissue paper (optical grade) moistened with a solvent that will not
degrade the glass. The vacuum pad of the cup should also be wiped with tissue and
water.
WARNING: AS INDICATED IN SECTION 2.1, EITHER A DIRTY VACUUM CUP OR A
DIRTY OPTICAL SURFACE CREATES A HAZARD OF DROPPING THE BLOCK.
4.1.4 Attach the 6-inch vacuum cup to the block’s top surface. Pressing the plunger creates
suction for holding the cup to the block. (The plunger is essentially a small pump.) Place
the cup so it is centered on the surface, as shown in Figure 4.2. Note: Pulling down the
hook line of the balancer requires effort because of the recoil.
WARNING: MAKE SURE THE VACUUM CUP IS COMPLETELY ATTACHED TO THE
SURFACE. DO NOT USE THE CUP IF IT FAILS TO MAINTAIN SUCTION. See Section
2.1.

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Figure 4.2 6” Vacuum Cup Attached to Workpiece
4.1.5 Attach two hand grips to the block’s top surface, operating the plungers to create suction
as when attaching the 6” cup. (The hand grips have a 3 X 6-inch oval pad.) Position the
hand grips next to the block’s shorter edges, with the 6-inch vacuum cup between them,
as shown in Figure 4.3.
WARNING: MAKE SURE THE GRIPS REMAIN COMPLETELY ATTACHED TO THE
SURFACE. DO NOT USE THE GRIPS IF THEY FAIL TO MAINTAIN SUCTION. See
Section 2.1.
Figure 4.3 Hand Grips Attached to Work piece
4.1.6 Stop the lapping plate’s rotation, by toggling the appropriate switch on the CP control
panel. The loading process must be done while the lapping plate is motionless.

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4.1.7 Using the hand grips (and relying on the load lessening effect of the weight balancer)
transfer the block from the transporter cart to the CP lapping plate, inserting it into the
carrier ring.
4.1.8 After the block is placed safely in the ring, remove the 6-inch vacuum cup and two hand
grips from the top surface. To loosen each of these from the surface, pull one of the
release tabs on the vacuum pad to break the suction (allowing air to get inside the pad.)
4.1.9 Unhook the 6-inch vacuum cup from the weight balancer, and move the jib crane’s
extension arm clear of the CP machine. Then unhook the weight balancer from the hoist.
Note: THE BLOCK IS NOW READY FOR PROCESSING.
4.1.10 Place on the block the load required for an effective polish. Use weights that are safe for
direct contact with the glass. After loading the block, switch on the CP through operating
the CP’s power control, to launch the polishing process.
4.2 REMOVAL PROCESS
4.2.1 Stop the rotation of the polishing lap: switch the CP to OFF through operating the
machine’s power control. Remove the weights used for loading the block.
4.2.2 Prepare to raise the carrier ring off the lap, for removing the block: attach one end of the
lifting chains to the hoist; and then connect the chains’ remaining ends to the carrier ring,
by hooking them to the three (3) eyelets on the top edge. See Figure 4.4.
Figure 4.4 Arrangement for Lifting the Carrier Ring
WARNING: STEPS 4.2.3 AND 4.2.4 REQUIRE TWO TECHNICIANS TO COMPLETE.
4.2.3 Get into position for raising the carrier ring.
Technician No. 1: Stand in the correct position for hoisting the carrier ring off the lap.

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Technician No. 2: Stand next to the carrier ring and hold the block. Be ready to guide the
carrier ring once Technician No. 1 starts the hoist.
4.2.4 Raise the carrier ring approximately 12 inches.
Technician No. 1: Pull down the hoist chain to raise the carrier ring. Do this until the
carrier ring is at the desired height.
Technician No. 2: While Technician No. 1 raises the ring, hold the ring to prevent it from
hitting the block. If allowed to swing too freely, the ring might strike the block, causing
damage.
4.2.5 Slide the block on the lapping plate’s surface, until the block is partially over the edge. For
safety, do not have the block extend beyond ½ its length. Position the block so the longer
edges aim toward the center of the plate.
WARNING: BEFORE LOWERING THE CARRIER RING, MAKE SURE THE BLOCK IS
CLEAR OF THE RING’S LOCATION ON THE LAPPING PLATE. If this precaution is
not carefully observed, the ring will have a greater risk of contacting the block,
resulting in damage to the ring and/or the block.
4.2.6 After positioning the block according to Step 4.2.5, lower the carrier ring back onto the
lapping plate, at its normal location for processing operations. Unhook the lifting chains
from the ring and the hoist.
4.2.7 Attach the 35 lb weight balancer to the hoist. Then attach the 6-inch vacuum cup to the
balancer, inserting the cup’s flip handle into the hook. (Refer to Figure 4.1.)
4.2.8 Clean the top surface of the block, to provide a dust – free surface for attaching the vacuum
cup. Wipe the vacuum pad of the 6-inch cup, if needed. Observe the WARNING of Step
4.1.3.
4.2.9 Attach the 6-inch vacuum cup to the block’s top surface, pressing the plunger to create
suction. (See Figure 4.2 for positioning on the surface.) Observe the WARNING of Step
4.1.4.
4.2.10 Attach two hand grips to the block’s top surface, operating the plunger of each to create
the suction. (See Figure 4.3 for positioning on the surface.) Observe the WARNING of
Step 4.1.5.
4.2.11 Using the hand grips, lift the block off the lapping plate and transfer it to the transporter
cart, placing the block on the Styrofoam pad. Make sure the block is properly seated in the
pad’s indentation.
4.2.12 After safely removing the block from the CP, remove the 6-inch vacuum cup and two hand
grips from the block’s top surface. Pull on the release tabs for loosening.
4.2.13 Place the Plexiglas cover over the block, to safeguard the block against dust and damage.
4.2.14 Switch the CP to ON through operating the appropriate power control, to continue
processing the remaining materials on the lapping plate.

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APPENDIX A PROCEDURE CHECKLIST
LOADING BLOCK INTO CONTINUOUS POLISHER
DO EACH STEP BELOW BEFORE POLISHING. Check corresponding box to show completion:
1. Two technicians available for operation.
2. 6-inch vacuum cup and 35 lb weight balancer attached to hoist.
3. Surface of block cleaned.
4. 6-inch vacuum cup attached to center of block surface.
5. Two oval vacuum cups attached close to block short side.
6. CP stopped.
7. Block moved into CP lap carrier, directed with oval vacuum handles.
8. Vacuum cups and weight balancer removed from block.
9. Weight placed on block.
10. CP restarted for processing.
11. 6-inch vacuum cup and weight balancer removed from hoist.
Name: Date:
REMOVING BLOCK FROM CONTINUOUS POLISHER
DO EACH STEP BELOW AFTER POLISHING. Check corresponding box to show completion:
1. CP stopped.
2. Weight on block surface removed.
3. Lifting chains hooked to polishing ring and hoist.
4. Technician No. 1 in position for lifting polishing ring.
5. Technician No. 2 in position for guiding polishing ring.
6. Polishing ring lifted approx. 12 inches while guided by Technician No. 2.
7. Block moved to edge of polishing lap, for access.
8. Polishing ring lowered to operating position.
9. Lifting chains removed.
10. 6-inch vacuum cup attached to 35 lb weight balancer, on hoist.
11. Surface of block cleaned.
12. 6-inch vacuum cup attached to center of block surface.
13. Two oval vacuum cups attached close to block short side.
14. Block lifted from CP lap carrier and into cart, directed with oval vacuum handles.
15. CP restarted for processing.
Name: Date: