After a factory changes over, operators often go straight to ramping up speed and running volume. The first reel of cable comes off the line, they glance at the surface, see no major issues, and keep running. By the time they’ve run several kilometers, the customer’s sampling inspection finds the pitch is off and the concentricity is insufficient – and the entire reel is scrapped.
Where’s the problem? The first reel of cable wasn’t inspected item by item.
After a changeover on a fiber optic cable production line, equipment parameters have changed, material batches may have changed, and dies may have been replaced. The first reel of cable is the “touchstone” – it must be confirmed as qualified item by item before mass production. Today let’s talk about first article confirmation for cable equipment, and how Hongkai, as a Premier Cable Machine Manufacturer, helps customers make this action solid at the equipment level.
1. First Article Confirmation: What Exactly Is Confirmed?
For the first reel of cable after a changeover, it is recommended to confirm the following indicators item by item:
1. Appearance. Is the sheath surface smooth, free of bubbles, scratches, pitting, or bamboo joints? The sheath surface quality of the fiber optic cable sheathing line must be checked on the first article.
2. Outer diameter. Measure the sheath outer diameter with a laser diameter gauge or micrometer to see if it is within tolerance. Hongkai’s fiber optic cable sheathing line is equipped with a high-precision laser diameter gauge (accuracy 0.2 μm) – the first article’s outer diameter can be read directly on the touchscreen.
3. Concentricity. Cut a cross-section and examine wall thickness under a microscope. Industry standards require concentricity ≥ 98%; Hongkai measures 98.6%. The first article must be cross-sectioned for confirmation.
4. Wall thickness tolerance. For a nominal 1.8 mm sheath, wall thickness tolerance should be ≤ 0.05 mm. Hongkai measures ≤ 0.04 mm. Measure at multiple points on the first article and take the average.
5. Stranding pitch. After a changeover on the SZ stranding line, take a section of cable core and measure the distance of a single helix with a steel ruler. Industry standard ≤ ±0.1 mm; Hongkai measures ≤ ±0.08 mm.
6. Pay-off tension. Check whether the real-time tension curve on the touchscreen is stable. Hongkai’s SZ stranding line has pay-off tension fluctuation ≤ ±0.4 N.
7. Length counter accuracy. Measure an actual length and compare it with the touchscreen display. If deviation exceeds 1%, recalibrate the length counter factor.
8. Fiber attenuation. Use an OTDR to test the attenuation of the first article cable. Whether the process parameters of the fiber coloring machine and secondary coating line for optical fiber are appropriate is ultimately reflected in attenuation.
9. Binder yarn quality. Is the binder yarn on the SZ stranding line uniform, free of yarn breaks or loose yarn? Is the yarn breakage switch sensitive?
10. Winding quality. Is the take-up winding on the fiber optic cable sheathing line and SZ stranding line neat, free of overlapping or jumping?
2. How to Perform First Article Confirmation: Three Steps
Step 1: Low-speed trial production. After changeover, run at low speed first. Once all units on the fiber optic cable production line – from the fiber coloring machine to the fiber optic cable sheathing line – are speed-matched, gradually increase speed. Take the first article sample at a stable speed.
Step 2: Item-by-item inspection. Inspect each item according to the checklist above and record the data. The touchscreen on Hongkai equipment can display real-time data such as tension, outer diameter, and temperature, which operators can read directly. Cross-section slicing, pitch measurement, and attenuation testing require dedicated tools.
Step 3: Sign-off confirmation. Once the first article passes inspection, the operator and shift supervisor sign off before mass production can begin. Inspection records are stored in the equipment archive.
3. What to Do If the First Article Fails Inspection?
Case 1: Sheath concentricity deviates. First wipe the laser diameter gauge lens, then check the alignment of the core and sleeve. For concentricity adjustment on the fiber optic cable sheathing line, Hongkai engineers can provide remote guidance.
Case 2: Stranding pitch deviates. First check whether the encoder coupling is loose, then check whether the pitch factor needs recalibration. For pitch calibration on the SZ stranding line, there is an operating guide on the touchscreen.
Case 3: Bubbles on the sheath surface. Check whether the sheath compound has absorbed moisture and whether the extrusion temperature is too high. LSZH material on the fiber optic cable sheathing line is temperature-sensitive – a temperature deviation exceeding ±2°C can cause bubbles.
Case 4: Fiber attenuation too high. Check whether the pay-off tension of the fiber coloring machine is too high, whether the excess length of the secondary coating line for optical fiber is appropriate, and whether the stranding tension of the SZ stranding line is too high.
Case 5: Inaccurate length counting. Recalibrate the length counter factor. There is a calibration page on the touchscreen – simply enter the new factor according to the formula.
4. How Does Hongkai Equipment Help Customers with First Article Confirmation?
First, real-time display of key data on the touchscreen. The touchscreens of the entire fiber optic cable making machine series display real-time data such as tension, temperature, outer diameter, and speed. Operators don’t need extra instruments – they can judge from the screen.
Second, recipe storage reduces changeover variables. Hongkai equipment can store process parameters for 20 products. During changeover, one-touch loading ensures parameters are not entered incorrectly. During first article confirmation, the parameters are already the “standard answer” – operators only need to confirm the equipment is executing them correctly.
Third, alarm troubleshooting guidance. When the first article fails inspection, the built-in fault code quick-reference table on the touchscreen tells operators “where to check first.” The fiber optic coloring line, loose tube line, SZ stranding line, fiber optic cable sheathing line, FTTH optical cable manufacturing machine, and indoor optical fiber production line all support this.
Fourth, remote support. If problems arise during first article confirmation, Hongkai engineers can provide remote video guidance, with a 2-hour response time during working hours. In 2024, Hongkai completed 89 overseas remote video support sessions, with an average resolution time of 32 minutes.
Fifth, first article confirmation process included in training. When Hongkai engineers go on-site for installation and commissioning (12 to 18 days from unpacking to producing the first qualified reel), they train customer operators to master the first article confirmation process. The bilingual (Chinese/English) Operation Manual can serve as a reference for compiling the first article confirmation checklist.
5. One Table to Understand: First Article Confirmation Checklist
| Inspection Item | Standard | Inspection Method | Hongkai Measured |
|---|---|---|---|
| Sheath appearance | Smooth, no bubbles, no scratches | Visual | — |
| Sheath outer diameter | Within tolerance | Laser diameter gauge/micrometer | — |
| Concentricity | ≥ 98% | Cross-section slicing microscope | 98.6% |
| Wall thickness tolerance | ≤ 0.05 mm | Multi-point measurement | ≤ 0.04 mm |
| Stranding pitch | ≤ ±0.1 mm | Steel ruler measurement | ≤ ±0.08 mm |
| Pay-off tension | ≤ ±0.5 N | Touchscreen real-time curve | ≤ ±0.4 N |
| Length counter accuracy | Deviation ≤ 1% | Actual measurement comparison | — |
| Fiber attenuation | Meets product standard | OTDR test | — |
| Binder yarn quality | Uniform, no yarn breaks | Visual + yarn breakage switch test | — |
| Winding quality | Neat, no overlapping | Visual | — |
📩 Get a First Article Confirmation Checklist Template and Training Support
If you are procuring a fiber optic cable production line for an overseas project, or want a bilingual (Chinese/English) first article confirmation checklist for your operators, feel free to contact the Hongkai technical team.
Just tell us three things:
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What type of cable do you want to make? (Loose-tube / FTTH / indoor cable)
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Where will the factory be built? (This affects voltage system and certification requirements)
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Is your current changeover frequency high?
We will provide a preliminary equipment configuration proposal, first article confirmation checklist template, and quotation within 5 working days.
📧 Email: sales2@hkofcmachine.com
🌐 Website: https://hkofcmachine.com/
