Not Such a Smooth Operator
Something happened at work that reminded me of a funny event from way back during
my time at Westinghouse Oceanic Division (now part of Northrop Grumman), in Annapolis,
MD. There is a moral to this story.
During my electronics technician days there, I spent the first couple years building
PCBs, wiring harnesses, and system-level assemblies for Navy sonar systems. We had some
really slick stuff like towed vehicles with transducer arrays along the sides, nose cones
for smart torpedoes, flow sensors, proximity fuse elements, etc. The exposure to all
that, and the super-smart people that designed it, fuelled my desire to go to the trouble
of earning an engineering degree.
of my tasks for a while was to build the transducer arrays, which entailed building the
hundreds of tiny transducer elements. The assemblies were made of a machined aluminum
base plate (about 1-inch square), onto which a precisely cut low density foam block was
attached. On the top of that was a set of two machined aluminum plates that sat on either
side of a piezoelectric ceramic transducer element, which was in the center of the foam
block. We soldered silver foil tabs onto the element for later attachment to tiny wire
leads that served as pigtails for connecting to an overall array bus. The final assembly
was an acoustic antenna. One mounted on each side of the towed vehicle (the AN/AQS-14,
for those familiar with it).
A CH-53 helicopter was used to deploy the vehicle, or it could be dragged off the
transom of a ship. Shortly after we began delivering the systems, an F-16 went down off
the coast of San Diego, and one of our first AQS-14s was sent to image the ocean bottom
during the search. It managed to locate the wreckage. The images that we saw were incredible!
You would have sworn that they were optical photographs instead of acoustically generated
images. We could see bolts in the landing gear and panel lines around the canopy. It
was amazing technology for the early 1980s, and I can only imagine the superiority of
Back to my story, though. During the construction of the transducer modules, we attached
the aluminum bases to a precision fixture that sat on a granite surface table. It was
very smooth and very flat. That table was measured and guaranteed by our in-house calibration
lab (in those days, most defense contractors had complete in-house capability for repair
and calibration of TE) to be flat across its entire surface with deviations no great
than something like ±0.0005 inches (half a mil). The granite block, measuring
about 4 feet by 6 feet and a foot thick, sat in the middle of the clean room. Although
not required to wear the types of 'bunny suits" that you see in photos of semiconductor
fab facilities, we were prohibited from having food or drinks in there. No smoking was
allowed, either (in the early 1980s, people were still smoking at their workplaces –
Aviation Electronics Technician 3rd Class Cassie Gibson and Aviation Structural Mechanic
1st Class Jeffery Osborne secure an AN/AQS-14 mine detection submersible unit. (U.S.
Navy file photo)
There is a good chance that I built the sonar transducer assembly
on the top.
Well, the guy from the Cal Lab that guaranteed the perfection of our surface table
was, to be kind, slightly pompous. He knew he held the power to shut our operation down
and get people in trouble if we were not functioning within the prescribed guidelines,
and enjoyed watching the managers spring into action whenever he "discovered" a violation.
I still remember the glee in his voice when he announced, in an imperious manner of course,
that our mammoth piece of granite had suddenly gone way outside of the required flatness
specification. We had not noticed water running uphill or any new dimension of space
appearing in the confines of our room, so presumably basic physics of the universe had
not changed, so our collective suspicions were aroused. While we pondered the situation,
Measurement Man bolted through the door to go find a manager. This was a big deal because
it meant possibly have to re-measure all the modules built since the last surface table
inspection, and scrapping any that were out of spec.
A few minutes later, a team of managers returned with our hero to witness the problem.
He re-enacted the measurements in their presence and concluded the same thing – our table
was out of specification. Oh, the on-site Navy QA inspector was there as well. The place
fell silent, and then some fur started flying. Finally, managers left the area to decide
whom to best blame for the situation.
Not believing that this could be so, one of the lead technicians investigated. Incredibly,
he discovered that the culprit was not a faulty surface table, but cookie crumbs on the
bottom of the laser measuring instrument! I kid you not. As it turns out, the Cal Lab
guy had been eating a pack of cookies just before coming into the clean room to do the
measurements, and had not washed his hands before commencing with the procedure. We routinely
washed the surface of the table down with alcohol and a lintless cloth, so we were sure
it was clean prior to his arrival. When confronted with the situation, he humbly admitted
to his sin, and even produced a partially filled cookie pack from his pocket. From thence
forward, he was known affectionately as the Cookie Monster. Our surface table was re-measured
and passed the test. We were back in business, and the Cookie Monster became a much more
humble being, at least in our presence.
This scenario probably would never prompt Aesop to write a fable with an accompanying
moral to the story, but if he did, the moral might be to never be so full of yourself
that your co-workers long for the day that you slip and take a fall. St. Louis Cardinals’
Dizzy Dean famously said, "It ain't bragging if you can back it up" in reference to his plan
to pitch well enough to win the World Championship in 1934. Dizzy fulfilled his promise.
Be certain that you can fulfill yours.
A huge collection of my 'Factoids' can be accessed from my 'Kirt's Cogitations'
table of contents.
Topical Smorgasbord, another manifestation of Factoids,
are be found on these pages:
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4 | 5
| 6 | 7
| 8 | 9
| 10 |
11 | 12 |
13 | 14
| 15 |
16 | 17 |
18 | 19
| 20 |
21 | 22
| 23 |
24 | 25 |
26 | 27
| 28 |
29 | 30 |
31 | 32
| 33 |
34 | 35 |
All pertain to topics that are related to the general engineering and science theme
of RF Cafe.