A guy that I work with was cleaning the bearings on a laser stage on a stepper, a multimillion dollar machine used to make computer chips. He noticed that a part of a mirror had broken off, so he did the appropriate thing and freaked out–the mirrors cost around $200,000; they’re made out of large chunks of quartz and polished to a flatness of a few ten millionths of an inch. Setting them up is one of the major pains in the ass for our part of the industry. He called our rep who said “Did you find another job for yourself when you were in there?” Money was tight, so we tried for a day to get the tool to work with the broken mirror. After that, we gave up and bought the part. It took several weeks to replace the part and requalify the tool. Oh yeah, my coworker had a reputation of being rough on tools, and and all of this was done under the watch of a new department head that was proud of his reputation as a hardass.
The guy swore that he didn’t do anything, and I’m pretty sure that he was right. I had bumped the mirror in the same place two years before, and I think that it took that long for the crack to propagate in the quartz (The tool had been acting worse over the last six months in a manner that backs me up.) I’m not sure which was worse, to have made a $200K screwup, or to be the flake that, when something broke when I was nowhere around and the “cowboy” of the department was doing the work, took responsibility because they bumped something years before.


