Utk Training Report

1

“A STUDY RELATED TO TECHNOLOGY USED IN COLOUR TELIVISION MANUFACTURING PROCESS”

A PROJECT REPORT

DURING SUMMER TRAINING IN VIDEOCON, KASHIPUR

Utkarsh Somani

Manipal Institute of Technology

2

ACKNOWLEDGEMENT

I am extremely thankful to Techno electronics Ltd., Kashipur for having consented to give me Summer Training, which is part of the Course Curriculum at Manipal Institute of technology, B.E Course.

As student I was accustomed to an academic environment in classrooms, it was a very different experience visiting a live working Production Plant. The learning was enormous and the experience is a memorable one. I could understand how the theory of classrooms gets converted into actual production practice – creating things of social value.

I am very thankful to Mr. Ankur Sharma, Assistant Manager, R&D [CE] and Digvijay Chaudhary, Engineer-II at Kashipur, Videocon who arranged and over saw our training here. I would also like to thank Mr. Naresh Pant, Quality Head and all the people who took out time of their busy schedule to explain to us the details of the Color Television manufacturing Process.

I would specially like to thank Mr. A.K. Gangwal, Factory Account Head for being there to help whenever required during my training session.

We dedicate this humble effort in the Feet of the Lord Almighty Who has constantly showered us with His Grace, Blessings and Protection.

3

TABLE OF CONTENTS

I KNOWING VIDEOCON

1. Chief executive officer (CEO)2. Mission and Vision3. Company profile

II VIDEOCON ASSEMBLY TELEVISION PLANT

1. LIQUID CRYSTAL DISPLAY T.V.2. Direct 2 Home (D2H)3. COLOUR PICTURE TUBE T.V.4. CASSIS DESCRIPTION5. Liquid crystal Display (LCD) Television

III TELEVISION ASSEMBLY PROCESS PLANT

a. LCD ASSEMBLY PROCESS

b. CPT ASSEMBLY PROCESS

1. P.M.S (Plastic Moulding Shop)

Formation of Front Cover

Formation of Back Cover

4

2. Paint shop

Front Cover, Switches Keys and Power Knobs

3. C.T.V CABINET ASSEMBLY LINE

Mask Assembly

Mask Assembly 1

Mask Assembly 2

Mask Assembly 3

Speaker Wiring

CPT Placing

CPT Preparation 1

CPT Preparation 2

Washer connection

Pre launching inspection

Placing speaker connection

4. C.T.V FA LINE

Chassis docking

Placing anode cap

Harnessing

Switch on

B+ Adjustment

5

Screen focus voltage adjustment

Purity patch check

NTSC check point

White Balance

Picture QC-1

5. Back Cover Placing

B/C Docking

B/C Fitting

6. Final Quality Checks

High voltage Testing

AV in & out checking

Sound Quality Check

Picture QC-2

Aesthetical checking

7. Last Quality Assurance (LQA)

8. Barcode pasting & Scan

9. Packaging

10. Outgoing Quality Assurance (OQA)

6

III Line Balancing Technique

IV CONCLUDING REMARKS59

CEO

7

K. R. KIMVice Chairman and CEOVideocon Industries LimitedK R Kim was appointed as Vice Chairman and CEO, Videocon Industries Limited in 2008. Since then, he has led the company to expand its operations throughout the country in the Domestic and Global operations of the consumer durables and infotainment division.A veteran in the consumer goods industries and the former MD of LG electronics, K.R Kim, a Law graduate from Seoul National University has been associated for over 30 years with LG Electronics before joining Videocon. During his tenure he served at esteemed positions of President and that of a Managing Director.K.R Kim’s proficient leadership skills, task driven approach and matchless degree of excellence and discipline has conspicuously carved his identity worldwide. Moreover, he has been the proud recipient of the ‘Super Achiever’ award from CETMA (Consumer Electronics and TV Manufacturers Association) for his role in advancing maturity of India’s Electronics and Durable goods market. He has also been awarded for Excellence in Corporate Leadership and Entrepreneurial Spirit established by CNBC – TV 18- by our Honorable Prime Minister Mr. Manmohan Singh.

8

VISION & MISSION

9

Today the group operates through 4 key sectors:

Consumer Electronics, Home Appliances & Compressor manufacturing in India

Videocon enjoy a pre-eminent position in terms of sales and customer satisfaction in many of our consumer products like Color Televisions, Washing Machines, Air Conditioners, Refrigerators, Microwave ovens and many other home appliances, selling them through a Multi-Brand strategy with the largest sales and service network in India. Refrigerator manufacturing is further supported

Videocon Group

Consumer Durables CPT CRT glass Oil & Gas

10

by our in-house compressor manufacturing technology in Bangalore.

Display industry and its components

With the Thomson acquisition Videocon has emerged as one of the largest Color Picture tube manufacturers in the world operating in Italy, Poland and China, continuing to lead through new innovative technologies like slim CPT, extra slim CPT and High Definition 16:9 format CPT.

Color Picture Tube Glass

Videocon is one of the largest CPT Glass manufacturers in the world with a high level of experience and technical expertise operating through Poland and India. Videocon will leverage on this synergy after the Thomson acquisition to internally source glass for its CPT manufacturing increasing efficiencies and lowering costs.

Oil and Gas

An important asset for the group is its Ravva oil field with one of the lowest operating costs in the world producing 50,000 barrels of oil per day. The group has ambitious plans for expansion in sector globally.

11

COLOR TELEVISION PICTURE TUBE

Introduction

Cutaway rendering a color CRT

1. Three Electron guns (for red, green, and blue phosphor dots)

2. Electron beams

3. Focusing coils

4. Deflection coils

5. Anode connection

12

6. Mask for separating beams for red, green, and blue part of displayed image.

7. Phosphor layer with red, green, and blue zones.

8. Close-up of the phosphor-coated inner side of the screen

The Cathode Ray Tube (CRT) is a vacuum tube containing an electron gun (a source of electrons) and a fluorescent screen, with internal or external means to accelerate and deflect the electron beam, used to create images in the form of light emitted from the fluorescent screen. The image may represent electrical waveforms (oscilloscope), pictures (television, computer monitor), radar targets and others.

The CRT uses an evacuated glass envelope which is large, deep, heavy, and relatively fragile

Construction

A cathode ray tube is a vacuum tube which consists of one or more electron guns, possibly internal Magnetic deflection plates, and a phosphor target. In television sets and computer monitors, the entire front area of the tube is scanned repetitively and systematically in a fixed pattern called a raster. An image is produced by controlling the intensity of each of the three electron beams, one for each additive primary color (red, green, and blue) with a video signal as a reference. In all modern CRT monitors and televisions, the beams are bent by magnetic deflection, a varying magnetic field generated by coils and driven by electronic circuits around the neck of the tube, although electrostatic deflection is commonly used in oscilloscopes, a type of diagnostic instrument.

Working

13

Color tubes use three different phosphors which emit red, green, and blue light respectively. They are packed together in stripes (as in aperture grille designs) or clusters called "triads" (as in shadow mask CRTs). Color CRTs have three electron guns, one for each primary color, arranged either in a straight line or in a triangular configuration (the guns are usually constructed as a single unit). A grille or mask absorbs the electrons that would otherwise hit the wrong phosphor. A shadow mask tube uses a metal plate with tiny holes, placed so that the electron beam only illuminates the correct phosphors on the face of the tube.

Phosphor persistence

Various phosphors are available depending upon the needs of the measurement or display application. The brightness, color, and persistence of the illumination depend upon the type of phosphor used on the CRT screen. Phosphors are available with persistence ranging from less than one microsecond to several seconds. For visual observation of brief transient events, a long persistence phosphor may be desirable. For events which are fast and repetitive, or high frequency, a short-persistence phosphor is generally preferable.

Micro channel plate

When displaying fast one-shot events the electron beam must deflect very quickly, with few electrons impinging on the screen; leading to a faint or invisible display. Oscilloscope CRTs designed for very fast signals can give a brighter display by passing the

Shadow Mask Aperture Grill

14

electron beam through a micro-channel plate just before it reaches the screen. Through the phenomenon of secondary emission this plate multiplies the number of electrons reaching the phosphor screen, giving a significant improvement in writing rate (brightness), and improved sensitivity and spot size as well.

Convergence in color CRTs

The three beams in color CRTs would not strike the screen at the same point without convergence calibration. Instead, the set would need to be manually adjusted to converge the three color beams together to maintain color accuracy.

Degaussing

The process of eliminating magnetization on the CRT is called Degaussing. The image quality of the monitor is adversely affected if the internal component becomes magnetized. This can happen due to exposure to magnetic field (by putting some magnet such as stereo speaker near the CRT). Magnetization manifests itself through splotches of color on the screen, especially in the corners.

Most of the modern CRT today uses built in Degaussing circuit. The degaussing circuit uses a coil of wire to neutralize magnetic fields within the CRT.

15

CHASSIS DESCRIPTION

VPCIC HPCT SMPS FBT 500v,220 µF PTC NTC

16

Base PCB AV in & out conn. Tuner NXP Micon (MCU) Sound IC

Main Parts of PCB:

1.Vertical projection control IC: This IC controls the vertical projection of the CTV Display.

2.Horizontal projection control IC: This IC controls the horizontal projection of the CTV Display.

3.SMPS: It stands for Switch Mode Power Supply. SMPS delivers various voltages according to the requirement.

17

4.FBT (Fly Back Transformer): This transformer converts the 230v to 2.2 kv.

5. High voltage Capacitor: Capacitor stores voltage up to 500volts. It has the storage capacity of 220µF.

6.PTC: PTC stands for Positive Temperature coefficient of resistance. It means resistance increase with the increase in temperature.

7.NTC: NTC stands for Negative Temperature coefficient of resistance. It means that resistance decrease with the increase in temperature.

8.Base PCB: This PCB is connected to the neck of the CPT. It controls the voltage to control the electron gun. Earth wire is also connected to the base PCB.

9.AV in & out connector: This is the connector for AV in & out for audio video connection to external device like DVD player, camera etc.

10. Tuner: Tuner basically tunes the frequency received from the external source according to the circuit.

11. NXPMicon Microcontroller: It is a microcontroller which control and process the data

18

related to picture brightness, contrast, sharpness and all channel details.

12. Sound IC: This IC control and process the sound signal taken from RF signal .

LIQUID CRYSTAL DISPLAY

19

A liquid crystal display (LCD) is a thin, flat electronic visual display that uses the light modulating properties of liquid crystals (LCDs). LCDs do not emit light directly.   It is an electronically-modulated optical device made up of any number of pixels filled with liquid crystals and arrayed in front of a light source (backlight) or reflector to produce images in colour or monochrome.

LCDs have displaced cathode ray tube (CRT) displays in most applications. Some of the reasons are stated below: -

1) They are usually more compact, lightweight, portable, and less expensive.

2) They are available in a wider range of screen sizes than CRT and other flat panel displays.

3) LCDs are more energy efficient and offer safer disposal than CRTs.

4) Its low electrical power consumption enables it to be used in battery powered electronic equipment. 

TYPES OF LIQUID CRYSTAL

There are various types of liquid crystals substances. Depending on the temperature and particular nature of a substance, liquid crystals can be in one of several distinct phases. Liquid crystal molecules are broadly categorized as thermo tropic and lyotropic.

Thermotropic liquid crystals will react to changes in temperature or in some cases, pressure so they are used to make LCD’s. Thermotropic liquid crystals are either isotropic or nematic. The key difference is that the molecules in isotropic liquid crystal substances are random in their arrangement, while nematics have a definite order or pattern.

20

Whereas Lyotropic liquid crystal does not react to the change to the temperature, pressure and nature of substance.

Liquid crystal molecules

Creating an LCD

The combination of four facts makes LCDs possible:

Light can be polarized. Liquid crystals can transmit and change polarized light. The structure of liquid crystals can be changed by electric

current. There are transparent substances that can

conduct electricity.

Construction:

21

Take two pieces of polarized glass. A special polymer that creates microscopic grooves in the surface is rubbed on the side of the glass that does not have the polarizing film on it. The grooves must be in the same direction as the polarizing film. You then add a coating of nematic liquid crystals to one of the filters. The grooves will cause the first layer of molecules to align with the filter's orientation. Then add the second piece of glass with the polarizing film at a right angle to the first piece. Each successive layer of TN molecules will gradually twist until the uppermost layer is at a 90-degree angle to the bottom, matching the polarized glass filters.

Working

As light strikes the first filter, it is polarized. The molecules in each layer then guide the light they receive to the next layer. As the light passes through the liquid crystal layers, the molecules also change the light's plane of vibration to match their own angle. When the light reaches the far side of the liquid crystal substance, it vibrates at the same angle as the final layer of molecules. If the final layer is matched up with the second polarized glass filter, then the light will pass through. If we apply an electric charge to liquid crystal molecules, they untwist.

22

When they straighten out, they change the angle of the light passing through them so that it no longer matches the angle of the top polarizing filter. Consequently, no light can pass through that area of the LCD, which makes that area darker than the surrounding areas.

LCD TV PREPRATION1)P.C.B Frame Prepration

Nitryl Foam is placed on the plastic panel of the L.C.D to avoid the buzzing sound produced, which is produced if pcb and plastic panel will come in direct contact.

Two P.C.B’s are placed on the plastic panel. Out of them one is power pcb and the another one is main pcb.

A steel plate with holes of A/V, S-Video, V.G.A, HDMI etc is placed with the pcb.

The P.C.B’s and steel plate, all are screwed at various positions on the plastic plate.

2)Front Cover Prepration

23

Stage-1 Front Cover is checked for any scratches, defects,

screen printing defects or any aesthetical defects. Led and Glass Lens are placed on the front cover

and screwed.

Stage-2

Button Knobs and PCB of the circuit is placed at the appropriate place and screwed.

Another PCB with I.R. Lens and an Led which indicates the power on of T.V. is placed and screwed.

F/C Inspection I.R. Lens Fitting

24

3)L.C.D Panel Prepration L.C.D. Panel is checked for any scratch of mark on

the screen. One end of LVDS connector is placed on the L.C.D.

Panel and another is left out to be connected to P.C.B.

Foam is also placed on the LCD screen to keep the distance between display and pcb plastic panel.

If the screen display is bigger than 22” then LCD needs more power to work so power connector are also placed on the LCD.

If a metal bracket is required to support the heavy LCD panel then a bracket metal is also placed on the LCD to support a heavy LCD.

4)Panel & Assembly FramePanel and Frame fixing to F/C The panel is placed on the front cover after the

application of the felt tape. Now the panel is screwed to the front cover. Foam

is also put on back side of the panel so that pcb

25

doesnt touch display otherwise electromagnetic field of both the things will get distorted.

PCB Placing Stage After the placement of the display panel, we place

the chassis i.e., plastic tray on which pcb’s are placed.

The panel is screwed from all the ends.

Reinforce Bracket and Connector Fixing Stage

26

A person places a metal bracket on plastic pcb frame to support the lcd when it is hanged to wall.

Then all the connecting wires are connected to the pcb’s properly. i.e., LCD Panel to Main PCB and to power PCB; Power PCB to the Main PCB; Connections of I.R. PCB and Key Knob PCB to te main PCB.

Speaker Fixing Stage Speakers are placed in the proper slot in the front

cover and the connecting wires of the speakers are also attached to te pcb.

The speakers are tightened to the Front Cover by screwing them.

Harnessing Stage The extra length of wires is collected together and

is tied together by the help of plastic tie, so that the wire doest interfare with te pcb.

27

Back Cover Docking and Fixing Stage Back Cover of the LCD is placed and screwed. The stand of the LCD is screwed.

5)Quality Check LineSwitiching On Whether the LCD is getting switched on or not, tis is checked

here. It is a critical process.

28

Design Data Verification Stage The person opens the main menu and enters te private factory

settings menu. Here the verifies the design data and corrects the design data is required.

QC-1 Stage Here the extra features of the LCD are checked like HDMI Port,

USB Port, S-Video etc. These all are checked by giving input to all these ports and checking the video and sound quality for them.

QC-2 Stage VGA Port is checked according to the specification sheet.

QC-3 Stage Here the DVD and AV port are checked.

Aesthetic Check Aesthetic Check of the complete LCD takes place. The panel is

sent to rejection or repair loop if any problem is found in it.

Final Packing The final packaging of the LCD is done.

DIRECT 2 HOMEThe Direct-To-Home (DTH) service is a digital satellite service that provides television services direct to subscribers anywhere in the country. Since the Signals are directly from the satellite into your

29

television sets, via our ODU (outdoor unit) that comprises of LNB / Dish / Co-axial cable & STB (Set Top Box) into your homes, you can enjoy uninterrupted viewing. This service is particularly valuable in remote and difficult to reach areas where cable Television and terrestrial television services are poor or nonexistent.

D2H is one of the advance satellite television technologies which offers:

MPEG and DVB-S2: new age television technology. Universal Remote 12 PIP Mosaic: language wise mosaic help user to see and

select channel rather than scroll channels on EPG. 246 channels Planet M Music Platform: we can listen to favorite music

on active Listening Platform. Tickers: It enables user to check latest stock market,

cricket, news update and bollywood while watching channels.

Movies: Viewer can watch most comprehensive list of Hollywood/ Bollywood/Regional pay per view movies.

Multi lingual call center. Multi lingual user interface: User can watch EPG in

2preferred languages out of the 9 language buttons on remote.

Weather watch: User can watch weather of their respective cities.

Channel Hide: User can hide specific channel from complete channel list.

30

Technical Description:

Videocon D2H service is basically nothing but the Set top Box (STB) PCB plate is placed within the television set. Due to which it can be used easily in rural and remote areas of the country.

MPEG PCB

Internal circuitry consists of MPEG power PCB which supplies power to the MPEG PCB. MPEG PCB consist of a slot in which smart card is inserted. This smart card is paired with the MPEG PCB.

31

Main PCB Main Power PCB

Apart from MPEG PCB there is a main PCB and also its power PCB. Main PCB process and control the signal coming from the RF Tuner slot.

Pairing of Smart card serial no. & Set top box serial no.:

32

It is one of the most important process in D2H Service. Smart card serial no. and set top box serial no. should match with each other. Detail information about pairing is loaded on the main server. Using Barcode scanner STBSN (set top Box serial no.) and SCSN (Smart card serial no.) is scanned and the serial no. is matched using the V- pot software.

Error occurring when SCSN and STBSN are not properly Paired:

33

If the STBSN and SCSN is scanned and “WAIT” signal is displayed on the VPOT screen then it means that smart card serial no. (SCSN) and set top box serial no. (STBSN) are not matched.

C.T.V LINE ASSEMBLY PROCESS

1) PLASTIC MOULDING SHOP Front Cover

Raw material i.e., plastic beads are feed to the I.M.M (Injection moulding machine).

34

This machine is loaded with the mould of front cover for a specific model.

This machine melts the plastic beads and injects the liquid form of plastic in the moulds.

This is cooled for few seconds and then machine forces out the formed Front cover out of the mould.

A robotic hand picks up the front cover and places it on the conveyer belt.

Now person check each and every piece aesthetically for any kind of defect or scratches on the cover.

Finally the front cover is placed in a plastic cover and stacked to be taken to the paint shop.

Back Cover

Raw material i.e., plastic beads are feed to the I.M.M (Injection moulding machine).

This machine is loaded with the mould of back cover for a specific model.

This machine melts the plastic beads and injects the liquid form of plastic in the moulds.

This is cooled for few seconds and then machine forces out the formed Back cover out of the mould.

A robotic hand picks up the back cover and places it on the conveyer belt.

35

Now person check each and every piece aesthetically for any kind of defect or scratches on the cover.

Finally the back cover is placed in a plastic cover and stacked to be taken to the paint shop.

NOTE: - If any defect is found in the front or back cover of the model then it is send for recycle.

2)Paint Shop F/C, Power Knobs and Switches

First of all it is checked for any moulding defects.

Front Cover is scratched with Emriy paper.

Masking Tape is applied if the front panel is to be coloured into two colours.

Clelisom Chemical is applied for cleaning of dust.

Then it is sent to a dry oven in order to reduce the moisture content in the F/C.

36

Surface of dry oven has innovizing gum which doesn’t let dust particles to settle on the surface.

Now a first coat of paint is applied to the cover then it is sent to the oven.

After first coat, a second coat of paint is applied and then sends to an oven which is regulated at a temperature of 55-60 DEGREE for 20 minutes.

There are three types of paints being used .

P.U. Paint Acrylic Plastic Paint U.V. Paint

Precaution

Mouth should be covered to prevent inhaling from toxic

Fumes. Gloves must be used to cover the hands.

F/C Inspection1

37

F/C is inspected aesthetically for any kind of molding defects such as scratches etc.

White tapes are pasted on the defect and defective pieces are placed in the trolley for recycling.

Appropriate logo of the model is pasted and checked for alignment.

Apart from molding defects rear edges of the F/C are also checked.

Precaution:

Gloves must be used to cover up the hands.

Note: F/C are then placed in trolley and sent to mask assembly line.

3)C.T.V CABINET ASSEMBLY LINE

Mask Assembly Mask Assembly 1

38

Here, the F/C is again inspected visually for any kind of sink mark, flashes or any other kind of molding defect on the F/C.

Power switch is connected according to the F/C and check for proper ON/OFF operation.

IR & Eye lens PCB Plate is connected to the F/C.

Mask Assembly 2:

Both left and right side Speakers are placed in the speaker slot provided on the F/C.

39

Key knob is fixed at slot provided on the F/C with appropriate sized screws.

Mask Assembly 3

Speakers are fitted on the F/C with appropriate size screw as per specification of the model.

Back Paper of the Nytril foam is removed and paste the nytril foam on the Side and top edges of the F/C.

Speaker Wiring:

40

Wires from the connector are soldered to the speakers

tweeter according to their polarity.

CPT Placing

Anti static Plastic cover is removed from the CPT screen and CPT is checked for scratches and then finally placed on the conveyor belt for further assembly process.

Precautions:CPT must be handled with care and gloves must be used while placing CPT on the conveyor belt.

41

CPT Preparation1 Degaussing Coil

Scotch Tape

Earth wire is connected to the CPT.

Degaussing coil is placed round on the CPT in order to remove patches from the Display, further it is pasted with 2 no.`s plastic ties connected at the top end of the CPT Corner.

CPT Preparation2

Scotch tape is pasted on the bottom side of the CPT so that degauss coil is held around the CPT and Excess plastic tie is cut off.

Placing CPT on F/C

42

Further CPT is placed on the F/C.

Washer Placing Washer and metal cap are placed on the corner of CPT

and Screwed with the help of appropriate sized screw tighten gently so that washer does not displace.

Screwing should be done on diagonal basis.

Screwing is done according to the order in displayed in above fig.

Pre launching Inspection

43

CPT connected together with the F/C is checked for any defect such as Scratches, molding defects etc.

Apart from Defects, Key knob and power knob are checked for proper operation.

Cushion under the F/C is taken back and F/C is locked in the locking pins placed on the pallet.

Placing Speaker

44

Chassis which is tested OK is docked at its position in the F/C.

DY connector is connected to 4 GT pin placed to chassis.

Connect the AV connector to the port on the chassis. Speaker connector is placed on chassis. CPT Base is connected to CPT neck properly.

Precaution:

Connector should not be pressed too much to avoid PCB Damage.

4)C.T.V FA LINE Chassis Docking

The chassis is docked to the front cover

Placing Anode Cap

45

Anode cap is placed to the anode cap position on the CRT.

Earth wire is taken from TBC wire and connected to base connected to the neck of CPT.

Harnessing

Flower cap is placed on the anode wire to avoid contact with CPT.

All the connecting wires are dressed together appropriately.

Switch on

Placing Flower CAP

46

RF signal is connected to the tuner.

Channel “EU 2 CH” is selected and sound and picture is checked.

FOCUS & INTENSITY Pot at FBT is adjusted for clear picture.

IR and Remote connection are checked for proper functioning.

TV is set in the manufacturing Mode (“M” mode) before soaking.

Picture and Sound Check

47

Quality of sound generated by the speaker is checked by the operator using oscilloscope.

Apart from that Television set is checked for picture.

B+ Adjustment

Lion Pattern is selected by selecting channel ‘EU 4CH’ and then B+ is adjusted as per given annexure.

It sets the voltage supply and sets the width of the picture.

Purity patch check:

48

Here the television set is checked for patches by applying magnetic field through different direction.

NTSC Alignment: NTSC stands for National Television system committee.

Color bar and circle pattern is selected by selecting ‘EU 43 CH’.

Horizontal Centering is adjusted using ‘HCH60’.

Vertical centering and height is adjusted using “VS60”,”VSH60”, and ”VA60”.

The Linearity of the circle is adjusted using “SC60” & “VL60”.

NOTE: - This is done only when T.V. is produced for international market. Here the centering of screen is done.

Picture QC1

Channel ‘EU 4 CH’ is selected and geometrical alignment & focus is adjusted to 3.5-4.5 and 5-6.

49

Cross Hatch Pattern is selected by selecting channel (EU 8CH) and convergence quality is checked by the operator.

White balance and Sub Brightness is checked at channel ‘EU2CH’.

Channel ‘EU6CH’ and ‘EU36CH’ is selected for Green and red parity respectively. Further patch is checked if the TV set is free from Patches it is passed to further stages otherwise sent to repair loop.

5)Back Cover Placing B/C Docking

Power cord is placed in the slot provided in the F/C.

Back cabinet is docked with the front cabinet.

B/C Fitting:

B/C is fixed to F/C with appropriate sized screw.

Auto WITE BALANCE setting macine

50

6)Final Quality Check High Voltage Testing

Television set is passed through the High Voltage Testing M/C, where 3.0 KV; 7 MILLI AMP for 1 SEC is applied.

AV in & out Checking

AV in and out port are checked for proper functioning.

Sound Quality Check

Quality of sound is checked in a sound room physically by a operator.

Picture QC-2

Here Again All parameters of Picture quality such as Alignment, white balance, focus, intensity, brightness etc. is checked and then finally controlled.

Aesthetically checking

Television set is cleaned properly with soft cloth and hand gloves for cleaning.

Scratches and other manufacturing defects such as flashes and sink mark etc. are checked.

51

LOGO on the F/C is checked for proper alignment.

7)Last Quality Assurance(LQA)

8)Barcode Pasting and Scan

Barcode Sticker is scanned using Barcode Scanning M/C and is pasted on the back cover of FG and simultaneously a M/C counts the no. of sets produced.

9)Packaging TV set is placed in the packaging box and barcode is

pasted on it.

10) Output Quality Assurance: At last stage, the Picture quality parameters are

assured.

III LINE BALANCING TECHNIQUE

52

Line Balancing is an effective tool to improve the throughput of the assembly line. Line balancing techniques is basically used to calculate the optimum utilization using the fewest operators to achieve the desired result. Line Balancing is tool used in industrial engineering to measure:

Everyone is doing the same amount of work. Doing the same amount of work to customer requirement. Variation is ‘smoothed’. No one overburdened. No one waiting. Everyone working together in a BALANCED fashion.

53

Here in this example, there are 4 operators. 1st operator is allocated 5 min. time, 2nd operator is allocated 25 min. time, and 3rd operator is allocated 15 min time while the 4th operator is allocated 10 min. time. Due to increased time variation between stages, wastages arises which are as follows:

Over processing Inventory Waiting Transportation Motion Rework

In order to overcome these wastages work is been equally balanced between the operator.

54

Here in these example we can see that work is been equally divided between the operators due to which all the 6 wastages are removed.

TAKT TIME

Takt time is a pre-requisite to line balancing. Takt is a German word meaning “conductor baton”. In television industry takt time is calculated for each television model because steps used in assembly of television set vary according to models.

In order to calculate the takt time each stage time is calculated, at least 5 readings are taken. After that average of the 5 reading are taken. After that Normal time is calculated:

NormalTime=Average Time×No .of Operator ×100 %

Normal Time Is calculated for each stage. Normal time is calculated in seconds (Sec.).

Next Step is to calculate the Standard Time. Standard time is calculated by using formula given below:

StandardTime=NormalTime×Rating

Rating is decided by the R&D department of the company. Standard time is calculated in Minutes.

55

Further, Takt time is calculated which is the sum of standard time is for each stage. Ex.VAF21ESV

56

CONCLUDING REMARK

Having undergone Summer Training in Techno electronics Ltd,

kashipur has indeed been a most unique and rewarding

experience.

Our effort at making a project report on “A study related to

technology used in Color television Assembly Process “has been

most educative and academically satisfying. We received our

initiation to a real life work place environment and it has been an

unforgettable experience.

57

(Sign of Training Incharge)