VISION AND MISSION y y

To develop an ultramodern consumer durables manufacturing facility, producing world class quality products for all the Videocon group brands. A big hub in Northern India to cater to Indian and overseas markets.

PHILOSOPHY

y To build a strong team of competent people, willing to work with passion and
dedication and therefore providing internal growth opportunities.

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PLANT DESCRIPTION:

y Plant Area and Manpower Strength  

It is spread over a total area of 13 acres [53,000 sq. mts.]. Employing 750 staff members and 1000 workers.

y Products Planned and Capacity

Products
    Television Refrigerator Washing Machine Microwave Oven

Per Annum
1.5 million 0.6 million 0.3 million 0.3 million

y Kashipur: Plant Location

Located 5 kms from Kashipur, 30 kms from Ramnagar, 225 kms from Delhi

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COMPANY PROFILE

Today the group operates through 4 key sectors:

Videocon Group

Consumer Durables

CPT

CRT glass

Oil & Gas

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 by our in-house compressor manufacturing technology in Bangalore.

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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 formats 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.

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Color Television Picture Tube

Introduction

Fig. 1

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 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.

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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

Fig.2

Fig.3

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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 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.
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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.

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CHASSIS DESCRIPTION

VPCIC

HPCIC

SMPS

FBT

500v,220 F PTC

NTC

Main Parts of PCB Fig.4

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.
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3. SMPS: It stands for Switch Mode Power Supply. SMPS delivers various voltages according to the requirement. 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 220F.

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 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.

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LIQUID CRYSTAL DISPLAY

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, and portable. 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.

Liquid Crystal Molecules Fig.5

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Thermotropic liquid crystals will react to changes in temperature or in some cases, pressure so they are used to make LCDs. 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. Whereas Lyotropic liquid crystal does not react to the change to the temperature, pressure and nature of substance.

Creating an LCD:

The combination of four facts makes LCDs possible:

y y y y

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:

Construction of LCD Fig.6

AIET/DOECE/2011-12/PTS/12

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:

Working of LCD Fig.7

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. 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.
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LCD TV PREPRATION

1) P.C.B Frame Preparation

y 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. y Two P.C.Bs are placed on the plastic panel. Out of them one is power pcb and the another one is main PCB. y A steel plate with holes of A/V, S-Video, V.G.A, HDMI etc is placed with the PCB. y The P.C.Bs and steel plate; all are screwed at various positions on the plastic plate.

2) Front Cover Preparation

y Stage-1
y Front Cover is checked for any scratches, defects, screen printing defects or any aesthetical defects. y Led and Glass Lens are placed on the front cover and screwed.

Fig.8

Fig.9

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y Stage-2

Arrangement of knobs on PCB Fig.10

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.

Fixation of I.R. Lens and an LED on the PCB Fig.11

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3) L.C.D Panel Preparation

y y 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. y 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 and Assembly Frame y Panel and Frame fixing to F/C

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

Panel and Frame Fixing to F/C Fig.12 AIET/DOECE/2011-12/PTS/16

y PCB Placing Stage

y After the placement of the display panel, we place the chassis i.e., plastic tray on which pcbs are placed. y The panel is screwed from all the ends.

PCB Placing Fig.13

y Reinforce Bracket and Connector Fixing Stage

y A person places a metal bracket on plastic PCB frame to support the LCD when it is hanged to wall. y Then all the connecting wires are connected to the PCBS 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 the main PCB.

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y Speaker Fixing Stage

y Speakers are placed in the proper slot in the front cover and the connecting wires of the speakers are also attached to the PCB. y The speakers are tightened to the Front Cover by screwing them.

Fixing of Speakers Fig.14

y Harnessing Stage
y The extra length of wires is collected together and is tied together by the help of plastic tie, so that the wire doest interfere with the PCB.

Harnessing Fig.15

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y Back Cover Docking and Fixing Stage

y y Back Cover of the LCD is placed and screwed. The stand of the LCD is screwed.

Back Cover Fig.16

5) Quality Check Line y Switching On

y y Whether the LCD is getting switched on or not, this is checked here. It is a critical process.

y Design Data Verification Stage

y The person opens the main menu and enters the private factory settings menu. Here it verifies the design data and corrects the design data is required.

AIET/DOECE/2011-12/PTS/19

y QC-1 Stage
y Here the extra features of the LCD are checked like HDMI Port, USB Port, SVideo etc. These all are checked by giving input to all these ports and checking the video and sound quality for them.

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

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

y Aesthetic Check
y Aesthetic Check of the complete LCD takes place. The panel is sent to rejection or repair loop if any problem is found in it.

y Final Packing
y The final packaging of the LCD is done.

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C.T.V LINE ASSEMBLY PROCESS

1) PLASTIC MOULDING SHOP  Front Cover

y Raw material i.e., plastic beads are feed to the I.M.M (Injection moulding machine). y y 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. y This is cooled for few seconds and then machine forces out the formed Front cover out of the mould. y y 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. y Finally the front cover is placed in a plastic cover and stacked to be taken to the paint shop.

 Back Cover
y Raw material i.e., plastic beads are feed to the I.M.M (Injection moulding machine). y y 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. y This is cooled for few seconds and then machine forces out the formed Back cover out of the mould. y A robotic hand picks up the back cover and places it on the conveyer belt.
AIET/DOECE/2011-12/PTS/21

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. Surface of dry oven has innovizing gum which doesnt let dust particles to settle on the surface. y y 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.

y y y y y y

There are three types of paints being used.  P.U. Paint  Acrylic Plastic Paint  U.V. Paint

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Precaution
y y Mouth should be covered to prevent inhaling from toxic Fumes. Gloves must be used to cover the hands.

 F/C Inspection1

Fig.17

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.

y y

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:
y Gloves must be used to cover up the hands.

Note: F/C are then placed in trolley and sent to mask assembly line.
AIET/DOECE/2011-12/PTS/23

3) C.T.V CABINET ASSEMBLY LINE  Mask Assembly  Mask Assembly 1

Fig.18

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:

Fig.19

AIET/DOECE/2011-12/PTS/24

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

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:

Fig.20

Wires from the connector are soldered to the speakers tweeter according to their polarity.

AIET/DOECE/2011-12/PTS/25

 CPT Placing
y 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.

 CPT Preparation1
y y 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
y 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

y Further CPT is placed on the F/C.

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 Washer Placing
y 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. y Screwing should be done on diagonal basis.

Fig.21

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

 Pre launching Inspection

y CPT connected together with the F/C is checked for any defect such as Scratches, molding defects etc. y Apart from Defects, Key knob and power knob are checked for proper operation. y Cushion under the F/C is taken back and F/C is locked in the locking pins placed on the pallet.

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 Placing Speaker

Fig.22

y y y y y

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

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4) C.T.V FA LINE  Chassis Docking

Fig.23

The chassis is docked to the front cover.

 Placing Anode Cap

Fig.24

AIET/DOECE/2011-12/PTS/29

y y

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

Fig.25

y y

Flower cap is placed on the anode wire to avoid contact with CPT. All the connecting wires are dressed together appropriately.

 Switch on
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.
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y y y y

 Picture and Sound Check

Fig.26

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

Apart from that Television set is checked for picture.

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 B+ Adjustment

  Fig.27

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:

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

Fig.28 AIET/DOECE/2011-12/PTS/32

 NTSC Alignment:
y y y y 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. y 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
y Channel EU 4 CH is selected and geometrical alignment & focus is adjusted to 3.5-4.5 and 5-6. y Cross Hatch Pattern is selected by selecting channel (EU 8CH) and convergence quality is checked by the operator. y White balance and Sub Brightness is checked at channel EU2CH.

Fig.29 AIET/DOECE/2011-12/PTS/33

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

y y Power cord is placed in the slot provided in the F/C. Back cabinet is docked with the front cabinet.

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

Fig.30

6) Final Quality Check  High Voltage Testing

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

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 AV in & out Checking

y AV in and out port are checked for proper functioning.

 Sound Quality Check

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

 Picture QC-2
y Here Again All parameters of Picture quality such as Alignment, white balance, focus, intensity, brightness etc. controlled. is checked and then finally

 Aesthetically checking
y y 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. y LOGO on the F/C is checked for proper alignment.\

7) Last Quality Assurance(LQA) y Finally the product is checked for assurance if it is for pasting barcode.

AIET/DOECE/2011-12/PTS/35

8) Barcode Pasting and Scan

Fig.31

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
y TV set is placed in the packaging box and barcode is pasted on it.

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

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LINE BALANCING TECHNIQUE

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:

y y y y y y

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.

Fig.32(a)

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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:

y y y y y y

Over processing Inventory Waiting Transportation Motion Rework

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

Fig.32(b)

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.
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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:

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:

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

Further, Takt time is calculated which is Ex.VAF21ESV

the sum of standard time is for each stage.

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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.

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REFERENCES

  

www.wikepiedia.com www.videoconworld.com Material provided by company

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