STUDY OF LED TV MANUFACTURING

* Why switch to led televisions?

The designer is expected to take into account
and arbitrate all the requirements that have
been enumerated above and then come up
with a design that meets all these
requirements and validates through.

People in factories are ordered to make

specific materials for the Television
manufacturing. The injection-molded plastic
and glass required for the housing cabinet of
the TV is made in the plant itself whereas all
the metals needed to produce the main
components of TV, such as silicon, aluminum,
copper, tin, bits of gold, etc are extracted from
the ground. Certain components such as ICs,
capacitors, inductors, resistors and sometimes
even the entire PCBs are shipped from
outside.

For LED Televisions, Gold and silver

compounds are most widely used for soldering
purposes and LED panel designing.

After a good amount of raw materials are

accumulated for the production of the desired
product as per the design, these raw materials
are converted to the final products by different
processes to obtain the appropriate output for
manufacturing the components required for
complete assembly.

 The housing is made out of plastic, and

has to go through a process of injection
molding. It is then cleaned and then the
plastic is ready to be joined together with
the help of the molds. The molds are
 designed and created so that brackets
supports the components of the Television.
 The next thing is the LED-LCD screen
which is activated with electric current. The
of glass pieces are cut in the precise size
and then washed and cleaned. A process
called lapping then takes place.
 After it is dried, it is overlapped with a layer
of silicon dioxide. & both front and rear
glass surfaces are coated with a very thin
layer of indium tin oxide. Then another
layer of light-sensitive material called photo
resist. Finally, the glass display is added
on and a raw structure is ready.

Later this, the TV sets are checked for

software functioning and hardware defects.

Now the fully assembled Television sets are

sent for packaging. The reason it is difficult is
because :-
  the Televisions are delicate, the machines
have to handle them with care.
 If they are damaged while packing it is the
packaging companies fault, unless they
can prove that it was the transportation that
sent it damaged.

The Television is first packed with packing film,

which protects it. Then Styrofoam is added
and cut to be placed on the four sides of the
Television, and then is put into a large
cardboard box, which just fits it so that it stays
compact.

 After the machines finish packing, they are

labeled with the appropriate stickers,
resembling the brand name, logo,
specifications, directions for the user, etc.

Later this, the packed boxes are wrapped

together in groups with the polythene and sent
to storage area for shipping to the market.
The packed box is examined carefully i.e. all
the stickers, for eg : content sticker, OPS
sticker, star rating, etc pasted on it are
properly checked for;

 tilts or shift
 required content present

LANDFILLS
RECYCLE
* IS TV SUSTAINABLE ?
YES !! Sustainable means to maintain.The
Television is made out of lots of different
materials such as plastic and metals. These
materials are good, because they can be used
over and over again. The television can last for
up to 6 years! When it does start to break
down, rather than sending it to the landfill, you
can send it back to the manufacturer. This way
when they receive the TV they can check for
anything that can be re-used and recycled to
be put into another TV.

This is how the cycle works, the items keep

getting used again and again, so maybe in
reality, the TV itself is not so sustainable, but
thanks to the TVs components and materials,
it really can be!

This section mainly deals with the over all

inspection of the final packaged product.

The quality assurance process takes place as

follows.

EXTRACTION OF RAW MATERIAL

ASSEMBLY LINE STAGES
The main aspect of manufacturing includes the
designing part of the basic components of a
TV, matching of their standards and validating
them.

It can be classified as:-

Lastly, the TV set is checked for all the

functions and configurations with the help of
remote.

Also, the certain tests such as:-

 Drop Test
 High Voltage Test

A random packaged carton containing the TV

set is picked from the batch & took for quality
check.
The box is opened & checked for the presence
of :

 protective thermocole sheets

 poly bags
 accessories bag
 TV set

If a particular TV set shows satisfactory

performance on all the parameters stated
above, it is approved & the batch is signed for
shipment. Else, the whole batch is rejected &
sent for revaluation.

Before the manufactured parts are received for

assembly, all the components, such as
fabricated PCB, speakers, panels, etc are
properly checked and passed through various
tests, under the IQC Testing Section, so as to
check their working.
Later this, all the parts are forwarded onto the
assembly line.

BASIC CONCEPTS RELATED TO

ASSEMBLY LINE PRODUCTION
After the batch is approved from the quality
assurance, it is loaded onto the trucks along
with other sets and sent to the market retailers
to be supplied to the customers.

2.
TECHNO ELECTRONICS PVT. LTD.
(KASHIPUR)
( A Videocon Group Company )

INTRODUCTION
Founded in 1979, by Shri Nandlal Madhavlal
Dhoot, Videocon Industries Limited is a large
diversified Indian company headquartered in
Mumbai. The group has 17 manufacturing
sites in India and plants in Mainland China,
Poland, Italy and Mexico.

In collaboration with Toshiba Corporation Of

Japan, India's first world class color televison :
Videocon was launched and today Videocon is
a household name across the nation.

VISION & MISSION

At Videocon, all the efforts are centered
around the customer and its needs.

 Ingenious Strategy
 Intrepid Entrepreneurship
 Improved Technology
 Innovative Products
 Insightful Marketing
 Inspired Thinking
Areas Of Business
Consumer Electronics & Home Appliances

Mobile Handsets/Phones

Telecommunication Services

DTH Services

Oil & Gas

Real Estate

UAE Commerce

Retail

KASHIPUR PLANT
LOCATION :-
5kms from Kashipur & 225 kms from New
Delhi.

PLANT AREA AND MANPOWER :-

 It is spread over a total land area of 13

acres [53,000 sq. m.]
 Employing 500 workers and 750 staff

PRODUCTS PRODUCED AND CAPACITY

 Television : 1.5 Mn
 Refrigerator : 0.6 Mn
 Washing machine : 0.3 Mn
 Air Conditioner : 0.3 Mn

* What is led tv & its working ?

 LED TV is a type of LCD television that
uses light-emitting diodes (LEDs) to
backlight the display instead of the cold
cathode fluorescent lights (CCFLs) used in
standard LCD televisions. LED TVs are
 more formally known as LED-backlight
LCD television.
 There are three different LED technologies
used :-

1. Edge-lit led display

 Most commonly used.
 The white LEDs are situated around the
edge of the screen and a diffusion panel
employed to illuminate the display evenly.
 Edge-lit LED displays can be very thin.

2. DYNAMIC RGB LED DISPLAY

 Placed behind the panel.
 RGB LEDs make it possible to target areas
for dimming more precisely, which in turn
leads to truer reproduction of blacks and
whites.

3. FULL ARRAY LED DISPLAY

 LEDs are positioned behind the panel
similarly to the way they are with RGB LED
 displays but there is no capacity for
localized dimming.

Energy efficient
LED televisions use less power & thus
produce less heat, which is a desirable feature
in crowded home entertainment systems.

Lifetime
Have 50,000 hours or more if properly
engineered.

thin & lightweight

LED-backlighting allows TVs to be even
thinner and lighter than standard versions,
especially on edge-lit models. This makes
them easily mountable on walls.

Resolution
Screen resolution is the number of pixels that
are used to comprise an image, and it directly
affects the clarity and crispness of an on-
screen image. LED TVs are made in both
high-definition formats: 720 p and 1080 p.

Refresh rate
LCD televisions are limited by a low refresh
rate, which can result in blurred images. But in
LED models, buyers can choose between 60
Hz, 120 Hz, and 240 Hz refresh rates.

CONTRAST RATIO
LED models with full array and local dimming
options have the strongest contrast ratios of all
LED TVs.

RUGGED
LEDs, being solid state components, are
difficult to damage with external shock and are
comparatively stronger for use.

LIFE CYCLE OF LED TV

DESIGN PROPOSAL
1.
 The process of introducing a new product
in the market evolves over a sequence of
stages, beginning with an initial product
concept or idea that is evaluated,
developed, tested and launched on the
market.
 The best known model which represents
the various steps in a new product
development are given by Booz, Allen and
Hamilton (1982) model, also known as the
BAH model, as shown.

COMMUNITY DEMAND
PRODUCT DESIGN
NEEDS IDENTIFIED BY EXPERTS
AVAILABLE RESOURCES
1. point of view of user
 Price and cost of using the product
 Usability and functionality configurations
 Appearance and quality of the model
 Ease of maintenance
 Size & weight considerations
 Ecological effects on the environment

2. point of view of MANUFACTURER

 Cost of production.
 Availability of raw material
 Ease of handling
 Investment & funding
 Compatibility
 Ecological effects on the environment

2. point of view of MARKETING

  Great number of potential customers?
 Will it be difficult to imitate the product?
 Is the idea new?
 Is the price competitive?

MANUFACTURING
3.
BODY DESIGN
This category includes the designing and
fabrication of the outer parts of the TV which
are required to house the internal components
responsible for working of the TV and also to
enhance the appearance and finishing of the
final product.

The main parts of body covered in this are:-

PANEL

BACK COVER
FRONT COVER

STAND

CIRCUIT DESIGN
This is the most important part of any product
life cycle, since at this stage, the backbone i.e.
the components are mounted on the PCB.

The ICs soldered on the PCB contain the

softwares required for running the product and
defining its functionality.

The main aspect of this category are:-

PCB Fabrication

Circuit design layout

Component mounting on PCB

Testing

4.
ASSEMBLY OF COMPONENTS
STAGE 1 : LOADING
Here, the TV panels from cartons are placed
onto the conveyor belt and moved further.

Following points are noted here:-

 The pet name on the piece is cross

checked with the check sheet
 Scratched and broken panels are sorted
 The gap between the front cover and panel
are checked (<1 mm)
 The brand logo & name must be properly
placed.

STAGE 2 : SPEAKER & IR SENSOR

ASSEMBLY
At this stage, the speaker and IR sensor
modules are placed onto the molds provided in
he FIM assembly and fitted tightly with the help
of screws.

After this, the product body is moved further on

the conveyor belt for remaining assembly.

STAGE 3 : COVER & CHASIS FIXING

The chassis i.e. the fabricated combo PCB
containing the software fed in by the designer
and all the driver circuitry necessary for the
operation of television and its compatibility, is
placed onto the panel. The wires are
connected to proper sockets via connectors
provided, and the back cover is placed onto it
for the protection against external
interferences.
The combo PCB the combination of the main
PCB & power PCB, which forms the main
circuitry of a TV set. It is preferred in LED-LCD
TVs in contrast to separate main and power
boards as in conventional CRT TVs so as to
justify the space, size and weight constraints.

STAGE 4 : PAIRING
At this stage, the chassis, panel & various
other components are linked to each other via
inventory software named VPOTS, developed
by Infidart pvt. ltd.

Each of the separate unit assembled are

represented by a unique barcode or a serial
number which are paired to each other
corresponding to a particular TV set for proper
identification and future references.
In case of duplicity, the software notifies the
bar code being scanned again & the worker
has to check the process.

ELECTROSTATIC DISCHARGE (ESD)

 It is a sudden flow of electricity between

two electrically charged objects caused by
contact on electric short or dielectric
breakdown. It occurs when differently
charged objects are brought close to each
other or the dielectric between them breaks
down with a visible spark.

DAMAGE PREVENTION IN ELECTRONICS :-

(1) It is based on the principle that there are no

highly charged materials in the vicinity of the
ESD sensitive component such as ICs,
Microchips, etc,all conducting objects are
grounded so as to prevent build up of
electrostatic charge discharge on the medium
between.. This may include:-

(a) using ESD safe packing material

(b) use of conductive filament on the garments

worn by workers

(c)wearing conducting wrist bands and foot

straps

LINE OF BALANCING

UNITS PER HOUR

PRODUCTIVITY

CYCLE TIME

BOTTLENECK STAGE
COST INNOVATION

PACKAGING
5.
6.
QUALITY ASSURANCE
7.
SHIPPING OF FINAL PRODUCT TO
MARKET
END OF LIFE
8.
After the Television has been used by the
household members, there comes a time
where the Television has to be disposed.
There are two things that can happen
depending on the situation.
Usually Televisions are just disposed and they
go to the landfill, as the components of the
television are mostly plastic, the Television
takes time to decompose. Also the metal is still
usually in good condition, but now that it’s in
the landfill, no-one will ever know. The
Television will then just sit in the landfill for
years. The alternative way, is to return it back
to the manufacturer so that they can recycle
the Television.

Some of the materials and components of the

TV may not be completely damaged or some
materials may be able to be recycled and re-
used, thus less waste is going to the landfill.
The other components which are still in
function, which do not need to be disposed,
can be used again.
Key Questions Answered in This Report?

- What are the key success and risk factors in

the LED industry?
- How has the LED market performed so far
and how will it perform in the coming years?
- What is the structure of the LED industry and
who are the key players?
- What are the various unit operations involved
in an LED plant?
- What is the total size of land required for
setting up an LED plant?
- What are the machinery requirements for
setting up an LED plant?
- What are the raw material requirements for
setting up an LED plant?
- What are the utility requirements for setting
up an LED plant?
- What are the manpower requirements for
setting up an LED plant?
- What are the infrastructure costs for setting
up an LED plant?
- What are the capital costs for setting up an
LED plant?
- What are the operating costs for setting up
an LED plant?
- What should be the pricing mechanism of an
LED?
- What will be the income and expenditures for
an LED plant?
- What is the time required to break-even?