RenewSys India Pvt. Ltd.

– Patalganga
Project Status Update – Week 1
8th March 2024

© Gemba Concepts.
All rights reserved. Confidential & Proprietary.
 CONTENTS

− Project Timeline
− Deliverable Status – Week 1
− Process Flow Diagram
− Process Description Station Wise
− Data Request Status
− Gaps Identified
− Next Steps

Page 2
© Gemba Concepts.
All rights reserved. Confidential & Proprietary.
PROJECT TIMELINE

Sl Activity M1 M2 M3 M4 M5 M6 M7 M8
No

1 Data Management System &

Present condition assessment

2 Gap
state
Assessment & future

3 Action
sign off
road map creation &

TPM Strategy for critical

4 equipment's

5 TPM Strategy training &

implementation

Utilization enhancement,
6 POC & implementation

KPI setup for supervisors,

engineers, &
7 production/maintenance
HOD

8 Sustenance & handover

Page 3
© Gemba Concepts.
All rights reserved. Confidential & Proprietary.
 DELIVERABLE STATUS - WEEK 1
Due
Objective Activity Start Date Status Responsible Remark
Date
Data Request 5/3/2024 5/3/2024 Complete Baibhav Mail sent to HOD for each department with list of
Data and documents required
Production data, Quality Data, Process parameter
Historical Data Data Procurement 6/3/2024 8/3/2024 Ongoing Baibhav and Cycle time data received . Maintenance Data to
Analysis be shared on 08/03/2024

Historical Data Analysis 8/3/2024 9/3/2024 To be started Will be started on receipt of historical data from
Baibhav respective departments
Process Mapping 5/3/2024 6/3/2024 Completed Prathmesh Process mapping completed . Standard process
parameters shared by Client
Process Flow Diagram 6/3/2024 7/3/2024 Completed Prathmesh Process flow diagram created

Time motion Study - Station wise process parameter study for

Current State Process parameter 8/3/2024 9/3/2024 Ongoing Prathmesh comparative analysis with Standard values done .
Assessment study Reasons for variations to be finalized by 7/3/2024

Listing of probabale Some issues have been identified during the Gemba
causes of deviation and 7/3/2024 8/3/2024 Completed Baibhav walk and time and motion study along with
failure modes Prathmesh.

Project Slide Preparation 8/3/2024 9/3/2024 Completed Baibhav

Presentation /Prathmesh

Summary

100%
Total No of Activities 8
Completed 5 62.5%
Ongoing 2 25.0%
To be Started 1 12.5%
Pending 0 0.0%

Page 4
© Gemba Concepts.
All rights reserved. Confidential & Proprietary.
Process Flow Diagram of PM-1 Line

1st 2nd
Glass Manual Manual Glass
EVA EVA
Loading Checking Checking Sealing
Loading Loading

Cell 2nd
Cell Auto Auto Pre
Tabbing & Layup EVA
Cutting Bussing Tapping EL & AOI
Stringing Loading

Junction Junction Aluminium Visual Auto

Trimming Lamination
box potting box fixing Framing Inspection Tapping

Corner Module Hitpot Post EL & RFID

Curing IV Testing
Filing Cleaning Testing AOI writing

Auto Operation Auto

Ware Module
sorting of
Manual Operation house Packing
module
Optional
Station/Machine wise details:-
1. Laser Cutting Machine:

Operation – Cutting of full size cells into half cut cells with help of laser

• No. of Machine – 2
• No. of Sides per machine – 2
• Hence, 4 cutting operation can run at a one time
• Input for one cutting operation = 240 Full cells
• Output from cutting operation = 560 half cut cells
• Time required to load cells into machine = 30 Sec
• Time required to cut 240 cells = 6 to 8 minutes depends upon setting
 Station/Machine wise details:-
Laser Cutting machine process parameters: -

Range
No changes required
Laser Oscillation Speed
Machine Speed
Oscillation
Min Max Min Max Spot Pulse
Power Freq.
Delay width
Units No. mm/sec No. No. mm/sec mm/sec % ms kHz ns
LCM 1A 7 2100 6 7 2000 2500 90 0.1 200 150
LCM 1B 7 2200 6 7 2000 2500 90 0.1 200 150
LCM 2A 8 2100 8 9 2000 2400 90 0.1 200 150
LCM 2B 10 2100 10 2000 2300 90 0.1 200 150
Station/Machine wise details:-
2. Stringer Machine:

Operation – Soldering of copper wires in order to interconnect them electrically and to

create cell string

• No. of Machine – 4
• No. of Sides per machine – 2
• Hence, 8 stringing operation can run at a one time
• 1 String = 12 Cells
• Input for one cutting operation = 540 Full cells (continues input)
• Time required to load cells into machine = 30 Sec
• Time required to prepare 12 strings for 1 module = 5 minutes
Station/Machine wise details:-

PM1-ATW Process set parameters

Optimized soldering parameters for ATW machines for "Solar space 10BB"

Channel Change parameters 1 2 3 4 5 6 7 8 9 10 11 12

Enable
Enable or Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes NO
Disable
Process
62 62 62 62 62 62 62 62 62 62 62 62
recommended
Set power
Min range 54 54 54 54 54 54 54 54 54 54 54 54
Max range 66 66 66 66 66 66 66 66 66 66 66 66
Correction Coeff. Not to change 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00
Standby power Not to change 30 30 30 30 30 30 30 30 30 30 30 30
Ungrouped strip Enable or Disable Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes NO

Light off Enable or Disable Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes NO
Soldering temp.
Last soldering time
Power
Process recommended 2200 mode
Soldering time (ms) Min, Max 1900 2600
Deg. KP
Min Soldering time 1900 KI
Max Soldering time 2600
Temp
Process recommended 250 mode
Set Soldering Temp Min, Max 230 300
Deg.
Station/Machine wise details:-
PM1-ATW Process set parameters
Optimized Flux temperature parameters for ATW machines for "Solar space 10BB"

Parameters Lower limit Set Upper limit

Flux temp manual © 35 40 50

Flux temp auto © 35 40 50

#1 Preheat base plate temp 100 110 120

Soldering base plate temp 130 140 150
#1 Holding base plate temp 115 130 140
Combined plates temp 105 120 130

#2 Holding base plate temp 100 110 120

#3 Holding base plate temp 90 100 110

Station/Machine wise details:-
PM1-ATW Process set parameters
Optimized soldering parameters for ATW machines for "Aiko, Tongwei, Jupiter and DMEGC 10BB"

Channel Change parameters 1 2 3 4 5 6 7 8 9 10 11 12

Enable
Enable or Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes NO NO
Disable
Process
58 58 58 58 58 58 58 58 58 58 58 58
recommended
Set power
Min range 54 54 54 54 54 54 54 54 54 54 54 54
Max range 62 62 62 62 62 62 62 62 62 62 62 62
Correction Coeff. Not to change 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00
Standby power Not to change 30 30 30 30 30 30 30 30 30 30 30 30
Ungrouped strip Enable or Disable Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes NO NO

Light off Enable or Disable Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes NO NO
Soldering temp.
Last soldering time
Power
Process recommended 2200 mode
Soldering time (ms) Min, Max 1900 2600
Deg. KP
Min Soldering time 1900 KI
Max Soldering time 2600
Temp
Process recommended 250 mode
Set Soldering Temp Min, Max 230 300
Deg.
Station/Machine wise details:-
PM1-ATW Process set parameters
Optimized soldering parameters for ATW machines for "Aiko, Tongwei, Jupiter and DMEGC 10BB"

Parameters Lower limit Set Upper limit

Flux temp manual © 35 40 50

Flux temp auto © 35 40 50

#1 Preheat base plate temp 100 110 120

Soldering base plate temp 130 140 150
#1 Holding base plate temp 115 130 140
Combined plates temp 105 120 130

#2 Holding base plate temp 100 110 120

#3 Holding base plate temp 90 100 110

Station/Machine wise details:-

3. Layup operation:

Operation – Placing of 12 strings on glass and EVA-1

Before layup auto machine are available for glass loading & placing of
• EVA-1 sheet on glass
• No. of layup machine – 4
• No. of glass loader – 1
• No. of EVA cutting and placing machine – 1
• Operation time for layup – 1 min 40 Sec

4. Manual Visual Inspection:

Operation – 2 helpers will check module visually for any crack or no joints between cells.
(Time = 15 Sec)
Station/Machine wise details:-
5. Auto Bussing Operation:

• Operation – Soldering of buss bars with solar cells

• No. of layup machine – 1
• Operation Time – 27 Sec

6. Auto Tapping Operation:

Operation – To joint cells with the help of taps, so cell position will not be
changed (40 taps per module)

7. Manual Visual Inspection:

Operation – 2 helpers will check module visually for any crack or no joints between
cells.
 Station/Machine wise details:-

8. 2nd EVA loading:

• Operation – Loading of 2nd EVA on module

• No. of machine – 1

9. Back sheet loading:

Operation – Loading of back sheet on 2nd EVA and also tag apply on back sheet

10. Pre EL and AOI:

Operation – Visual inspection with the help of camera and AI tools to detect
defects from module like dry soldering, cracks, bubbles, holes in backs sheet,
more gap between cells etc.
 Station/Machine wise details:-

11. Rework Line:

Operation – Rework in modules in case of defect observed in mould

• No. of rework lines – 3

• Rework stations - 9

12. Lamination Operation:

Operation – Lamination of Module

• No. of laminator – 2
• Floor per laminator -2
• Hence, 4 lamination operation can run at a one time
• Cycle time – 9 Min
• Modules in one cycle – 6 Modules
Station/Machine wise details:-

13. Trimming Operation:

Operation – Trimming of extra parts from module

• No. of machine – 1

14. Visual Operation:

Operation – Manual Visual operation of module

• No. of stations – 2

15. Aluminium Framing:

Operation – Joining of aluminium frames with module

• No. of machine – 1
 Station/Machine wise details:-

16. Junction Box Fitting and soldering :

Operation – Fitting of junction box on module and soldering of junction box with
module

• No. of station – 2 (1 station for each operation)

17. Junction box Potting :

Operation – Filling potting material into junction box to prevent from corrosion,
moisture

18. Curing:

Operation – Curing of modules in curing area

• Time required for curing – 4 hrs

• No. of stacks in curing line - 18
• No. of modules maintained in one stack – 20 to 29
 Station/Machine wise details:-

19. Auto filing machine:

Operation – Filling of module corners due to sharp edge

• No. of machine – 1

20. Manual checking and Cap fixing on JB:

Operation – Manual checking of potting, back sheet and cap fixing on junction box

• No. of stations – 2

21. Cleaning of module:

Operation – Manual module cleaning

• No. of station – 1
• Man power – 4
 Station/Machine wise details:-

22. IV testing:

Operation – Voltage and current testing of module

• No. of machine – 1

23. Hipot testing:

Operation – GD, IR and DC testing of module (electric performance test)

• No. of machine – 1

24. Post EL & AOI:

Operation – Checking of module with the help of camera and AI to detect defects

• No. of station – 1
Station/Machine wise details:-
25. RFID Tag scanning:

Operation – Scanning of RFID tag

• No. of station – 1

26. Auto Sorting:

Operation – Sorting of tags as per grade and defects

• No. of machine – 1

27. Packing:

Operation – Manual packing of modules

No. Box – 29 modules

DATA REQUEST STATUS

S No Data Type Due Date Status Remarks

1 Monthly production 7/3/2024

Received
2 Monthly Scheduled downtime data 7/3/2024
Received
3 Monthly Unscheduled down data 7/3/2024
Received
4 Monthly Rework data 7/3/2024
Received
5 Monthly rejection data 7/3/2024
Received
Machine/Station wise capacity and
6 7/3/2024
actual output Received
Machine/Station wise Scheduled
7 7/3/2024
downtime data Received

Machine/Station wise Un scheduled

8 7/3/2024
downtime data
Received
Due to major breakdown in Bussing station team was
9 Maintenance Data 7/3/2024 Not Received engaged in corrective maintenance and have committed to
provide the same by 08/03/2024

10 MTBF/MTTR Data 7/3/2024 Not Received

 CONTENTS
S No Gap Identified

1 Less clarity on process parameters and cycle time amongst workmen/operator

Visual inspection done only for 10 to 15 seconds before bussing for – no check list for visual inspection – No
2
supporting tool for visual inspection
3 Systematic RCA/5 -Why analysis not available

4 PFMEA exists but no lack of updating the same periodically

5 No reason logged for variation in parameter

6 Stand by time capturing mechanism during change over not defined

7 Knowledge sharing between departments not mature / lack of dash board with all KPIs
For errors detected before bussing, due to lack of bypass conveyer the modules to be transferred to EL/AOI for
8
rework
9 Shift handover done verbally, no signed off on shift hand over document
Huge variation in target date of issue resolution and actual resolution date, escalation mechanism not
10
structured
11 High attrition rate, new joinee has less efficiency due to lack of training, hence output is affected

Page 23
© Gemba Concepts.
All rights reserved. Confidential & Proprietary.
 PENDING ACTIVITIES - WEEK 1
S No Activity Type Activity Description Target Date

a) Monitor the process and record relevant process

parameters for comparative analysis with standard
parameters
1 Time and Motion Study b) Record data pertaining to actual values of the process 9/3/2024
parameters and analyze the variation in each reading of
the sample .
c) Identify and record reasons for the variation

a) Procure Maintenance data

b) List out KPIs defined
2 Data Procurement 8/3/2024
c) Process Parameter for Laminator

Production data Analysis

Downtime Analysis
3 Data Analysis for Baseling Pareto analysis of reasons for Downtime 9/3/2024
Rejection rate / Rework analysis
Pareto analysis of reasons for Rejection / Rework
 Thank
you

© Gemba Concepts.
All rights reserved. Confidential & Proprietary.