quality assurance of led tv & speaker- panasonic
TRANSCRIPT
Dhriti Rattan, B.Tech-ECE , SRM Chennai
Acknowledgement
The internship opportunity I had with Panasonic India Private Ltd was a great chance for learning and professional development.
I express my deepest thanks to Mr. Ajay Yadav Sir, Head of Quality Assurance for taking part in useful decision & giving necessary advices and guidance and arranged all facilities.
I also wish to thank Mr. Dinesh Gupta Sir for their careful and precious guidance which were extremely valuable for my study both theoretically and practically.
Date – 29 June 2017 Dhriti RattanPlace - Gurgaon
Dhriti Rattan, B.Tech-ECE , SRM Chennai
S.No. Topic Page No.
1 Company Profile 1
2 Panasonic – Vision & Mission 2
3 Television – Transmission & Relay Process 3
4 Television Types 4
5 Difference between LED & LCD 5
6 Product Development Process 6
7 LED TV – Block & Circuit Diagram 7
8 LED TV – Dissemble & Assemble to study components 8
9 Speaker – To study components 9
10 Organizational Quality Standard 10
11 Safety Standard - BIS 11
12 Energy Consumption Standard – Schedule 11 12
13 Organization Tree – QA Operation Position 14
14 QA – Operations 15
15 LED Quality Process at Assembly Line 18
16 LED Inspection SOP 20
17 User Performance Functions 22
18 Sound Presets 23
19 LED Outgoing Quality Test 24
20 Experience & Learning at Panasonic 26
Table of Contents
Dhriti Rattan, B.Tech-ECE , SRM Chennai
Company Profile
Panasonic India Pvt Ltd
Panasonic follows the idea of “A Better Life , A Better World” and it continuously contributes to the evolution of the society and to the happiness of the people around the globe.
Panasonic India focuses on market research, product innovation and talent hiring in India for work in areas like energy, water, remote access and food.
Panasonic has a wide range of Products in various category , such as ,
• Consumer Electronics like LED TVs, Speaker System• Home Appliances like Air Conditioners, Washing Machines, Refrigerators, Microwave Ovens•Communication Products like Mobile Phones, High Definition Videoconferencing•Professional Audio Video Products like Broadcast Cameras, Projectors and Displays
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Dhriti Rattan, B.Tech-ECE , SRM Chennai
Panasonic – Vision & Mission
Vision • To be the leading Factory Automation Solutions Provider & Consumer Electronics Board in Asia Pacific, Middle East & Africa.• To offer advanced technologies and solutions in urban farming to promote sustainable healthy lifestyle globally.
Mission • To serve as a one-stop solutions provider that achieves manufacturing excellence through process and product innovation to deliver environmentally friendly products.• To provide excellent customer service.
PANASONIC believes in following the Seven Principles •Contribution to Society•Fair and Honesty•Cooperation and Team Spirit•Untiring Effort for Improvement•Courtesy and Humility•Adaptability•Gratitude
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Dhriti Rattan, B.Tech-ECE , SRM Chennai
Television –Transmission and Relay Process
Block Diagram
Basically has four parts : 1.TV Camera that turns a picture and sound into a signal – Broadcasting Centre2.TV Transmitter that sends the signal through the air – Earth Station3.Satellite that receives the signal from Broadcast Centre and rebroadcast them to Earth4.TV Receiver which with the help of viewing card shows the picture on TV
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Dhriti Rattan, B.Tech-ECE , SRM Chennai
Television Types
TV Type CRT LCD LED OLEDFull Name Cathode Ray
DisplayLiquid CrystalDisplay
Light EmittingDiodes
Organic Light Emitting
DiodeBody Shape
Bulky Flat panel Same as LCD
Thinner, flexible &
fasterLight
SourceContains screen & projector gun
CCFLbacklight
LED backlight
Uses organic material to supply light
Types of Resolution 4K (4096 x 2160) Ultra High Definition (UHD)2K (2048 x 1080)1080p (1920 x 1080) Full High Definition (FHD)720p (1280 x 720) High Definition (HD)480p (640 x 480) Standard Definition (SD)
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Dhriti Rattan, B.Tech-ECE , SRM Chennai
Difference between LED & LCD
Difference Light Emitting Diode (LED)
Liquid CrystalDisplay(LCD)
Power Consumption Less More
Color Accuracy Better Good
Viewing Angles Larger & Better Less
Response Rate Fast Slow
LED LCD
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Dhriti Rattan, B.Tech-ECE , SRM Chennai
- Establish Process Plan- Procedure Production System , Machine , Tools and other resources
Product Development ProcessInput (Technology) : R&D Idea & Innovation
Study for the feasibility
Product DevelopmentInput (Internal)- Capability of Firm-Internal R & D-Finance & Marketing Effort
Competitive Analysis
Input (External)- Customer Need- Supplier Profile- Competitors strength & weakness
Cost Benefit Analysis
Assessment of Technology
Stop
Assessment of Market
Is productEconomically
Feasible?
Test Market
Analyze the Process and System
Commercialize the Product
Stop
- Establish Preliminary Design , make a prototype-Circulate drawing to concerned expert
DesignModification
Establish Detailed Production Planning & Control
No
No
No
Yes
Yes
Yes
Marketing Team(Requirement)
Is productTechnicallyFeasible?
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Dhriti Rattan, B.Tech-ECE , SRM Chennai
LED TV – Dissemble & Assemble to study components & layout – 1/2
Basic Block diagram of LED Circuit diagram of LED
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Dhriti Rattan, B.Tech-ECE , SRM Chennai
LED TV – Dissemble & Assemble to study components & layout – 2/2
3. Main Board PCB
2. Source PCB
5. Key PCB
4. Remote control IR Receiver
1. Backlight cable
6. Back cover
8. TFT Panel
7. Remote Control9. Speaker
LED unit – Inside view
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Dhriti Rattan, B.Tech-ECE , SRM Chennai
Speaker – To Study Components
Voice Coil Magnet
Terminals
SpiderDust Cap
Basket
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Dhriti Rattan, B.Tech-ECE , SRM Chennai
ISO Certification helps the customers to know about a company. Everyday
consumer wont typically know what company certification codes stands
for. But , through ISO they will trust the organization.
Organizational Quality Standards
International Organization for Standardization (ISO)• It is a worldwide federation of national standard bodies from some 100 countries, with one standard body representing each member country.
ISO consists of three most popular standards •ISO 9001 Quality Management – It makes sure products and services meet customers need.•ISO 14001 Environmental Management – Improves your environmental performance.
Benefits •Become more consistent competitor in your marketplace.•More efficient ways of working will save time, money and resources.•Improved operational performance will cut errors and increase profits.•Win more high value customers with better customer service.
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Dhriti Rattan, B.Tech-ECE , SRM Chennai
Safety Standards - Bureau of Indian Standards
Bureau of Indian Standards• The National Standards bodies of India functioning under ministry of consumer affairs in all matters concerning standardization, quality , certification.
Objectives of BIS • To safeguard publics health• To promote consumers confidence
Activities of BIS • Standard formulation• Certification – Hallmarking• Product/Schemes• Consumer related activities• Sale of standard publication
IS616/IEC60065 is a part of BIS. It is an Indian standard for
audio ,video and similar electronic safety.
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Dhriti Rattan, B.Tech-ECE , SRM Chennai
Calculation of Annual Energy Consumption –
AEC = (6 x Pa + 12 x Ps) x 0.365 kWh/Year
Where:
Pa: On Mode power consumption in Watts
Ps: Standby Mode power consumption in Watts
Energy Consumption Standard- (Schedule 11) – 1/2
Need of Schedule 11 -• To meet the requirements of safety in order to qualify for BEE (Bureau of Energy Efficiency) level.
Star wise annual consumption of different screen size
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Dhriti Rattan, B.Tech-ECE , SRM Chennai
Star wise Annual Energy consumption – 2/2
for LED TVs (with LED backlight)for LCD (with CCFL backlight) and
Plasma TV’s
for LED/LCD TV’s for preferred Screen Sizes (January 01, 2016 to December 31, 2017)
BEE – Sample Label
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Dhriti Rattan, B.Tech-ECE , SRM Chennai
QC/QA Operation - page 1/3
Quality Assurance
New Product
Evaluation
Incoming Quality Test
Line Quality Test
Outgoing Quality Test
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Dhriti Rattan, B.Tech-ECE , SRM Chennai
QC/QA Operation – page 2/3
Incoming Quality Test
Supplier Quality Records Parts Planning Control Vendor List Check
Dimensional/VisualFunctional Inspection
New Product Evaluation
DQA Test Product Testing Safety PerformanceReliability –Environment/Transportation
Standards – Energy & Safety
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Dhriti Rattan, B.Tech-ECE , SRM Chennai
Outgoing Quality Test
Visual/FunctionalInspection
Reliability test Safety
Line Quality Test
Automated /Manual Inspection
Identify factors for improvement
Inspection on assembly line
QC/QA Operation – page 3/3
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Dhriti Rattan, B.Tech-ECE , SRM Chennai
LED Quality Process at Assembly Line – page 1/2
1.Check the panel. Use ok, on the production line.
2.Plug the LVDs wire in the panel asin the picture.
3.Assemble the key board as shown in the figure.
4.Fasten the wires by the filament tapes avoiding the red circle.
5.Assemble the main board with the AV BKTS.
6.Fix the main board with 5 screws.
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Dhriti Rattan, B.Tech-ECE , SRM Chennai
LED Quality Process at Assembly Line – page 2/210.Screw in the back cover with suitable screws shown in figure.
11.Paste the AV sticker & back cover label.
12.Put the accessories in the attached poly bag.
13. Final packing.
9.Fix the back cover & make sure it is locked well.
8.Plug speaker line before attaching the back cover.
7.Fix the speakers with the speaker line. Assemble the speakers with 4 screws on the back cover & fasten the wires by the tapes.
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Dhriti Rattan, B.Tech-ECE , SRM Chennai
LED Inspection SOP – 1/2
1. High Pot TestInstruction –• Switch on the High pot equipment.• 2-Adjust/Check HV at 3.5KVdc for 3Sec,Leakage current is less than 10mA.• Adjust insulation resistance greater than 4Mohm at test voltage 500Vdc for 02sec.•Connect HV cable in TV tuner jack.• Press green button to start HV/IR function Testing• Check if green LED glows then set pass,If red LED glows –set fail
2. SW Upload
Instructions –• Connect SW loaded USB in USB jack.• Connect power cord in UPS.• Press AV+3195 Factory data will open & Select Software update. Press OK from RC - SW loading will start, after SW update Again select special set & Press OK from RC. • Again select Factory Reset & Press 8899 from RC software process complete.
3. Chanel Preset Function & Burn Mode OnInstructions –• Press AV+3195 Factory data will open. • Select Aging Mode & press OK Aging mode will start.
4. Panel Dot Inspection & MURRAInstructions –• Check Panel Dot On RED, GREEN, BLUE & WHITE pattern.• Check MURRA in Display Panel on Black/Dark pattern• Aging mode OFF the set.•Display LOGO on Screen should be as per required.
5. HDMI 1 Function CheckInstruction –• Take HDMI signal from DVD.• Connect HDMI cable in TV HDMI 1 Jack.• Select HMDI option from RC then press OK from RC• Check HDMI 1, Picture & Sound should be defect free
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Dhriti Rattan, B.Tech-ECE , SRM Chennai21
Inspection SOP – 2/2
6. HDMI2 Function CheckInstructions –• Take HDMI signal from DVD.• Connect HDMI cable in TV HDMI 2 Jack.• Select HMDI option from RC then press OK from RC.• Check HDMI 2, Picture & Sound should be defect free.• Check sound on Earphone.
7. AV In , Function Key & Sound Balance Check
Instructions –• Take all the incoming signals from DVD.• Press Input key from RC & Select AV IN option then press OK from RC.• Check Picture & sound should be defect free.• Check function key, No malfunctioning allowed.• Check Sound balance Left & Right.
8. USB Function CheckInstructions –• Insert USB device , Select USB sourcesfrom RC ,Photo, Music & Video display.• Selected options should be defect free.
9. PC,PC Audio & Woofer Function Check
Instructions –• Take the RGB signal from PC.• Connect RGB socket & PC audio socket in their respective jack.• Press Input key from RC & Select PC option, press OK key.• Check PC input & PC audio sound to be defect free. • Check Woofer audio.
10. Final Inspection & User Reset
Instruction –• Press Menu key select Picture mode &Check for any defects• Press Menu key & select sound mode & check.• Check for sound abnormality. • Press AV+3195 Factory data will open .• Press Menu & Select SETUP, press OK.• Select "Restore Factory default" & Press Ok.• Select YES & Restore will start.Press standby.
Dhriti Rattan, B.Tech-ECE , SRM Chennai
User Performance Functions
1. Picture Function 2. Sound Function
3. Time , Setting , Lock Function 4. USB Function
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Dhriti Rattan, B.Tech-ECE , SRM Chennai
1. Picture Mode 2. Sound Mode
3. White Balance
Sound Presets
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Dhriti Rattan, B.Tech-ECE , SRM Chennai
LED - Outgoing Quality Test – page 1/2 Mechanical Tests
1 Chassis fitment Should be smooth OK OK
2 Speaker fitment Should be smooth OK OK
3 Front & Back cover fitment Should be smooth OK OK
4 Door panel function Should be smooth OK OK
5 All switch function Should be smooth OK OK
6 Sound BuzzingThere should not be any buzzing OK OK
7Cabinet paint conductivity test
should withstand 5KV@4mA NA NA
8 Drop TestPl. attach separate report NA NA
9 Transportation TestPl. attach separate report NA NA
10 Anything unusual observed
Pl. mention details in a separate sheet and attach
Reliability Test
Life Test 100 Hrs. AgingAGING START AT 10:30 AM 14/06/17
ELECTRICAL TESTS :
S.No. Particulars of Test Specifications CHECK RESULT Remarks
1 All features ningfuncti should be ok Ok Ok
2 Channel Locking TestShould Lock all available
channels in all BandsOk Ok
3All system PAL/NTSC check (Both in RF/AV
mode)should be ok Ok Ok
4Picture Performance
TestOk Ok
4a Vertical Jumping Should no be present Ok Ok
4b White Light Spreading Should no be present Ok Ok
4c Picture Interference Should no be present Ok Ok
5 Sound Performance Test Ok Ok
5aAt Normalized Sound Setting Distortion free sound
Ok Ok
5b vertical Jumping Ok Ok
6 Weak Signal Test Ok Ok
6aChannel Locking
TestAll available channels in all bands must lock
Ok Ok
6b Color SensitivityShould have color till
Min of 35dB signal strength
Ok Ok
6cAll Picture
Performance Tests
6dAll Sound
Performance Tests
6e
Minimum signal strength up to
which a channel should lock
30dB Ok Ok
7 On/Off OperationNothing abnormal
should be observedOk Ok
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Dhriti Rattan, B.Tech-ECE , SRM Chennai
LED - Outgoing Quality Test – page 2/2
Electrical & Mechanical Test Reliability
Sound Performance TestPicture Performance Test
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Dhriti Rattan, B.Tech-ECE , SRM Chennai
Experience & Learning at Panasonic India
• Knowledge about Panasonic brand , history & its products.
• Working Culture & Organization Setup.
• QA processes , Quality Standards & Quality Checklist tools.
• Practical Knowledge of LED TV & Speaker.
• Study about Assembly Lines.
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Dhriti Rattan, B.Tech-ECE , SRM Chennai
My Gratitude to Panasonic
My family house has two Panasonic Air Conditioners & are very satisfied with performance.
I’m very happy to complete my summer training in this iconic company