Quality Assurance of LED TV & Speaker- Panasonic

Dhriti Rattan, B.Tech-ECE , SRM Chennai

Quality Assurance


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


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


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

1


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

2


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

3


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)

4


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

5


- 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?

6


LED TV – Dissemble & Assemble to study components & layout – 1/2

Basic Block diagram of LED Circuit diagram of LED

7


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

8


Speaker – To Study Components

Voice Coil Magnet

Terminals

SpiderDust Cap

Basket

9


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.

10


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.

11


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

12


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

13


Organization Tree – QC Operation Position

14


QC/QA Operation - page 1/3

Quality Assurance

New Product

Evaluation

Incoming Quality Test

Line Quality Test

Outgoing Quality Test

15


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

16


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

17


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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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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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.


User Performance Functions

1. Picture Function 2. Sound Function

3. Time , Setting , Lock Function 4. USB Function

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1. Picture Mode 2. Sound Mode

3. White Balance

Sound Presets

23


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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LED - Outgoing Quality Test – page 2/2

Electrical & Mechanical Test Reliability

Sound Performance TestPicture Performance Test

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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.

26


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


Thank You

Quality Assurance of LED TV & Speaker- Panasonic

Engineering

Transcript of Quality Assurance of LED TV & Speaker- Panasonic