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“A STUDY RELATED TO TECHNOLOGY USED IN COLOUR TELIVISION

MANUFACTURING PROCESS”

A PROJECT REPORT

DURING SUMMER TRAINING IN VIDEOCON, KASHIPUR

Utkarsh Somani
Manipal Institute of Technology
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ACKNOWLEDGEMENT
I am extremely thankful to Techno electronics Ltd., Kashipur for having consented
to give me Summer Training, which is part of the Course Curriculum at Manipal
Institute of technology, B.E Course.

As student I was accustomed to an academic environment in classrooms, it was a

very different experience visiting a live working Production Plant. The learning
was enormous and the experience is a memorable one. I could understand how the
theory of classrooms gets converted into actual production practice – creating
things of social value.

I am very thankful to Mr. Ankur Sharma, Assistant Manager, R&D [CE] and
Digvijay Chaudhary, Engineer-II at Kashipur, Videocon who arranged and over
saw our training here. I would also like to thank Mr. Naresh Pant, Quality Head
and all the people who took out time of their busy schedule to explain to us the
details of the Color Television manufacturing Process.

I would specially like to thank Mr. A.K. Gangwal, Factory Account Head for
being there to help whenever required during my training session.

We dedicate this humble effort in the Feet of the Lord Almighty Who has
constantly showered us with His Grace, Blessings and Protection.
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TABLE OF CONTENTS

I KNOWING VIDEOCON

1. Chief executive officer (CEO)

2. Mission and Vision
3. Company profile

II VIDEOCON ASSEMBLY TELEVISION PLANT

1. LIQUID CRYSTAL DISPLAY T.V.

2. Direct 2 Home (D2H)
3. COLOUR PICTURE TUBE T.V.
4. CASSIS DESCRIPTION
5. Liquid crystal Display (LCD) Television

III TELEVISION ASSEMBLY PROCESS PLANT

a. LCD ASSEMBLY PROCESS

b. CPT ASSEMBLY PROCESS

1. P.M.S (Plastic Moulding Shop)

Formation of Front Cover

Formation of Back Cover

2. Paint shop

Front Cover, Switches Keys and Power Knobs

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3. C.T.V CABINET ASSEMBLY LINE

Mask Assembly

 Mask Assembly 1

 Mask Assembly 2

 Mask Assembly 3

Speaker Wiring

CPT Placing

 CPT Preparation 1

 CPT Preparation 2

Washer connection

Pre launching inspection

Placing speaker connection

4. C.T.V FA LINE

Chassis docking

Placing anode cap

Harnessing

Switch on

B+ Adjustment

Screen focus voltage adjustment

Purity patch check

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NTSC check point

White Balance

Picture QC-1

5. Back Cover Placing

B/C Docking

B/C Fitting

6. Final Quality Checks

High voltage Testing

AV in & out checking

Sound Quality Check

Picture QC-2

Aesthetical checking

7. Last Quality Assurance (LQA)

8. Barcode pasting & Scan

9. Packaging

10. Outgoing Quality Assurance (OQA)

III Line Balancing Technique

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IV CONCLUDING REMARKS 59

CEO
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K. R. KIM
Vice Chairman and CEO
Videocon Industries Limited
K R Kim was appointed as Vice Chairman and CEO, Videocon Industries
Limited in 2008. Since then, he has led the company to expand its operations
throughout the country in the Domestic and Global operations of the consumer
durables and infotainment division.
A veteran in the consumer goods industries and the former MD of LG electronics,
K.R Kim, a Law graduate from Seoul National University has been associated for
over 30 years with LG Electronics before joining Videocon. During his tenure he
served at esteemed positions of President and that of a Managing Director.
K.R Kim’s proficient leadership skills, task driven approach and matchless degree
of excellence and discipline has conspicuously carved his identity worldwide.
Moreover, he has been the proud recipient of the ‘Super Achiever’ award from
CETMA (Consumer Electronics and TV Manufacturers Association) for his role
in advancing maturity of India’s Electronics and Durable goods market. He has
also been awarded for Excellence in Corporate Leadership and Entrepreneurial
Spirit established by CNBC – TV 18- by our Honorable Prime Minister Mr.
Manmohan Singh.
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VISION & MISSION

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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 format 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

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

Aperture Grill
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
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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.

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 HPCT SMPS FBT 500v,220 µF PTC NTC

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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.

3. SMPS: It stands for Switch Mode Power Supply. SMPS delivers

various voltages according to the requirement.
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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 220µF.

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.
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12. Sound IC: This IC control and process the sound signal
taken from RF signal .

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.
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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, portable, and less expensive.
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.

Thermotropic liquid crystals will react to changes in temperature or in some cases,

pressure so they are used to make LCD’s. 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.

Liquid crystal molecules

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Creating an LCD

The combination of four facts makes LCDs possible:

 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:

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
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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.

LCD TV PREPRATION
1) P.C.B Frame Prepration
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 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.
 Two P.C.B’s are placed on the plastic panel. Out of them one is
power pcb and the another one is main pcb.
 A steel plate with holes of A/V, S-Video, V.G.A, HDMI etc is
placed with the pcb.
 The P.C.B’s and steel plate, all are screwed at various positions
on the plastic plate.
2) Front Cover Prepration

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

I.R. Lens Fitting

Stage-2
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 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.

3) L.C.D Panel Prepration

 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.
 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 & Assembly Frame
Panel and Frame fixing to F/C
 The panel is placed on the front cover after the application of
the felt tape.
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 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.

PCB Placing Stage

 After the placement of the display panel, we place the chassis
i.e., plastic tray on which pcb’s are placed.
 The panel is screwed from all the ends.
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Reinforce Bracket and Connector Fixing Stage

 A person places a metal bracket on plastic pcb frame to support
the lcd when it is hanged to wall.
 Then all the connecting wires are connected to the pcb’s
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 te main PCB.
Speaker Fixing Stage
 Speakers are placed in the proper slot in the front cover and the
connecting wires of the speakers are also attached to te pcb.
 The speakers are tightened to the Front Cover by screwing
them.

Harnessing Stage
 The extra length of wires is collected together and is tied
together by the help of plastic tie, so that the wire doest interfare
with te pcb.
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Back Cover Docking and Fixing Stage

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

5) Quality Check Line

Switiching On
 Whether the LCD is getting switched on or not, tis is checked
here.
 It is a critical process.
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Design Data Verification Stage

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

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

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

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

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

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

DIRECT 2 HOME
The Direct-To-Home (DTH) service is a digital satellite service that provides
television services direct to subscribers anywhere in the country. Since the Signals
are directly from the satellite into your television sets, via our ODU (outdoor unit)
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that comprises of LNB / Dish / Co-axial cable & STB (Set Top Box) into your
homes, you can enjoy uninterrupted viewing. This service is particularly valuable
in remote and difficult to reach areas where cable Television and terrestrial
television services are poor or nonexistent.

D2H is one of the advance satellite television technologies which offers:

 MPEG and DVB-S2: new age television technology.

 Universal Remote
 12 PIP Mosaic: language wise mosaic help user to see and select channel
rather than scroll channels on EPG.
 246 channels
 Planet M Music Platform: we can listen to favorite music on active
Listening Platform.
 Tickers: It enables user to check latest stock market, cricket, news update
and bollywood while watching channels.
 Movies: Viewer can watch most comprehensive list of Hollywood/
Bollywood/Regional pay per view movies.
 Multi lingual call center.
 Multi lingual user interface: User can watch EPG in 2preferred languages
out of the 9 language buttons on remote.
 Weather watch: User can watch weather of their respective cities.
 Channel Hide: User can hide specific channel from complete channel list.

Technical Description:
Videocon D2H service is basically nothing but the Set top Box (STB) PCB plate is
placed within the television set. Due to which it can be used easily in rural and
remote areas of the country.
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MPEG PCB

Internal circuitry consists of MPEG power PCB which supplies power to the
MPEG PCB. MPEG PCB consist of a slot in which smart card is inserted. This
smart card is paired with the MPEG PCB.
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Main PCB Main Power PCB

Apart from MPEG PCB there is a main PCB and also its power PCB. Main PCB
process and control the signal coming from the RF Tuner slot.

Pairing of Smart card serial no. & Set top box serial no.:
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It is one of the most important process in D2H Service. Smart card serial no. and
set top box serial no. should match with each other. Detail information about
pairing is loaded on the main server. Using Barcode scanner STBSN (set top Box
serial no.) and SCSN (Smart card serial no.) is scanned and the serial no. is
matched using the V- pot software.

Error occurring when SCSN and STBSN are not properly Paired:
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If the STBSN and SCSN is scanned and “WAIT” signal is displayed on the
VPOT screen then it means that smart card serial no. (SCSN) and set top box serial
no. (STBSN) are not matched.

C.T.V LINE ASSEMBLY PROCESS

1) PLASTIC MOULDING SHOP

Front Cover
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 Raw material i.e., plastic beads are feed to the I.M.M

(Injection moulding machine).

 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.

 This is cooled for few seconds and then machine forces out
the formed Front cover out of the mould.

 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.

 Finally the front cover is placed in a plastic cover and

stacked to be taken to the paint shop.

Back Cover

 Raw material i.e., plastic beads are feed to the I.M.M

(Injection moulding machine).

 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.

 This is cooled for few seconds and then machine forces out
the formed Back cover out of the mould.
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 A robotic hand picks up the back 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.

 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.
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 Surface of dry oven has innovizing gum which doesn’t let

dust particles to settle on the surface.

 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.
There are three types of paints being used .

 P.U. Paint
 Acrylic Plastic Paint
 U.V. Paint

Precaution

 Mouth should be covered to prevent inhaling from toxic

Fumes.

 Gloves must be used to cover the hands.

F/C Inspection1
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 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.

 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:

 Gloves must be used to cover up the hands.

Note: F/C are then placed in trolley and sent to mask assembly line.

3) C.T.V CABINET ASSEMBLY LINE

Mask Assembly
 Mask Assembly 1

 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.
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 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:

 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
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 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:

 Wires from the connector are soldered to the speakers tweeter

according to their polarity.

CPT Placing
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 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 Degaussing Coil

Scotch Tape

 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.
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 CPT Preparation2

 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

 Further CPT is placed on the F/C.

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

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

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Pre launching Inspection

 CPT connected together with the F/C is checked for any defect such
as Scratches, molding defects etc.

 Apart from Defects, Key knob and power knob are checked for proper
operation.

 Cushion under the F/C is taken back and F/C is locked in the locking
pins placed on the pallet.

Placing Speaker

 Chassis which is tested OK is docked at its position in the F/C.

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 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:

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

4) C.T.V FA LINE
Chassis Docking

 The chassis is docked to the front cover

Placing Anode Cap

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 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

Placing Flower CAP

 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.

 TV is set in the manufacturing Mode (“M” mode) before soaking.

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Picture and Sound Check

 Quality of sound generated by the speaker is checked by the operator

using oscilloscope.

 Apart from that Television set is checked for picture.

B+ Adjustment

 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.
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Purity patch check:

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

NTSC Alignment:

 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”.
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 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

 Channel ‘EU 4 CH’ is selected and geometrical alignment & focus is

adjusted to 3.5-4.5 and 5-6.

 Cross Hatch Pattern is selected by selecting channel (EU 8CH) and

convergence quality is checked by the operator.

 White balance and Sub Brightness is checked at channel ‘EU2CH’.

Auto WITE BALANCE setting macine

 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

 Power cord is placed in the slot provided in the F/C.

 Back cabinet is docked with the front cabinet.

B/C Fitting:

 B/C is fixed to F/C with appropriate sized screw.

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6) Final Quality Check

High Voltage Testing

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

AV in & out Checking

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

Sound Quality Check

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

Picture QC-2

 Here Again All parameters of Picture quality such as Alignment,

white balance, focus, intensity, brightness etc. is checked and then
finally controlled.

Aesthetically checking

 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.

 LOGO on the F/C is checked for proper alignment.

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7) Last Quality Assurance(LQA)

8) Barcode Pasting and Scan

 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

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

10) Output Quality Assurance:

 At last stage, the Picture quality parameters are assured.

III LINE BALANCING TECHNIQUE

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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:

 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.

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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:

 Over processing
 Inventory
 Waiting
 Transportation
 Motion
 Rework

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

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=Average Time × No .of Operator ×100 %
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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:
Standard Time=Normal Time × Rating

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

calculated in Minutes.

Further, Takt time is calculated which is the sum of standard time is for each
stage. Ex.VAF21ESV
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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
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satisfying. We received our initiation to a real life work place environment and it

has been an unforgettable experience.

(Sign of Training Incharge)