萬佳驗廠報告

1、GE Shirley的萬佳訪廠報告.跟萬佳的技術(shù)管理談過后了解現(xiàn)況如下：萬佳正完成一些毛管樣辦， 是有較厚的ALON涂層(保護層)，用了 日雅燈粉。于12月8日將會有 100小時的數(shù)據(jù)，12月12日會有200小時數(shù)據(jù)可作大約計算光衰的改善。After talked to Wanjias tech. leader, the current situation is: Wanjia has finsihed some samples with thicker Alon coating, use NICHIA phosphor, on Dec-8, they can get the 1 OOhrs

2、test data, and Dec-12, can get the 200hrs test data to get a roughly evaluation on lumen maintenance improvement.2.無論測試成績?nèi)绾嗡麄兌紩_始造余下型號。將會在12月14日完成。全部 送交SuperTrend這樣安排是比原來的時間表遲了 2天。是否可以接受？請通 知SuperTrend。no matter the test result is OK or not, they will start producing all the samples we needed for te

3、sting consider with our suggestion according to todays process check, and all the samples will send to Supertrend on Dec-14(two days delay compare with the original schedule? is it acceptable or not? please confirm with the team and call Supertrend if the timing is not acceptable) 3.今天他們造了一些樣辦，讓我們檢查

4、由第一個工作站開始的生產(chǎn)程序。但發(fā) 現(xiàn)了一些問題，請跟進以下事項：Today, they build some samples for our process check from the first station, there is some problems with their process control, below items please follow up:TCP是他們的大客戶,他們是從TCP買燈粉的。TCP做完了試產(chǎn)(根 據(jù)TCP的生產(chǎn)流程)之后就把燈粉送去萬佳使用。但萬佳是沒有再做 試產(chǎn)(基于萬佳的流程)，亦沒有萬佳的混制燈粉記錄。所以我們監(jiān)管不 了 DVP/PVP/第

5、一次生產(chǎn)是否用了同樣的燈粉。但萬佳的人說三次都是 用了 日雅粉。12月12日的生產(chǎn)，他們?nèi)菰S了會做一次試產(chǎn)及燈粉來料 試產(chǎn)及混制燈粉的試檢,假設(shè)OK,那么開始做其余型號的樣辦，亦容許了做樣 辦生產(chǎn)記錄。a. TCP is one of their big customer, they bought the NICHIA phospher from TCP and after TCP finished the trial run test based on their own products/ process, the phospher will sent to Wanjia to produ

6、ce without wanjia*s own trial run based on wanjias process/products.No phospher/powder preparation record can check, can not know the DVP/PVP/ 1st production used same phospher or not(wanjia told me they used NICHIA phospher for the all three times); For the samples making on Dec-12, they will do a

7、trial run for the phospher incoming check and phospher preparation check, if OK, then, start to produce all samles, the related record will be setup;ALON保護層的控制：他們增加AL2O3的濃度(由4% = 5%)使光 衰表現(xiàn)較好。涂保護膜之前，用純水清洗玻管在同一機器上做群 辦，玻管沒有干時，水滴回去AL203回收液里。我檢查過有保護涂層的 玻管,發(fā)現(xiàn)有些玻管是幾乎透明的，這說明了可能漏涂或可能AL2O3濃度太低。在12月12日的生產(chǎn)是，要先干

8、管后涂保護膜,更加 上100%檢查,更需要提供已涂好的樣辦,給工人做對照。Alon coating(precoating) control: they has increased the A12O3 concentration from 4% to 5% to get better lumen maintenance. But, they use hot DI water to clean the tube before pre-coating on the same machine without drying the tube, the water dropped into the rec

9、ycle A12O3 liquor directly, which keep the A12O3 liquor being diluted during pre-coating. We checked the pre-coated tubes after precoating and before phoshor coating, can found some tubes are almost transparent, maybe did not pre-coating because of the operators carelessness, maybe because the A12O3

10、 concentration is too low. For the samples making on Dec-12, will dry tubes after cleaning offline and then do the precoating; 100% precoating inspection need to be done before phosphor coating, and the limit samples for the inspection will be prepared to help the inspectors inspection;3.涂粉后烤管的機器在05

11、年中已換過，以前是比擬平直的烤管機，但現(xiàn) 在是如圖中的機(不一樣)。機中只有一個溫度計放于中間的加熱區(qū),而 在兩邊斜波區(qū)是沒有發(fā)熱器的。機內(nèi)有2米予熱區(qū),2米加熱區(qū)及2 米冷卻區(qū)。展示熱區(qū)的溫度是480,但機器是沒有溫度分布數(shù)據(jù)表的。據(jù) 他們的現(xiàn)有流程,2-3只變形燈管是可以接受的。我檢查過生產(chǎn)線上的 記錄發(fā)現(xiàn)有2只變形燈。我覺得烤管線入口區(qū)溫度不對，用手試溫發(fā) 覺溫度跟室溫差不多。至于變形燈我懷疑是加熱區(qū)溫度太高這會影響 燈粉的質(zhì)量。他們?nèi)菰S了測試機器各程序的溫度,取得溫度分布數(shù)據(jù)請 把這些數(shù)據(jù)給匈牙利參考。Tube baking after phosphor coating machine

12、 changed from mid of last year(the PVP use new baking machine), the original is flat and straight, the new machine is like this shape , there is only 1 temp tester in the middle of the top heating area( the two slope area has no heating tube), 2 meters long for the heating area and 2m for entrance p

13、reheating area, 2m for the cooling area, the displayed heating area temp is around 480C, no temp. profile for this baking machine, according to their current process, 2 to 3 pcs deforming lamps is acceptable (I checked one of their inspection record online, there are 2pcs deforming lamps) ,1 feel th

14、e entrance part temp, by my hand, it is much cool like the environment temp in the room, from the deforming lamps, maybe some place temp, in the heating area is very high, that might affect the phosphor quality. They will test the baking machine/process to get the temp, profile, please get the temp.

15、 profile and send to hungary for suggestion.4.月12日做的燈Ar氤氣的壓力會由3加至3.5 (Colums)增加改善光 衰的表現(xiàn)。而在排氣前的加熱時間可以用軟件來控制到中級加熱 時間。For the samples making on Dec-12 ? the Ar fill preasure will be increased from 3 to 3.5 columns to improve the lumen maintenance, the heating before exhausting time will be controled by

16、 the software to make sure the minmun heating time.5.平封程序是要操作員用手去改正（芯柱）的方向。這樣手接觸到芯柱陰 極局部，是會影響到排氣質(zhì)量及燈的壽命,所以這樣程序要用一些 工具來代替手指操作防止碰到陰極局部。Sealing process need correct the stem direction by hand before close the tube on the stem, and the operators finger may touch the cathod, that will effect the exaustin

17、g quality and may effect lamp life, some tooling need to use to avoid finger touch the cathod.6.涂保護層及涂燈粉的操作指導(dǎo)上，沒有注明溫度、公差及氣 壓的要求，這些工藝上的要求是一定要在操作指導(dǎo)上顯示，而每次進 行生產(chǎn)之前一定要檢查正確的。precoating/ phosphor coating, no temp. requirement/tolerance and air blow pressure defined in the WIs, all process parameters need to be defined in the WIs and be checked before production;7