万佳验厂报告

1、GE Shirley的万佳访厂报告.跟万佳的技术管理谈过后了解现况如下：万佳正完成一些毛管样办， 是有较厚的ALON涂层(保护层)，用了 日雅灯粉。于12月8日将会有 100小时的数据，12月12日会有200小时数据可作大约计算光衰的改善。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.无论测试成绩如何他们都会开始造余下型号。将会在12月14日完成。全部 送交SuperTrend这样安排是比原来的时间表迟了 2天。是否可以接受？请通 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.今天他们造了一些样办，让我们检查

4、由第一个工作站开始的生产程序。但发 现了一些问题，请跟进以下事项：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是他们的大客户,他们是从TCP买灯粉的。TCP做完了试产(根 据TCP的生产流程)之后就把灯粉送去万佳使用。但万佳是没有再做 试产(基于万佳的流程)，亦没有万佳的混制灯粉记录。所以我们监管不 了 DVP/PVP/第

5、一次生产是否用了同样的灯粉。但万佳的人说三次都是 用了 日雅粉。12月12日的生产，他们容许了会做一次试产及灯粉来料 试产及混制灯粉的试检,假设OK,那么开始做其余型号的样办，亦容许了做样 办生产记录。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保护层的控制：他们增加AL2O3的浓度(由4% = 5%)使光 衰表现较好。涂保护膜之前，用纯水清洗玻管在同一机器上做群 办，玻管没有干时，水滴回去AL203回收液里。我检查过有保护涂层的 玻管,发现有些玻管是几乎透明的，这说明了可能漏涂或可能AL2O3浓度太低。在12月12日的生产是，要先干

8、管后涂保护膜,更加 上100%检查,更需要提供已涂好的样办,给工人做对照。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.涂粉后烤管的机器在05

11、年中已换过，以前是比拟平直的烤管机，但现 在是如图中的机(不一样)。机中只有一个温度计放于中间的加热区,而 在两边斜波区是没有发热器的。机内有2米予热区,2米加热区及2 米冷却区。展示热区的温度是480,但机器是没有温度分布数据表的。据 他们的现有流程,2-3只变形灯管是可以接受的。我检查过生产线上的 记录发现有2只变形灯。我觉得烤管线入口区温度不对，用手试温发 觉温度跟室温差不多。至于变形灯我怀疑是加热区温度太高这会影响 灯粉的质量。他们容许了测试机器各程序的温度,取得温度分布数据请 把这些数据给匈牙利参考。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日做的灯Ar氤气的压力会由3加至3.5 (Colums)增加改善光 衰的表现。而在排气前的加热时间可以用软件来控制到中级加热 时间。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.平封程序是要操作员用手去改正（芯柱）的方向。这样手接触到芯柱阴 极局部，是会影响到排气质量及灯的寿命,所以这样程序要用一些 工具来代替手指操作防止碰到阴极局部。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.涂保护层及涂灯粉的操作指导上，没有注明温度、公差及气 压的要求，这些工艺上的要求是一定要在操作指导上显示，而每次进 行生产之前一定要检查正确的。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