by December 31, 2001 0 comments

Last month we saw the first two stages of assembling a monitor — creating the printed board and assembling the larger components on it. Now, we take a pictorial tour of stages three and four

Assembling a monitor takes four stages. In the first stage the PCB (printed circuit board) is populated with the smaller components like jumpers, resistors, capacitors and GT pins. In stage two, the larger components, including the larger capacitors and transformers, are added by hand to this assembly. In stage three, the CRT and the other components are added. In stage four the monitor goes through electrical adjustments and testing.


After PBA assembly, stage two is complete. Last month we saw the assembling of a monitor till here


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The picture tubes are imported into the country for integration with the rest of the circuitry at the plant. This picture shows stacks of picture tubes moving in for assembly

The next stage is putting the degaussing coil around the picture tube. As the name suggests, this coil is used to degauss the picture tube


Now the pre-assembled printed board assembly is fitted to the front bezel, and the connectors from the board are connected to the appropriate points on the CRT. The physical assembly of the monitor is more or less complete now. 
The first adjustment is the tilt adjustment for the CRT. A total of four screws are used to connect the CRT to the front bezel. These screws are adjusted to adjust the tilt of the CRT



Now come the voltage adjustment and the white balance adjustment (adjusting the ratio of R,G and B to get pure white)

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Next, comes the function check stage. Here the monitor is checked to see if all the functions are working properly, and if there are any physical defects

At this stage, the monitor is sent for ageing. Ageing is like burn-in, where the monitor is left on for 30 min, passing it through overhead racks


After ageing come final white balance adjustment and focus adjustment. This focus adjustment is one of the most critical steps in the assembly of a monitor. After focus adjustment comes auto image adjustment. Here the height and width of the image is adjusted for four different modes that the monitor will operate in. Once that is done, the white balance is adjusted again, in what is called the final-final white balance adjustment stage. Auto image adjustment is now done for four more modes

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Now comes another critical stage in the adjustments–the convergence adjustment. After this, the convergence and focus are checked using a powerful camera. After this comes the DPMS or digital power meter check. Here the power consumed by the monitor in sleep mode is checked to ensure that it conforms to specs. Once the monitor passes this test, the back cover is fitted on.
Testing is not over yet. The monitor now goes in for the high voltage test. 2.4 KV DC is fed to the monitor, and it is checked for leakages, continuity, etc 

Next comes the shock test. The monitor is physically beaten from both sides using the gloved device shown in the picture, and the final inspection is done. Once the monitor passes the final inspection, it goes in for DDC (Display Data Channel) write. The basic information about the monitor is written into ROM. The written data is read back for accuracy in the next stage called DDC read


Once the monitor successfully completes DDC read, it is ready for packing. Before packing, the cable, the manuals, driver floppy, warranty card, etc, are manually inserted into the package. The packed monitor is stacked and moved to the godown for onward shipping to sales points 

Salient features of the Samsung India monitor plant, Noida
Capacity: 150 thousand per month Work force: 180 operators in one shift, 55 engineers
Raw material sourcing: India, Malaysia and China. Localization now at 20%, expected to go up to 50%
Manufacturing for: Samsung India requirements. Indian OEM for IBM, Zenith, Vintron, etc. Exports to Europe to start soon
Production planning: Linked to sales forecast through Samsung’s worldwide production-management system
Quality control: Inbound and outbound QC at plant, FCC checks at designated laboratories in India, sample sent to Korea for internal QC

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