Inline & Integrated Manufacturing Equipment. Marcel Grooten CEO OTB Engineering

Transcription

1 Inline & Integrated Manufacturing Equipment Marcel Grooten CEO OTB Engineering

2 OTB Introduction New development Supporting other BU s Ophthalmic Car glazing Inline solar-cell production equipment Tabbers Anti-reflection deposition tools Inline OLED display production equipment Development of high accuracy industrial print heads. Print strategy software. Print material recipes Application research for organic electronics

3 Company evolution & track record OD&ME Worlds 1st inline CD production system: monoliner MKI 91 Philips ODM ODME Worlds 1st inline CD mastering system: AMS OTB-E inline CD-R production system: Dye-Line 97 ToolexAlpha Toolex Worlds 1st inline soft contact lens production system 99 Worlds 1st inline SOLAR cell production system 01 inline DVD-R production system: Profi-Line Singulus VDL Mastering / Molding Replication Philips PolyLED OTB-D OTB-S OTB-E Fully electrical Injection Molding System: MoldPro Thin film SiN deposition tool: DEPx Worlds 1st inline PLED production system: PCAP

4 Manufacturing in Europe Trends & Threats Intense and growing pressure from overseas competitors. In high-tech fields, especially, other developed economies compete. Manufacturing in more traditional areas is increasingly migrating to low-wage countries rapidly modernizing their production methods and enhancing their technological capabilities. European Commission launched December 2003 ManuFuture Platform : July 2006: Strategic Research Agenda based on research and innovation,, securing high added value employment and winning a major share of world manufacturing output in the future knowledge-driven economy. Implementation in EU Research Framework Program FP7 Be smart, Innovate!

5 Type of Industry Mature Scale Intensive Specialized Suppliers Science Based

6 Typical Examples Cost reduction by Lean Manufacturing principles Value stream Operational excellence Tape-drive Production line in EU Cartridge Production line in USA

7 Tape Drive Production NL Inline Manufacturing

8 Data Cartridge Production USA Inline Manufacturing

9 Value Stream Leadership, Business Strategy, Management Systems & Infrastructure People Development Work Processes Value Stream Customer Focus Information Systems Supply Chain Principles: Customer defines value Value Stream Delivers Make value flow Supply on demand Continuously improve

10 Lean Manufacturing Pro all energy and creativity focussed on optimizing product quality at lowest costs. Con No drive for innovation or application of breakthrough technology. Cutting costs is a must, but at the end of the day a lost battle for Europe Innovate

11 Approach OTB s approach: Innovation in production technology Invent, design and develop: Inline & Integrated Manufacturing Equipment High throughput, uptime, yield, quality, material utilization and automation Enable local for local manufacturing at lowest cost

12 Inline philosophy Minimizing process steps and operator intervention Production equipment dedicated for a small group of products Balancing and reducing of tact times Elimination of buffers Integration in one machine Reduced inspection steps to one at the end Fast feed back loops enabled by short throughput times Minimize product handling

13 Integrated Solutions Product OTB Lowest cost price per product Equipment Process Integrated Systems & Technology Lowest Total Cost of Ownership

14 OTB Technologies

15 OTB s Innovation Process Polymer Oled production machine Fast SiNx Deposition equipment Industrial Printer POP Proto Pilot Production Phase Phase Phase Phase

16 Examples OLED Displays SOLAR cells Contact Lenses

17 OLED Displays OLED devices are simpler than LCD s lower cost Eliminate need for: backlight, polarizers, liquid crystal layer, alignment films and color filters LCD OLED

18 OLED Potential Manufacturers advantages Lower capital cost Simpler bill of materials Lower manufactured cost Versatile product design Comparison of LCD vs OLED display from OTB Display End-user advantages High contrast Wide viewing angle Ultra-fast response Lightweight, thin New product forms

19 OLED Device Antiscratch Cathode Organic layer PM Substrate: Cathode separator ITO Glass SiN x OTB process: Anti-scratch coating coating Thin Thin film film Encapsulation Cathode LEP LEP PEDOT PEDOT

20 OLED Process IJ IJ printing printing PEDOT/LEP Cathode deposition Thin Thin film film Encapsulation Anti-scratch coating coating

21 OLED Production System PEDOT/LEP Inkjet Inkjet printing printing Cathode deposition Thin Thin film film Encapsulation Anti-scratch coating coating Input High yield Same history for all products No buffers Minimization of substrate handling High up-time Redundant modules Integration of functionality Minimization of parts Low tact-time Dedicated process modules Minimization of loadlock volumes One-time alignment

22 OLED Production System Designed for low cost mass production through: -High yield -High up-time -Low tact-time In-line polymer OLED production system

23 Solar Cell Manufacturing Inline Solar cell Manufacturing Equipment: LINEx

24 DEP X Inline SiN deposition system for ARC. Integration latest technologies: Ultra fast PECVD, Linear Motor System 960 PV Solar cells/h Cell efficiency 13% 16% (Mono Crystal) MONO & MULTI process available Installed base:

25 DEP X : Inline SiN Deposition High deposition rates; µm/min (SiNx) High Vacuum in extreme short cycle Variety of layers SiOx, SiNx,.. Flexible gas injection system Linear Motion System in Vacuum

26 Inline Production Equipment Inline Solar Cell equipment 1600 PV Solar cells/h Footprint 50 m Cell efficiency 15%..22% Installed base: 4 Cell Passivation module (DEPx): Installed base: 14 In order : 17 Inline Display equipment 1 st fully automated production platform 14 x 14 substrate size 30 substrates/hour No Clean room

27 Inline production equipment Inline contact lense equipment Fullyautomated inline production machine 4800 lenses per hour Footprint 6 m Installed base: 20 Inline spectacle lenses equipment Fully automated inline production platform: 360 lenses/hour New prescription technologies

28 OTB Results OTB Achieved results Product Batch In-line Solar cells 3 MW/year 50 MW/year 160 operators 25 operators 5000 m m 2 Compact Discs 3,5 / CD 0,12 / CD 20 Million/Year 8 Million/year 400 operators 1 operator 100 m 2 3 m 2 80% yield >97% yield Contact lenses 0,40 / Lens 0,12 / Lens 42 Million/year 42 Million/year 25 operators 1 operator 180 m 2 10 m 2 70% yield 90% yield

29 Summary Batch New or unknown processes Variation in product configuration Pilot production stage Small volumes for niche applications Lower initial investments Inline Integrated total solution Mass manufacturing Significant investment Lowest Cost point per product Highest ROI

30 Inline production Inline, Modular or Batch production? Develop a product & manufacturing process based on inline manufacturing philosophy Investment costs versus tact-time constrains Define modular automated inline production system Design product & process suitable for inline manufacturing Tune system size & investment on Local-for-Local approach. Competitive edge by integrating breakthrough technology solutions based on High Tech content and know-how

31 THANK YOU OTB Engineering B.V. Luchthavenweg 10, 5657 EB Eindhoven The Netherlands phone +31 (0) fax +31 (0) website