Q:/Marketing/Pres/Tradeshow & Conf Pres/Cornell Flex Electronics Class - May 2006/Flexible Manufacturing Concepts 041906 1 of 138AGI Abbie Gregg, Inc.Based on a Modelcompleted for the UnitedStates DisplayConsortium (USDC)Titled,“Flexible Microelectronicsand Roll-to-RollProcessing Study”Q:/Marketing/Pres/Tradeshow & Conf Pres/Cornell Flex Electronics Class - May 2006/Flexible Manufacturing Concepts 041906 2 of 138AGI Abbie Gregg, Inc.Lara YorkAGI: VP Advanced TechnologyBS Engineering – United States Military Academy, West PointMS Systems Management – USCCo-Author : Roll to roll manufacturing of Flexible DisplaysQ:/Marketing/Pres/Tradeshow & Conf Pres/Cornell Flex Electronics Class - May 2006/Flexible Manufacturing Concepts 041906 3 of 138AGI Abbie Gregg, Inc.AGI: Abbie Gregg, IncHigh Technology Consulting for 20 years•Semi Conductor•Nanotechnology•BiotechnologyBased in Tempe, ArizonaQ:/Marketing/Pres/Tradeshow & Conf Pres/Cornell Flex Electronics Class - May 2006/Flexible Manufacturing Concepts 041906 4 of 138AGI Abbie Gregg, Inc.Background:Critical Steps in Modeling of Factories for CostReduction, Yield Improvement and Output forFlexible Displays and ElectronicsThe race is on to get new applications to market.How do I insure time to market and a successfulproduct launch?Presented by:Lara York, Vice President Advanced TechnologyImages courtesy of E Ink, Citala, Aveso Displays, Estee LauderQ:/Marketing/Pres/Tradeshow & Conf Pres/Cornell Flex Electronics Class - May 2006/Flexible Manufacturing Concepts 041906 5 of 138AGI Abbie Gregg, Inc.Case Studies• Touch Screen-Digitizer– Moving from sheet process in development to either techtransfer to a production line OR outsource to remote foundry• Flexible Reflective Display– Moving from small lab R&D to manufacturing in nearby factory• Flexible Battery– Moving from medium scale sheet based production to highvolume, low cost production at several worldwide sitesQ:/Marketing/Pres/Tradeshow & Conf Pres/Cornell Flex Electronics Class - May 2006/Flexible Manufacturing Concepts 041906 6 of 138AGI Abbie Gregg, Inc.The Existing Lab Setup• Slow• Sheets• ManualImage courtesy of Display ScienceQ:/Marketing/Pres/Tradeshow & Conf Pres/Cornell Flex Electronics Class - May 2006/Flexible Manufacturing Concepts 041906 7 of 138AGI Abbie Gregg, Inc.Vision of the Roll to Roll Line• Clean• Automated• High YieldImages courtesy of Northfield Automation and Creo, Inc.Q:/Marketing/Pres/Tradeshow & Conf Pres/Cornell Flex Electronics Class - May 2006/Flexible Manufacturing Concepts 041906 8 of 138AGI Abbie Gregg, Inc.Baseline Existing/Proposed Processing• List each process (travelers are helpful)– Don’t skip even the most “trivial” step– List off line support steps (premixing of inks, pre cut of laminated materials, etc. etc.)• List associated tools and equipment• List process parameters– Pareto the most critical parameters for each step- work on top 3– Include• Observations of products- metrology tools and criteria• Environmental conditions• Settings on equipment• Expected defects and faults• List process times (set up, wait time, process)• List materials• Obtain cost data (equipment, materials, labor, overhead etc…)Q:/Marketing/Pres/Tradeshow & Conf Pres/Cornell Flex Electronics Class - May 2006/Flexible Manufacturing Concepts 041906 9 of 138AGI Abbie Gregg, Inc.Example of Process Detail Needed• Etch Process C- Lab process that needs to be scaled up:• Immersion in an etch solution• Immersion in DI water baths• Rinsing with DI water• Drying in the oven• Etch process details– Etchant: Hypochlorite solution 2. Temp = 25C3. Time= 45 sec• We do this in our lab in a plastic bath• 3 baths one after the other• first bath – 20 sec, second bath 20 sec, third bath 1 min (Do you know why?)• Requires Shaking the film/bath in each stage (video the motions)• Observations:• The material swells in water and becomes sensitive to mechanical stress• QC – Test etched lines:– Resistance x : 300 Kohm ± 30 Kohm– Resistance between lines: greater than 5MohmQ:/Marketing/Pres/Tradeshow & Conf Pres/Cornell Flex Electronics Class - May 2006/Flexible Manufacturing Concepts 041906 10 of 138AGI Abbie Gregg, Inc.Process Detail Needed for Lamination• Lamination• Position the y substrate on a milimetric paper• Clean with antistatic spray• Laminate PSA to the y substrate using an antistatic gun anda laminating roller at Pressure A +/- a, temperature B+/-b• Remove PSA residue around the substrate y using a sharpknife• Position the film x to film y using positioning aid #1• Remove PSA liner and lamination of film x using antistaticgun and lamination roller.• Clean upper side of film with antistatic spray• Parameters• Class 100 Clean Room (probably we can use 1000 but neverbeen tested).• Material type: Adhesives Research PSA1• Positioning aid #1 - Works for specific product dimensions.• Equipment• Antistatic spray• Laminating roller• Antistatic gun• Sharp knife• Milimetric paperImages courtesy of confidential clientsQ:/Marketing/Pres/Tradeshow & Conf Pres/Cornell Flex Electronics Class - May 2006/Flexible Manufacturing Concepts 041906 11 of 138AGI Abbie Gregg, Inc.Ask the People Who Inspect the Product• Inspectorssee morethan theyrecord• Identifyprocesses/tools andmaterials noton thetravelerImage courtesy of confidential clientQ:/Marketing/Pres/Tradeshow & Conf Pres/Cornell Flex Electronics Class - May 2006/Flexible Manufacturing Concepts 041906 12 of 138AGI Abbie Gregg, Inc.Capture All Visual Aids in Production• Crispdefinition offailing andpassing units.• Communicateto offshorefoundries withphotos.Image courtesy of confidential clientQ:/Marketing/Pres/Tradeshow & Conf Pres/Cornell Flex Electronics Class - May 2006/Flexible Manufacturing Concepts 041906 13 of 138AGI Abbie Gregg, Inc.Notes on Product Dimensions – R&D• Be sure tocapture valuesandengineeringcommentsand anyengineeringevaluationstepsImage courtesy of confidential clientRegistration marks.Q:/Marketing/Pres/Tradeshow & Conf Pres/Cornell Flex Electronics Class - May 2006/Flexible Manufacturing Concepts 041906 14 of 138AGI Abbie Gregg, Inc.Observe Two Different Operators,Especially Manual Tool Setups• Pilot for automation may reveal new variables• Operators may not support automation at firstImages courtesy of confidential clientQ:/Marketing/Pres/Tradeshow &