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Behind the scenes at Samsung's TV factory: Part II

By Ty Pendlebury, CNET.com.au

Our lounge rooms are dominated by the chaebol, and most of our entertainment comes from the company, but have you ever wondered how a TV is made? In Part I, we looked at the design process, and how the bezel was made. This time, we toured the nearby LCD factory where the panels themselves are made.

While TVs of one type or another have been around for over 50 years, they have gone through several changes, with flat panels the latest iteration. LCD TVs have been mainstream products for about four years, but what makes them tick? This year, we were fortunate enough to have visited both the Samsung and LG plants in South Korea to get a better understanding of how an LCD TV is made, and what the future holds for the technology.

Samsung is one of the world's largest manufacturers of LCD panels, and it claims to produce one out of every four in the world. One of its largest facilities is in Tangjeong, 80km south of Seoul. Samsung has four different plants on this site, and this is where the joint Sony/Samsung S-LCD plant was first built--and still produces Sony panels to this day. We visited Tangjeong recently and got not only a look at the production lines, but also the opportunity to meet with the engineers and designers who helped make them possible. Samsung's two main facilities had dozens of 20-something year olds wandering around sculpted gardens with huge planters filled with purple flowers acting as road dividers. They felt more like universities than industrial think tanks.

(Credit: Ty Pendlebury/CNET Australia)


Inside the factory
The Tangjeong factory is a large facility south of Seoul and produces panels for the five-year-old S-LCD collaboration between Sony and Samsung. As a result of this union, Sony owns part of the production lines on the Tangjeong site--this equates to 50 percent of the L7-1 line, plus half of the combined L8 (1 and 2) lines. The L8-2 factory came online only in June 2009.

Samsung has begun planning its ninth plant, which will produce its Generation 11 panels (L9), and this will fit in behind the two existing factories. It will be capable of producing much larger panels than the L8 plant with 40, 62 and 72 inches possible.

We got to see one of the L7 (no relation to the LA-based band) lines in operation after donning the fetching blue shoe covers. Unfortunately, we were unable to take photos inside the LCD factory as apparently corporate espionage is a big problem. However, we'll do our best to explain the long corridor with its helpful blue signs and series of LCD panels in various states of undress explaining each part of the process.

The setup to these "demonstration" assembly lines doesn't seem to change from factory to factory, but we wouldn't appreciate working in one of these "fish bowl" situations. Imagine if you had to work behind a long glass corridor with all of your things labeled with blue signs and thousands of strangers peering in at you. It's like a factory zoo!

There were several different "lines" in each factory--each doing a different-sized panel. Apparently, it takes three days to convert one line to produce another size, so there is some redundancy built into the system to cover for any downtime.


Tags: Factory, Samsung Electronics Co. Ltd., TV, South Korea, Tangjeong Factory
 

 

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