TV Manufacturing Process
The LCD TV production line is a complex assembly process involving precision assembly in multiple links. In the raw material preparation stage, the factory needs to purchase core components such as LCD panels, casings, and circuit boards, and conduct warehousing inspections. The assembly of the LCD panel is a key step. It requires first installing the backlight, accurately assembling the panel and connecting the cables. Motherboard assembly requires the installation of various electronic components on the circuit board, such as signal processing chips, power supplies, etc. After assembly, the LCD TV also needs to undergo comprehensive functional testing to check image, sound and other effects. After passing the test, it enters the packaging and shipping process. Unqualified products need to be reworked and repaired. Every step of the entire production line must be strictly controlled to ensure the speed and efficiency of the assembly line and the high reliability of the product.
LCD TV manufacturing places high demands on production line quality control and optimization, which requires close cooperation between various departments to produce high-quality TV products.
Today in this article, we will be taking Mianhong as an example, to verify how a bulk order can be completed.
1. Raw material preparation - Purchase and prepare raw materials such as LCD panels, housing plastic parts, circuit boards, and protective films.
1. LCD panel This is the core component of the LCD TV. The factory will purchase LCD panels of different sizes and resolutions according to the model. It is necessary to check whether the panel is damaged, whether the pixels are lit, etc.
2. Shell plastic parts The shell is usually made of plastic injection molding, including the front shell, rear shell, etc. It is necessary to check the plastic housing for cracks, missing corners, and color spray problems.
3. The main control circuit board is equipped with signal processing chips, power management chips, etc., from suppliers with SMT capabilities. The circuit board needs to be checked for short circuits, missing soldering, missing components, etc.
4. Accessories such as power cords, bases, remote controls, screws, and other auxiliary materials will be purchased and inspected according to the BOM list.
5. Packaging materials such as fluffy cotton, environmentally friendly packaging bags, cardboard boxes, etc. need to be checked to meet the size and not damaged.
Raw material preparation requires warehousing inspection and classification storage of various purchased raw materials so that subsequent assembly line calls can be made to ensure assembly quality.
2. LCD panel assembly - Assemble the LCD panel into the rear case, connect the cables and backlight, etc.
Backlight installation: Install the LED light strip to the appropriate position inside the rear casing and fix it.
Optical film lamination: Laminate optical films, such as diffusion films, brightening films, etc., on the backlight in order to even out the light and improve the display effect.
LCD panel assembly: Carefully place the tested LCD panel into the rear case and accurately align the position of the backlight. Assembly is usually accomplished using a robotic arm.
Flat cable connection Use a flat cable to connect the connection terminals on the LCD panel to the backlight and circuit board. The cables should be arranged neatly and the connectors should be firm.
Screw fixation: Use special screws to fix the LCD panel to the rear case. It should not be too loose or too tight.
Inspection After the assembly is completed, perform a visual inspection to ensure that the panel is not displaced, the wiring is neat, and there are no loose problems.
This step is crucial to the product’s optical performance and service life, and assembly must be completed carefully to ensure the LCD effect.
3. Motherboard assembly - Installing various electronic components on the circuit board, such as main control chip, power board, etc.
Can skip this part because we have motherboard supplier
SMT Assembly – Use surface mount technology to install various electronic components such as resistors, capacitors, chips, etc. on the main control circuit board.
Plug-in assembly – Use plug-in technology to install some large components, such as power interfaces, switches, connectors, etc.
Dispensing – dispensing glue at certain locations on the board to fix specific components.
Component assembly – manually assemble some components such as power management chips and audio processing chips to designated locations.
Wire soldering – Use a soldering station to solder the chip to the gold fingers on the board and connect the wires.
Inspection Testing – Optical inspection and electrical performance testing of the assembled motherboard.
Repair and adjustment – If there is a problem, dismantle the board and repair it to ensure the quality of the motherboard assembly.
Motherboard assembly requires precise control of each step because the performance of the motherboard directly affects the picture and sound effects of the LCD TV. We have various motherboard suppliers and they often provide us with the completed motherboards. All Mianhong need to do is to put the motherboard in the right position, and assemble the cable from the LCD panel to the motherboard.
4. Functional testing - Functional testing of the assembled circuit board, detecting images and sounds, etc.
Power-on test: Connect the power supply and check whether the LCD TV can be turned on normally.
Image test: Check whether the display screen has debris, dirty spots, scratches and other problems, and whether the display color, contrast, brightness, resolution and other parameters are up to standard.
Sound test: Use the audio signal source to check the volume, sound quality, left and right channel balance, etc.
Key test: Check whether each key function is normal, such as channel, volume, menu keys, etc.
Interface test: Check the connection and signal transmission function of USB, HD, earphone, and other interfaces.
Functional testing ensures that the TV’s performance meets design specifications and user requirements. Unqualified products will be reworked, repaired, and adjusted before being tested again.
5. Housing assembly - Install the tested circuit board into the front housing and connect the components and interfaces.
Carefully place the main control circuit board that has passed the assembly test into the rear housing of the LCD TV.
Align the assembled LCD panel components into the rear case and securely connect them.
Place the front shell on the rear shell and integrate the positions of the components.
Use screws to secure the front and rear cases tightly.
Connect speakers, control buttons and other components to the corresponding interfaces on the front case.
Use connecting cables to connect the interfaces on the motherboard to speakers, control boards, power boards, etc.
Conduct a visual inspection to ensure that the interfaces of each component are firmly connected and the wires are arranged neatly.
Connect the test signal source and check the image and sound effects.
The quality of the shell assembly directly affects the appearance and service life of the product, and requires careful assembly to ensure the reliability of the interface connection.
6. Packaging and shipping - products that have passed the test are cleaned, packaged, labeled and shipped to the shipping area.
Cleaning the TV: Use special tools and materials to clean the outer shell of the assembled LCD TV to remove fingerprints, dust, etc.
Film and labeling: Put a protective film on the TV and label it with name, specifications, barcode and other labels.
Packing boxes: Put the qualified LCD TVs into pre-packed cartons or plastic packaging boxes.
Marking on the box: Put a mark on the box to indicate the brand, model, quantity and other information.
Warehousing and loading: Put the packaged products into containers in the designated warehousing area for temporary storage.
Shipping: According to the order, take out the packaging box from the storage cabinet and load it onto the truck for distribution and shipping.
Record and traceability: Scan the product serial number and barcode and record it for audit and subsequent traceability.
Retour processing: sorting, reworking or scrapping products returned due to quality problems.
The packaging and shipping link completes the packaging and transportation of finished products and is an important link connecting manufacturing and sales.
The production process of LCD TVs can be said to be a perfect combination of modern industrial equipment and precise assembly operations. From raw material preparation to final packaging and shipment, each link requires a high degree of concentration and meticulous operation to assemble complex LCD panels, circuit boards and other components into an exquisite consumer electronics product. Factories need to continuously optimize assembly lines, improve machine automation levels, and strictly control the quality of each step to minimize failure rates. At the same time, production personnel are also very demanding, requiring professional skills and patience to ensure that the assembly quality of each LCD TV meets the design specifications. Only by comprehensively improving management, operations, equipment, materials, and other aspects can the LCD TV production line operate efficiently and stably and deliver high-quality TV products that satisfy customers.