mar., 2005 verbatim confidential dvd production process & key factors for quality discs...

Mar., 2005 Verbatim Confidential

DVD Production Process &Key Factors for Quality Discs

Verbatim, Product MarketingMar., 2005Ronan Ryan

/Satoshi Wakabayashi


Revenue $18 billion (March 2004)

33,500 employees (1,500 in USA)

Performance Chemicals, Pharmaceuticals, Petrochemicals

100% Subsidiary of Mitsubishi Chemical Co.

Total Revenue $650 million

Optical Disc, Magnetic Media, Flash Memory

100% Subsidiary of Mitsubishi Kagaku Media CO.,LTD.


Verbatim / Mitsubishi Kagaku Media Group

Vision & Mission

Verbatim / MKM is an international sales, marketing and optical technology development organization known as the innovative market leader in removable storage media and related accessories providing reliable, unique technologies and products that are highly sought after and broadly distributed world-wide.

Our mission is to develop and market high quality products that users want for storing, moving and using digital content.

January 2004 MKM Executive Committee


HeadquartersDistributionManufacturing

Tijuana, MexicoFloppy/CD-R

Charlotte NCVerbatim USA HQ

USA DC

Toronto CanadaCanada DC Mizushima, Japan

MO, UDO, Stampers

Taipei, TaiwanFloppy, CD-R/RWDVDR, DVDRW

SingaporeDVDR, DVDR DL

DVDRW

Frankfurt, GermanyVerbatim European DC

Tokyo , JapanMitsubishi Chemical Corp.

UruguayVerbatim South America DC

Egham, UKVerbatim EUMEA HQ Odawara , Japan

VAP DC

Melbourne, AustraliaVAP DC

Sunnyvale, CAMFD/Tape

Coating

Hong KongVAP DC

Shenzhen, ChinaVAP DC

Global Supply Chain

IndiaDVDR, DVDRW

CD-R


MKM Core Competencies

Stamper

Production Process

Plastic

Ink

Phase Change

Dye

MitsubishiCore Technology

Fast Dry Printable


Verbatim Product Direction• Products are designed and manufactured for the highest compatibility and reliability

– Technology is co-developed with hardware OEMs (designed into hardware)

– Unique manufacturing partnerships • Specify & qualify manufacturing lines

• Tighter than industry specifications

• On site Quality Assurance and Engineering support

• Unique ID codes that insures the highest level of compatibility in the industry

• Continually expanding our product offering

– Latest in core optical technology products• Speeds (16X DVDR, 8X DVDRW)

• Layers (DVD+R and DVD-R DL)

• Surfaces (Ink-jet and thermal printable, Hardcoat)

• Blue laser (UDO, Blu-Ray, HD DVD)

– Continue to broaden our non-optical lines (imaging, USB, accessories)

• Always differentiated from the competition

– Technology and quality (AZO, SERL, Crystal, etc..)

– Product marketing (Digital Vinyl, Gold and Platinum, DigitalMovie, VideoGard, etc.)


Verbatim Brand

• Well established brand (35 years)

• Clearly recognized as a quality brand

• Extremely well known & distributed brand throughout the world– #1 World-wide market share for DVD +/- R

– #1 World-wide market share for CD-R

– #2 World-wide market share for DVD +/- RW

– #2 World-wide market share for CD-RW

Source: Santa Clara Consulting Q4 2004


Major Cause of Problem

Full Surface PI error

0

200

400

600

800

1000

1200

2300

3

2480

6

2648

9

2806

8

2956

7

3098

9

3235

3

3365

8

3491

4

3612

8

3730

5

3844

3

3954

8

4062

2

4167

0

4269

1

4368

8

4466

4

4561

9

4655

4

4747

1

4837

1

4925

2

5011

8

5096

9

5180

7

5263

2

5344

7

5424

5

5503

1

5580

7

5657

5

5733

2

5807

5

Radius

PI e

rror

Media A Media B Media C Media D

Spec : <280

Effect of bad media shape

Recording layer (Dye) has

problem

Good dye, good media shape and optimized

write strategy


Dye CoatingDye Coating

Dry upDry up

InspectionInspection

InjectionInjection CoolingCooling

SputteringSputtering

BondingBonding

CoolingCooling

(Recording Side)

(Dummy Side)

InjectionInjectionPlastic Substrate

with grooves

Substrate with dye recording layer

Reflective layer is added

Dummy substrate

Glue attached both side

Production Process of R-DVDMasteringMastering

Stamper


InjectionMachine

InjectionMold

Injection Process

• Key process - to attain flat media shape - avoid micro crack - form uniformed groove shape to prevent recording/reading problem

• Key factors - quality stamper - quality mold - high grade polycarbonate - optimization of injection condition (pressure, timing, temperature)


Mastering Process & Design of Mold

• Mastering is the key process - for making quality stamper

• Key factor - sophisticated operation of the cutting machine - deep knowledge/experience of polycarbonate and injection process

• Mold is the key material - for injection process - for attaining higher production cycle time

• Key factor - deep knowledge/experience of polycarbonate and injection machines


Dye coating

Baking Oven

Dye Coating & Drying Process

• Key process - to attain good recording performance - to achieve superior archival performance • Key factor - quality dye material (ability to develop quality dye) - optimization of spin coater condition (rotation speed, speed control, temperature, humidity) - optimization of the baking condition


DVD-R disc Jitter power margin660nm NA=0.65

5

6

7

8

9

10

11

12

13

14 16 18 20 22 24 26 28 30 32

Power (mW)

Jitte

r (%

)

Brand A(4X)

Brand A(6X)

Brand A(8X)

Brand-B(4X)

Dye is Important!

Spec =8%

0.0

0.2

0.4

0.6

0.8

1.0

400 500 600 700 800

Wavelength (nm)

Abs

orpt

ion

Dye 1Dye 2

Even though you optimize the process condition, you have no chance to producequality discs using wrong dye.

We should develop the dye which can- absorb laser of 650 to 660 nm wavelength- yet, reflect enough for playback- have good margin against the variation of wavelength


Sputtering Process

• Key process - to attain stable recoding/reading performance - to achieve superior archival performance • Key factor - deep knowledge of forming thin metal film - optimization of the sputtering condition - material

Sputtering Machine


Bonding Process

Bonding Machine

• Key process - to attain flat media shape - to achieve superior archival performance • Key factor - quality bonding glue in terms of both media shape and durability - optimized process condition

High Quality Glue (0 hour)

0.00E+00

5.00E-05

1.00E-04

1.50E-04

2.00E-04

3000

0

4A

000

6400

0

7.00

E+

00

9800

0

B

2000

C

C00

0

E

6000

1000

00

11A

000

1340

00

1.40

E+

01

1680

00

1820

00

19C

000

1B

6000

1D

0000

1E

A00

0

2040

00

2.10

E+

01

2380

00

2520

00

High Quality Glue (600 hour)

0.00E+00

5.00E-05

1.00E-04

1.50E-04

2.00E-04

3000

0

4A

000

6400

0

7.00

E+

00

9800

0

B

2000

C

C00

0

E

6000

1000

00

11A

000

1340

00

1.40

E+

01

1680

00

1820

00

19C

000

1B

6000

1D

0000

1E

A00

0

2040

00

2.10

E+

01

2380

00

2520

00

Low Quality Glue (0 hour)

0.00E+00

5.00E-05

1.00E-04

1.50E-04

2.00E-04

3000

0

4A

000

6400

0 7

9800

0

B

2000

C

C00

0

E

6000

1000

00

11A

000

1340

00 14

1680

00

1820

00

19C

000

1B

6000

1D

0000

1E

A00

0

2040

00 21

2380

00

2520

00

Low Quality Glue (600 hour)

0.00E+00

5.00E-05

1.00E-04

1.50E-04

2.00E-04

3000

0

4A

000

6400

0

7.00

E+

00

9800

0

B

2000

C

C00

0

E

6000

1000

00

11A

000

1340

00

1.40

E+

01

1680

00

1820

00

19C

000

1B

6000

1D

0000

1E

A00

0

2040

00

2.10

E+

01

2380

00

2520

00

Aging Test Result for Selection of the Glue


Inspection Process

Inline 100% Defect InspectionMachine

Off lineCompatibilityTest

• Key process - to attain consistent quality among production lots - to confirm expected compatibility among major writers • Key factor - Appropriate setting of defect criteria - tight communication with major writer manufactures


Dye Layer A

Power off

Power on

Time: X

Power: Y

Dye Layer B

Power off

Power onTime: X-a

Power: Y-b

Writing StrategyEvery dye material has its own recording characteristics, so recoding power and laser exposing timeshould be optimized separately for the quality recording . (Writing Strategy: WS)

00100000100.. 00100001000..

Also Problem!

Power off

Power on

Recording with optimized WS

Power off

Power on

Recording with default WS


Summary of Key Factors for Quality Discs

• Material- Stamper, Mold, Polycarbonate, Dye, Bonding Glue- Capability of developing these materials and deep chemical knowledge are required

• Process Control- Optimization of the process condition of Injection, Dye coating/drying, Sputtering, Bonding process- Capability of designing each process and ample experience of the production of optical discs are necessary

• Quality Control- In-process control should be carefully designed and feedback procedure should be consistently implemented to all of the production lines for quality consistency among production lots- Strict engineering change control should be taken place

• Writing Strategy- Ideally, optimized writing strategy should be implemented in all of major writers before the shipment of the discs- Tight communication with major writer manufacture from the development stage is crucial


Verbatim (MKM) • Material

- one of the leading developing company of key materials like dye, stamper and polycarbonate, and have designated chemical engineers for each material development- also a major supplier of those materials

• Process Control- years of experience of producing all type of optical discs. (CD-R, CD-RW, DVD+/-R, DVD+/-RW, MO and UDO)- capable of designing each process

• Quality Control- possesses an established quality control procedure which has been refined through OEM business with major PC, writer and other disc manufactures

• Writing Strategy- has been in good communication with all of major writer manufactures from the development stage of high speed (8X, 16X), high capacity (double layer) or unique (UDO or LightScribe) writers/discs- member of the key industry organization like DVD-Forum or DVD+RW Alliance


• We are convinced that we are supplying quality discs in terms of complete compliance with industry specification (DVD forum, DVD+RW alliance) and superior compatibility with all of major writers

• We are developing discs and materials very carefully with paying attention to both recording performance and durability

• We are supporting the efforts by NIST to better define archival test methods.

Bottom Line

mar., 2005 verbatim confidential dvd production process & key factors for quality discs...

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