Lens-Hardcoating-General-procedure-guideline.doc

APU1 Work InstructionHardcoating General procedure guidelineNo: WI-APU1-030 APU1ALCNConcern原因This procedure applies for processing and handling of lens in Hardcoating plant.程序应用于镀膜硬化车间的过程和操作。Objective目的This internal work instruction in established to:内部操作指导为了：1. Provide basic guidelines and procedure of hardcoating process; 提供基本的指导方针和硬化程序2. Explain the process details and handling of lens in hardcoating Production; 解释在生产过程中详细的过程和硬化过程的处理3. Explain the safety precaution during handling, using and disposing of used chemical/waste chemical 解释在操作，使用和处理化学品或废弃化学品过程中的安全预防措施 4. To define the responsible personal for process establishment and safe keeping of all related documentation.定义生产过程责任人和保存相关的文件4.1 Line leader must change and collect document when produce project. 更换产品时线长需要更换和收集文件4.1 Supervisors manage and tidy all the document. 主管管理并整理所有的这些文件Procedure程序1. Raw material from moulding area for hard coating process.硬化过程中来自注塑区的原材料。2. Loading 上货 2.1 Raw lens must be inspected for cosmetic defect such as silver streak, black dot, scratches, stain and short moulding未硬化透镜必须进行外观检验，喷射纹，黑点，划伤，脏污，缺料。 2.2 Raw lenses must be free from dust, oil and grease also 未硬化透镜必须无尘，无油。 2.3 Raw lens need to be ionized air, cleaned and wiped with IPA using with lint free cloth before loading. 未硬化透镜在上夹具前必须经过离子风枪，和沾有无水酒精的防静电无尘布的清洁。3. De-Ionizing 除静电 Vacuum suction should be clean to absorb all dust particles. 真空系统应该被清洁以吸附灰尘4. Flow coating 流涂 4.1 Flow coating hard coat lacquer, Red Spot UVT 610 V2. 流涂涂料为：红点 UVT 610 V24.2 Flow coating solvent, 99,0% purity for every single solvent at 0,15 % of total humidity 稀释剂：每一种溶剂纯度99%，总湿度小于0.15%4.3 Process environment must be 1,000 air qualities. 空气洁净度必须为1000级4.4 Humidity: Maximun 50% 空气湿度最大50%4.5 Room temperature (20-25) 室温，20到25度4.6 Lights and windows must be covered by amber UV shielding from UVPS part. 所有的灯和窗户必须贴UV防护膜5.Drip off 滴干 Excess coating need to be dripped off from the lens at room temperature with maxium 50% RH. 流涂中多余的油漆必须在最大湿度50%室温下滴干6. Infra Red(IR) Flash Off 红外闪干 The lens surface temperature should reach at 65 to 75 during the flash off process 在闪干过程中，透镜表面温度须达到65到75度7. UV Curing 紫外固化 The coated lens should be cured under curing energy at 3500 to 6000 mJ/c which measured by Power Map. 流涂后的透镜必须经过紫外固化，紫外固化能量3500 到6000 mJ/c（能量图测试）8. Cooling 冷却 After curing the lens should be cooling down at 15 to 20 固化后的透镜必须在15到20度的温度下冷却9. Unloading 下货 9.1 Coated lens must be inspected for cosmetic defect such as black dot, lints, fish eye, lacquer pilling, scratches, fingerprints, lacquer accumulation. 硬化后的透镜必须作外观检验，如，黑点，杂质，鱼眼，划伤，手指印，堆漆等 9.2 First coated lens must be test the Adhesion and Thickness. 首件必须作附着力和膜厚测试 9.3 Coated lens need to be ionized air for cleaning the dust before package. 透镜必须经过离子风枪的清洁10. Adhesion and Thickness Test 附着力和膜厚测试 10.1 According the internal test standard GTS001,.There shall be no appreciable impairment of the gridded area. Impairments at the intersections between squaresor at the edges of the cuts shall be permitted 5% of the gridded surface. 依照AL内部测试标准 GTS001，不得有明显的漆层脱落，在格子边缘或中心的交叉处，脱落不得超过5%，具体操作方法见附着力测试指导书 10.2 Total thickness is should be at 6 to 16 um, 总膜厚须在6到16微米，操作方法见膜厚测试操作指导书11. Packaging and Moving 包装和运输 Coated lens should be packaged according to the package WI and then move them to sub-assembly or assembly line. 硬化后的透镜必须按照包装作业规范中的要求包装，然后转移到预装配线。生产和设备控制1.开机检查每次运行或重新启动设备之前必须由线长或技术员做开机检查，将结果记录在开机/紧急停止后重新开机检查表。并且只有开机检查结果完全符合要求方可运行或重新启动设备。该记录每月收集一次，保存在生产文记录文件中2.设备日常点检每个班在正式生产前（上货前）必须由操作工做设备日常点检，将结果记录在透镜硬化车间日常维护检查清单中，并且检查结果完全符合要求后方可进行生产。该记录每周收集一次并保存在生产记录文件夹中3.设备工艺参数点检 每个班正式生产前必须由线长做设备工艺参数检查，将结果记录在硬化车间工艺参数检查表，并且只有在检查结果完全符合要求后方可进行生产。该记录每周收集一次并保存在生产记录文件中3.首件放行每个班生产出的首件必须由操作工做膜厚和附着力测试，将测试结果保存在膜厚/附着力测试记录表中，只有首件完全符合要求方可继续生产。该记录每周收集一次并保存在生产记录文件夹中。4.生产看板，生产日报 正式生产时，每小时操作工须将每种产品的生产状况记录在生产看板中，在当班结束后由线长统计生产看板并填写生产日报表并上交。5.产品缺陷记录 正式生产时，操作工必须将每种产品的不良品的数量，类型，位置，发生时间等信息记录在产品缺陷记录表中，在当班结束后由线长收集并上交。6.设备维护保养 线长和技术员在每周生产结束后检查设备维护保养计划，并确认当周需要执行的设备维护保养项目，在设备保养结束后，将结果记录在设备维护保养计划中。该记录每年收集一次，保存在设备维护保养记录文件中。Important Note重要通知The setting for IR heater and UV energy are dependent of efficiency of the IR heater and UV lamps.红外加热和紫外能量的设置取决于两者的功率Lens temperature at flash off zone and UV energy measurements at UV zone are recommended to be measured and verified at least once in a month. The settings for the IR heater and UV lamp need to be revised if the result measured are out of specification.建议每月一次测量和确认红外加热的温度和紫外固化的能量。当测试结果超出标准范围，必须更改两者的参数设置。Process Parameter/Specifications过程参数和标准General condition of all process整体条件最小值/Min最大值/MaxSetting ValuePaint Kitchen Room 供漆房Lacquer Density油漆密度0.8750.89 0.885Lacquer Temp.油漆温度182523Lacquer Flow 油漆流量13 kg/min17 kg/min15 kg/minLoading Room 上货室Loading Room Temp. 上货室温度172520Loading Room Humidity 上货室湿度30%50%40%Flow coating room 流涂室Coating room humidity 流涂室湿度30%50%40%Coating room temp. 流涂室 温度202523IR Room 红外加热室Flash Off Temp.闪干温度657570Zone 1 Energy (lateral) 灯组1 能量比（侧边）70%90%80%Zone 2 Energy (top) 灯组2 能量比(顶部）75%95%80%Zone 3 Energy (lateral)灯组3 能量比（侧边）70%90%80%Zone 4 Energy (top)灯组3 能量比(顶部）75%85%80%UV Room UV室UV energy UV 能量比50%100%75%Cooling Room冷却室Cooling Room Temp.冷却室温度152520Driver System 驱动系统Conveyor Speed 链条速度4.5m/min4.5m/min4.5m/minChiller System冷水机系统Chiller Water Temp.冷冻水温度597Note备注：Any chemical waste or scheduled waste generated shall be disposed off accordingly. This is to ensure safe handling and storage of waste chemical, in compliance to the statutory requirements.依照环境法令，任何的废弃化学品必须得到相应的处置，以确保安全的处理和储存。Flow Chart of Lens Hard coating Process透镜硬化车间过程流程图Unloading and in