Monitor Basics in Plain English

The Making of a FlexScan Monitor

Introduction Production Line Characteristics A Tour of Our Production Line

A Tour of Our Production Line

There are six steps to manufacturing a FlexScan monitor: AssemblyAgingAdjustmentWhite Balance and DUE Adjustment (for SX series models)AdjustmentTestingPackaging. Here, we will briefly introduce each step.

 

Assembly

The assembly process begins with the LCD panel. LCD panels arrive from our suppliers wrapped in plastic sacks and stored inside Styrofoam containers. Once ready for assembly, they are removed from their bags and placed face up on pink protective cushions.

The assembly process begins with the LCD panel. LCD panels arrive from our suppliers wrapped in plastic sacks and stored inside Styrofoam containers. Once ready for assembly, they are removed from their bags and placed face up on pink protective cushions.

 

A plastic cover that protects the screen surface is removed and the LCD panel is then turned face down.

A plastic cover that protects the screen surface is removed and the LCD panel is then turned face down.

 

An inverter PCB (printed circuit board) is placed on the back of the LCD panel and affixed with an electric drill.

An inverter PCB (printed circuit board) is placed on the back of the LCD panel and affixed with an electric drill

 

A protective metal frame is placed over the LCD panel.

A protective metal frame is placed over the LCD panel.

 

The next worker prepares the front bezel and adds cushioning material before placing the LCD panel inside.

The next worker prepares the front bezel and adds cushioning material before placing the LCD panel inside.

 

Once the LCD panel is encased inside the bezel, the power PCB and main PCB, manufactured by EIZO at a separate factory, are added.

Once the LCD panel is encased inside the bezel, the power PCB and main PCB, manufactured by EIZO at a separate factory, are added.

 

The next part of the assembly process is automated screw insertion. Here, each model is recognized by its RFID (radio frequency identification) tag. A CCD (charge coupled device) camera confirms the proper location for screw insertion and then a robotic arm inserts the screws. The screen superimposed in the video shows the movement of the CCD camera and robotic arm.

 

Flexible flat cables that connect the power board and the main controller are attached.

Flexible flat cables that connect the power board and the main controller are attached.

 

A shielding plate is placed over monitor and then affixed with an electric drill.

A shielding plate is placed over monitor and then affixed with an electric drill.

 

The final stage in the assembly process is the attachment of the stand. The stand shown here is known simply as a "height adjustable stand." EIZO offers a variety of stands, all of which are developed in-house.

After the stand is attached, the monitor is placed in an upright position and outfitted with power and signal cables and turned on (not shown).

The final stage in the assembly process is the attachment of the stand. The stand shown here is known simply as a "height adjustable stand." EIZO offers a variety of stands, all of which are developed in-house.

 

Once assembly is complete, each monitor undergoes an initial screen check inside of an image inspection apparatus. Inside black curtains, a CCD camera automatically determines if the monitor is displaying an image correctly.

Once assembly is complete, each monitor undergoes an initial screen check inside of an image inspection apparatus. Inside black curtains, a CCD camera automatically determines if the monitor is displaying an image correctly.

Aging

After the initial screen check, monitors are automatically moved down the production line where they go through an "aging" process. Aging serves three purposes.

  • To check that the LCD module does not exhibit image retention when left on for a short period of time.
  • To ensure the circuit boards are operating properly.
  • To stabilize brightness before adjusting the monitor's white balance in the next step of the production process.

The image quality has not been tested and adjusted yet so discrepancies in brightness and color display between monitors are noticeable.

The image quality has not been tested and adjusted yet so discrepancies in brightness and color display between monitors are noticeable.

Adjustment

In this automated process, a camera inside a glass compartment examines then adjusts the color temperature, gamma, white balance, and brightness of each monitor. Most monitors continue on to the next phase of testing, but in the event that a monitor does not pass, then it is removed from the line and examined.

White Balance and DUE Adjustment (for SX series models)

EIZO's SX series of FlexScan monitors for graphic and web design, CAD/CAM work, and digital photography, undergo white balance and DUE (digital uniformity equalizer) adjustment. Two monitors at a time are automatically moved into a dark room. The first phase of the testing is preliminary white balance testing to stabilize the brightness. Next, DUE adjustment minimizes the discrepancies in brightness between the center and the perimeter of the screen that are characteristic of all LCD panels. After the DUE adjustment is completed, the white balance is adjusted so that neutral colors will be rendered correctly. White balance and DUE adjustment are performed in a dark room, but the process and the results are shown on monitors outside the dark room.

White Balance and DUE Adjustment (for SX series models) White Balance and DUE Adjustment (for SX series models)

Testing

Each monitor is individually inspected by the human eye. Although automated testing by a machine is adequate for low grayscale tones, the human eye is still the best tool for judging whether midtones and hues are displayed properly. If the monitor has built-in speakers then the worker checks the audio with earphones and taps the frame with a padded stick to ensure it can withstand light shocks.

Each monitor is individually inspected by the human eye. Although automated testing by a machine is adequate for low grayscale tones, the human eye is still the best tool for judging whether midtones and hues are displayed properly. If the monitor has built-in speakers then the worker checks the audio with earphones and taps the frame with a padded stick to ensure it can withstand light shocks.

 

After the monitor clears all tests, the serial number is scanned, the RFID tag is removed from the palette, and the product is ready for packaging.

After the monitor clears all tests, the serial number is scanned, the RFID tag is removed from the palette, and the product is ready for packaging.

Monitors continue down the conveyer belt where they will be transported to another floor for packaging.

Monitors continue down the conveyer belt where they will be transported to another floor for packaging.

Packaging

Monitors are delicately hand-packed prior to shipping in recyclable cardboard boxes.

 

After packaging is complete, the monitors are loaded onto a truck where they will begin their journey to the customer.

After packaging is complete, the monitors are loaded onto a truck where they will begin their journey to the customer.

 

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