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0:08

Tuner

1:50

Life Testing Laboratory

13:23

Parts Testing

桜を描くプロセス。７０歳の蒔絵職人が絵を描く。

桜を描くプロセス。７０歳の蒔絵職人が絵を描く。

Channel: ジャパニーズインダストリー / Japanese Industry

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00:00:05

here is the heart of a television set

00:00:07

the tuner each circuit in the tuner is

00:00:13

aligned individually by a skilled

00:00:15

technician to assure peak operating

00:00:18

performance all components and sub

00:00:23

assemblies that reach this point have

00:00:25

passed all checks tests and inspections

00:00:29

many wire connections are made quickly

00:00:31

and effectively by use of special wire

00:00:34

wrapping guns this is a new technique

00:00:37

developed by the communications industry

00:00:39

for making electrical connections where

00:00:42

extreme dependability is required it's

00:00:45

cleaner faster and neater than soldering

00:00:49

and all along the line there are

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inspectors watching probing searching in

00:00:56

the endless effort to maintain all

00:00:59

chassis receive a 100 percent inspection

00:01:01

and performance check to make certain

00:01:06

that all sets can be aligned exactly and

00:01:09

tested under actual operating conditions

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this master signal Center contains

00:01:14

approximately five times the amount of

00:01:16

transmitting equipment found in the

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average commercial television station it

00:01:22

can generate test patterns and signals

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of over 100 different frequencies it

00:01:28

sends out these test patterns and

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pictures in color and black and white to

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control points throughout the plant

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as each chassis passes its performance

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test it moves on to final assembly to be

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joined with cabinet and kinescope

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samples of finished sets are selected

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for the life testing laboratory where

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they are tested from 50 to 2000 hours

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the sets are continually turned on and

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off on for 105 minutes off for 15

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minutes to subject them to alternate

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heating and cooling off throughout the

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tests technicians using sensitive

00:02:11

testing equipment keep a closed clinical

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report on the action of each step

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at each stage of assembly inspectors

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judge with a trained eye the work of men

00:02:24

yes and the work of machines for example

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printed circuit boards are soldered

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instantly in a single operation this

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type of design and soldering assures the

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same reliable electrical performance as

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demanded and used in such exacting

00:02:40

equipment as computing machines and

00:02:43

guided missiles even this mechanical

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operation is checked over 17 million

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printed circuit boards have already been

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produced for RCA Victor consumer

00:02:54

products alone amazing testimony to the

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effectiveness of printed circuit boards

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is the fact that less than two-tenths of

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one percent has been required for spare

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parts replacement stock every soldered

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joint on each printed circuit board is

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checked by a trained eye it must have

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just the right amount of solder not too

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much not too little

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but just enough in the mechanical

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laboratory the chassis prototype is

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assembled with all of its component

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parts once the chassis is assembled it

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is sent into an electrical laboratory

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where engineers make elaborate tests to

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check out all its circuitry aided by

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test pictures and patterns originating

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from this room in the Cherry Hill

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laboratories it operates much the same

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as any television station however by

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using a closed circuit engineers can

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simulate conditions such as distance

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they can also create their own

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interference so that they can be sure

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that a quality picture will be produced

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even under adverse conditions when photo

00:04:08

type cabinets and chassis have been

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checked individually they are assembled

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as a unit

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then they are placed in a special eco

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proofed chamber to study sound

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characteristics sound systems and

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speakers are thoroughly tested a moving

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microphone picks up the sound at varying

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angles this machine makes 19 different

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tests on each tube

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it automatically rejects any that do not

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pass at each stage of to manufacturing

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samples are taken for even closer

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analysis and testing to make doubly sure

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quality standards are maintained

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in Harrison all incoming basic materials

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are sample tested the control of purity

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of the materials used in making tubes is

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a vital necessity if contamination and

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breakdown are to be eliminated another

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example of the philosophy to produce the

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best you must begin with the best in

00:05:18

this work at Harrison research engineers

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work with the unusual machines that

00:05:24

clean materials with ultrasonic sound

00:05:26

waves machines capable of testing the

00:05:29

strength of wire finer than a human hair

00:05:33

even liquid nitrogen as well as

00:05:35

induction furnaces capable of heats of

00:05:38

over 4,000 degrees Fahrenheit to

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maintain accuracy a special laboratory

00:05:45

checks all test equipment using units

00:05:47

certified by the National Bureau of

00:05:49

Standards air quality standards are also

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controlled by checking characteristics

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of tube samples against master

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specifications after manufacturing every

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tube is aged in racks at three to four x

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rated filament voltages and then 100%

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tested for operating characteristics

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when packed each lot is coded to

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identify them and event sampling checks

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reveal deficiencies in Harrison's life

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testing laboratory a quarter million

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sample tubes can be given rigorous life

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and performance tests each year 15,000

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to 25,000 tube samples can be tested

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here at one time some up to $5,000

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$10,000 or as much as $25,000 to hours

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on 10 minutes all day and night samples

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are turned off and on to duplicate years

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of actual operation where warehouse

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samples are checked in use in all types

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of operating television sets in

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Lancaster Pennsylvania caller kinescopes

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are produced with the same cautious

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guarding of quality typical of

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Lancaster's painstaking controls is the

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incoming inspection of kinescope glass

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face plates and funnels in a series of

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54 checks critical dimensions are

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measured within thousandths of an inch

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to make certain that when assembled with

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electrical components each tube can

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deliver the peek picture performance

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built into the design this electric

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pneumatic contour gauge checks the inner

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surface of face plates to make certain

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they are sections of a sphere in one

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simultaneous operation it can check 15

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gauging points the shadow mask is

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subjected to even more exacting

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inspections ashed with over a quarter

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million holes it shadows the phosphor

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dots yet is transparent to the correct

00:08:06

electron beams this plant is completely

00:08:11

air conditioned and filtered to keep

00:08:12

dust from getting into any components

00:08:14

such as this 3-gun assembly and

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affecting operation once sealed in the

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tubes

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before being applied to the tube face

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each phosphor color is mixed in its own

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room where color and brightness can be

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matched down to a wavelength the

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resulting mixture is then photo

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sensitized and taken to the screen room

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application of the color passport dots

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is a precision operation requiring

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microscopic inspection

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here each faceplate is married to a

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shadow mask and placed over a housing

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which uses mercury arc lamps to

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duplicate electron gun beams every

00:09:01

completed to receives a 100% performance

00:09:03

inspection followed by the life testing

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of representative samples these checks

00:09:09

reveal consistently a life expectancy

00:09:12

equal to that of black and white

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kinescopes prior to shipment quality

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checks are made after a three day

00:09:20

waiting period in shipping pack all

00:09:23

three guns are tested electrically and

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an entire law retested if deficiencies

00:09:28

are revealed research engineers and

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advanced designers work together in the

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pursuit of quality electronic engineers

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continually probe into the future their

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only guide posts are ideas as to where

00:09:45

sound and picture reproduction may be

00:09:48

improve these are the men who unlock the

00:09:52

secrets of improved performance or find

00:09:56

practical answers for improving quality

00:10:01

as these men work one of their first

00:10:05

steps is to build prototypes before

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being used a new component is taken to

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the components development and test

00:10:13

laboratories here it receives exhaustive

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tests before it is put into production

00:10:22

transformers for instance are passed

00:10:24

only if their insulation will withstand

00:10:26

five times the voltage they will carry a

00:10:29

normal operation an average capacitor

00:10:34

must be able to withstand at least twice

00:10:37

its rated voltage and is also tested to

00:10:40

measure stability under various

00:10:41

temperature changes all switches relays

00:10:45

and bearings are mechanically tested to

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make sure that they are able to

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withstand the equivalent of up to ten

00:10:51

years where before manufacturing

00:10:56

prototype coils are handmade and then

00:10:59

subjected to exhaustive tests

00:11:02

some components are even tested under

00:11:04

steam pressure to simulate extreme heat

00:11:07

and humidity and then electrically

00:11:10

retested only after proving conclusively

00:11:14

that they can function effectively under

00:11:17

conditions far worse than those they

00:11:19

will be subjected to in the average home

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our electrical components okayed for

00:11:23

production while basic electrical

00:11:28

components are being designed and tested

00:11:30

tuners are being developed and improved

00:11:33

upon in a special laboratory much of

00:11:37

this highly specialized work takes place

00:11:39

inside individual cages designed to

00:11:42

screen out electrical interference the

00:11:47

operating characteristics of prototype

00:11:49

tuners mark Lampley such as monticello

00:11:52

craftsmanship and precision are also

00:11:55

important aspects of quality production

00:11:58

workmen in these plants are skilled

00:12:01

craftsmen who come from families where

00:12:03

woodworking is a tradition starting with

00:12:07

selected raw materials such as mahogany

00:12:09

planks these craftsmen proceed to

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transform them step by step

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government parts are carefully matched

00:12:20

so that the color and grain of the wood

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will be complementary the machine used

00:12:26

here is capable of making 15 different

00:12:28

cuts simultaneously and is accurate to

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within one 64th of an inch two cabinet

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legs are carved here at the same time

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and then cut apart some cabinets receive

00:12:43

as many as 12 finishing operations each

00:12:47

receives multiple coats of lacquer to

00:12:49

produce depth of finish seal in the

00:12:51

quality and protect the rich beauty

00:12:54

produced by quality craftsmanship each

00:13:00

cabinet is given a final inspection

00:13:04

cabinets are then shipped to the

00:13:06

Bloomington Indiana or the Indianapolis

00:13:08

plan

00:13:12

you

00:13:14

but before cabinets or any other

00:13:17

incoming part or component go on the

00:13:19

manufacturing line samples of the

00:13:22

shipment are taken to a parts testing

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center within the plant itself here

00:13:28

exhaustive tests double-check the

00:13:30

quality of parts to be used in the

00:13:32

production of sets if for any reason

00:13:36

parts fail to meet engineering

00:13:38

specifications they are rejected

00:13:41

together with the complete shipment and

00:13:43

returned to the manufacturer

00:13:46

mechanical parts are sample tested for

00:13:49

dimensional accuracy such things as

00:13:52

thicknesses hole placements and

00:13:55

diameters must be exact to get such

00:13:59

accurate measurement checks this table

00:14:02

of solid granite weighing over 2 tons is

00:14:05

used as a base it's flat polished

00:14:09

service is accurate to within one one

00:14:12

thousandth of an inch parts with

00:14:16

dimensions too small to check with the

00:14:18

naked eye are placed in testing

00:14:21

equipment which magnifies them as much

00:14:23

as 50 times this permits the accurate

00:14:26

measurement of the most minut cuts where

00:14:28

tolerances must be exact

00:14:32

every shipment is sample tested from the

00:14:34

smallest part to the largest only after

00:14:40

this quality check do skilled workers

00:14:42

together with millions of dollars of

00:14:44

precision machines begin the task of

00:14:47

accurately assembling the thousand and

00:14:49

one parts that result in a finished

00:14:52

product accepted as the recognized

00:14:55

leader in its field

00:14:58

skilled workers share the responsibility

00:15:02

that comes with the pride of building

00:15:03

the television set found in more homes

00:15:05

than any other each adding a priceless

00:15:08

touch that comes only from years of

00:15:10

experience this craftsmanship is ensured

00:15:14

in each of the manufacturing plants by

00:15:17

quality engineers whose sole job is to

00:15:20

make sure that quality is maintained in

00:15:22

the assembly of component parts the aim

00:15:26

of these men is to discover troubles

00:15:28

before they can get into the field these

00:15:31

are the men who plan the strategy and

00:15:33

solve any quality control problems that

00:15:35

may arise other sets coming into the

00:15:39

light test laboratory are given some

00:15:41

mighty rugged testing after tests such

00:15:44

as these the sets are taken out and

00:15:47

given performance tests of course all

00:15:50

cartons are designed to protect their

00:15:53

quality cargo from the rigors of rough

00:15:55

handling in addition to all of the

00:15:59

quality tests and inspections maintained

00:16:02

in the course of manufacture of finished

00:16:04

goods testing operation of extensive

00:16:07

proportions is conducted at the factory

00:16:09

covering instruments selected at random

00:16:11

from warehouse stocks in one year alone

00:16:14

between 30 and 35,000 instruments are

00:16:18

checked some sets are sent on local road

00:16:21

tests still others are shipped to Cherry

00:16:24

Hill New Jersey for examination in a

00:16:26

laboratory unique in the industry the

00:16:30

consumer acceptance laboratory where the

00:16:33

instruments are inspected completely

00:16:35

from the consumers point of view

00:16:38

a report is made on each cell if a fault

00:16:42

is uncovered which proves to be in

00:16:44

several sets from the same lot typical

00:16:46

of a representative lot the

00:16:48

manufacturing plant is notified

00:16:50

immediately and manufacturing and

00:16:52

shipping are halted until the fault is

00:16:54

corrected manufacturing plants submit

00:16:56

samples of work before authorized to

00:16:58

produce on a quantity basis this sample

00:17:02

is subjected to the same exhaustive

00:17:03

testing as the prototype to make certain

00:17:06

that none of the original quality is

00:17:08

lost in the manufacturing process it has

00:17:13

long been known that an instrument such

00:17:15

as a television receiver could if not

00:17:18

properly shielded produce picture

00:17:20

interference in other nearby sets due to

00:17:23

signals being fed back into the air by

00:17:25

the receiver

00:17:27

engineering models and prototypes of

00:17:29

sets are brought to this laboratory and

00:17:32

checked in developing circuits that keep

00:17:34

such interferences well within the

00:17:36

required limits

00:17:41

special equipment is used that can

00:17:43

measure signal field strength in terms

00:17:45

of millions of volts they actually use

00:17:48

them to develop sets with built-in

00:17:50

quality long before FCC requirements

00:17:53

were enacted as a law when components

00:17:57

have passed all tests all forms and

00:18:00

reports are tabulated and searched for

00:18:02

any information that will help to

00:18:04

increase the quality performance and

00:18:06

value or eliminate trouble spots this

00:18:10

information is sent back to the men who

00:18:12

design test and build the sets quality

00:18:16

conscious men who pursue and crystallize

00:18:20

elusive and advanced ideas that will

00:18:23

lead to greater quality who demand that

00:18:27

component parts come up to the highest

00:18:29

quality standards men who are prepared

00:18:32

to cut deep beneath the circle in their

00:18:34

division searches for designs that

00:18:37

reflect tastes and trends from all over

00:18:39

the world hand in hand with styling

00:18:43

design is the selection of quality

00:18:45

materials to assure lasting beauty wood

00:18:48

samples from all over the world are

00:18:50

carefully considered Hardware and

00:18:53

fittings are selected carefully to

00:18:55

complement the basic design colors and

00:18:59

finish types are selected from a wide

00:19:01

range of samples again all these

00:19:05

materials undergo initial testing to

00:19:07

make sure they are able to withstand

00:19:09

normal wear and still retain their

00:19:12

beauty

00:19:14

samples are put into freezing chests for

00:19:16

a period of a half-hour or more then

00:19:19

immediately put into a heat oven for a

00:19:21

similar period after which they are

00:19:24

closely inspected for any tendency to

00:19:26

shrink warp or swell paints and plastics

00:19:32

are examined under ultraviolet lights to

00:19:35

check their characteristics and make

00:19:37

sure that they will retain full color

00:19:39

and luster when all components have

00:19:44

passed quality tests the go-ahead is

00:19:46

given to build a prototype cabinet

00:19:53

in RCA Victor's own cabinet shop skilled

00:19:56

cabinet makers now help to bring to

00:19:59

reality a handmade prototype finally

00:20:03

after the test finishes apply than is

00:20:06

hand rubbed the completed cabinet is

00:20:08

ready to be tested as a unit and even

00:20:12

though each part has been individually

00:20:13

quality tested they are again tested to

00:20:16

make sure that they do not lose any of

00:20:18

their quality characteristics when

00:20:21

assembled with other components

Description:

Production assembly line operations showing electricians and technicians wiring and soldering various parts such as vacuum tubes & CRT's. Quality control testing is performed using oscilloscopes and other devices. Craftsmen and carpenters construct cabinets by hand, before painting and shipping.

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