WEBVTT 00:00:00.000 --> 00:00:06.160 Long story short, I have just 2 and 1/2 hours to film this sponsored tour of the 00:00:04.160 --> 00:00:09.320 Hisense TV factory behind me. Before my dust covers turn to glass slippers, my 00:00:07.880 --> 00:00:13.120 head turns into the Great Pumpkin, and I get shipped back to Canada. We've got to 00:00:10.960 --> 00:00:16.040 get through backplane prep and assembly, backlight installation, mainboard and 00:00:14.840 --> 00:00:20.560 power supply installation, panel mounting, QA and validation, packaging. 00:00:18.080 --> 00:00:24.080 Good grief, even miracles take a little time. And the longer we stand here, the 00:00:22.440 --> 00:00:27.680 less we're going to have. That's another 5 seconds. LET'S GO GO GO. 00:00:34.320 --> 00:00:41.520 This is going to be cool. The production line we're about to see has seven 00:00:38.440 --> 00:00:44.080 first-of-their-kind machines. A third of 00:00:41.520 --> 00:00:50.160 it is assisted by AI or machine learning in some capacity, and it has a total 00:00:46.200 --> 00:00:51.760 automation rate of over 70%. 00:00:50.160 --> 00:00:56.560 Wow. This level of automation isn't just to 00:00:54.040 --> 00:01:00.840 save on labor costs, but also to improve quality. These back panels being loaded 00:00:58.840 --> 00:01:04.839 onto the assembly line used to be done by squishy humans, but as you guys might 00:01:03.120 --> 00:01:11.120 have seen in our recent video taking delivery of a Hisense 116-in 00:01:08.000 --> 00:01:13.640 RGB backlit TV, panel sizes have gotten 00:01:11.120 --> 00:01:18.160 kind of out of control, which means that when you've got people lifting these 00:01:15.440 --> 00:01:22.760 backplanes, there's a significant risk of deformation. Since they switched to 00:01:20.720 --> 00:01:26.800 this automated system that grabs them, shakes off the protective corner pieces, 00:01:24.920 --> 00:01:32.040 then places them onto the line, they've reduced their defects by over 90% Next 00:01:30.240 --> 00:01:37.920 door, the backplanes are treated for any static build-up, then they're flipped 00:01:34.160 --> 00:01:37.920 over to prepare them for the next step. 00:01:39.520 --> 00:01:46.760 Now you probably think of major components like the panel, power supply, 00:01:44.080 --> 00:01:52.280 and processing chips as the big drivers of cost for large TVs. But here's the 00:01:50.160 --> 00:01:57.560 thing, for televisions to be one of the only seemingly inflation-proof consumer 00:01:54.800 --> 00:02:02.640 goods, manufacturers need to dig deeper than that. Behind me is an automated 00:02:00.120 --> 00:02:07.040 glue dispenser that relies on an AI model to control flow rate, pressure, 00:02:04.720 --> 00:02:11.880 movement speed, and more to apply hundreds of glue points for LED light 00:02:09.080 --> 00:02:16.080 bars, and this results in a savings of 9% on glue. 00:02:14.240 --> 00:02:20.800 Nice. After a quick trip through the spray gluing machine and a pass under 00:02:18.520 --> 00:02:25.720 this UV curing lamp, we're going to apply our LED strip and lens arrays that 00:02:23.760 --> 00:02:29.680 are going to serve as our backlight. This is one of the few steps that is 00:02:27.320 --> 00:02:33.600 still manual, but if what we've seen so far is anything to go by, it probably 00:02:31.600 --> 00:02:37.320 won't be for long. The glue theme that we've kind of established so far 00:02:35.120 --> 00:02:41.960 continues behind me with their automatic primer coating machine. The backplane is 00:02:39.800 --> 00:02:46.440 going to be joined to our front panel by a foam tape to reduce light leakage, but 00:02:44.480 --> 00:02:50.400 that requires a primer to be sprayed in order to improve adhesion. By using 00:02:48.600 --> 00:02:54.440 machine vision to verify their coatings in real time and an AI model to make 00:02:52.520 --> 00:02:59.760 adjustments, they were able to reduce their primer consumption by 58% while 00:02:57.480 --> 00:03:03.200 also dramatically reducing defects. Unfortunately, this machine is patent 00:03:01.800 --> 00:03:08.000 pending, so if you're watching this video right away, it's going to be blurred. But once they get their patent, 00:03:06.520 --> 00:03:13.240 we're hoping to replace that blurred footage, so come back in 6 months. As 00:03:10.880 --> 00:03:18.840 TVs get bigger and bigger, maintaining efficiency and backlight uniformity are 00:03:16.280 --> 00:03:22.920 major challenges. So behind me, Hisense is applying a reflective film to the 00:03:20.480 --> 00:03:27.480 backplane to make the absolute most out of any light from the backlight LEDs. 00:03:25.800 --> 00:03:31.720 They're also using automated spring-loaded applicators to apply the 00:03:29.640 --> 00:03:34.920 sheet more evenly, which reduces the risk of dark spots in the finished 00:03:33.680 --> 00:03:41.680 product. You'll still need your diffusion layer and optical sheet, and of course, even 00:03:39.040 --> 00:03:45.040 the best processes are imperfect. So that's where this station comes in, 00:03:43.440 --> 00:03:50.320 where they're using machine vision and AI to analyze the backlight for 00:03:47.320 --> 00:03:52.880 uniformity. Hisense somewhat sheepishly 00:03:50.320 --> 00:03:57.800 admitted that industry norms used to be to have a person look into the backlight 00:03:55.040 --> 00:04:02.280 and go, "Yeah, that looks pretty even." So it makes sense that this change 00:04:00.040 --> 00:04:05.640 resulted in a major improvement to inspection accuracy. By the way, you 00:04:04.120 --> 00:04:10.240 might have noticed this is a white backlit TV, whereas Hisense's cutting 00:04:08.000 --> 00:04:14.080 edge is RGB backlighting. We're going to be taking a closer look at their RGB 00:04:12.040 --> 00:04:18.079 backlight technology a little bit later in the video. 00:04:16.400 --> 00:04:22.800 Now that our backplanes are validated, it's time to apply the foam tape that's 00:04:20.079 --> 00:04:26.920 going to seal them to the panel. This is also automated, which Hisense boasts 00:04:24.920 --> 00:04:31.200 they are the first in the industry to do. 00:04:28.480 --> 00:04:36.480 Now it's time for a big moment, panel assembly. This is yet another process 00:04:33.800 --> 00:04:42.760 that has become simply impractical to do by hand with modern monstrous TV panels. 00:04:40.200 --> 00:04:47.080 The old way involves two operators with suction cups attempting to line up the 00:04:45.200 --> 00:04:51.960 panel with the backplane and stick it down exactly the same every time. 00:04:49.000 --> 00:04:56.240 Breakage was a real problem. This new way brings the fresh panels in on a 00:04:54.200 --> 00:05:00.760 conveyor, moves them over to an automated peel machine to remove the 00:04:58.680 --> 00:05:03.520 protective covering that's on the back of the panel, 00:05:04.560 --> 00:05:12.720 picks them up and places them onto the backplane with better than 0.02 mm 00:05:10.280 --> 00:05:17.320 precision. Now we're looking up at those same 00:05:15.000 --> 00:05:21.200 robots that we were just in front of. At this station, the source board gets 00:05:19.520 --> 00:05:24.360 folded up and then covered with the front plastic bezel. 00:05:25.520 --> 00:05:32.000 Next, behind me, these two robots affix the front bezel with screws. And this is 00:05:30.320 --> 00:05:37.360 a lot cooler than you might realize. I mean, it wasn't that long ago that I was 00:05:34.360 --> 00:05:39.440 here in China being told that screws, 00:05:37.360 --> 00:05:43.680 especially little ones, were still too hard to do economically with robots. Not 00:05:41.800 --> 00:05:48.880 anymore. And not only is it more economical, but this is apparently 00:05:45.760 --> 00:05:50.428 responsible for a 44% reduction in the 00:05:48.880 --> 00:05:57.000 defect rate at this step. >> [music] >> The final step for what they call module 00:05:54.080 --> 00:06:00.254 assembly is these foam rollers pressing down the panel on the backplane to 00:05:58.760 --> 00:06:05.640 secure the foam tape. >> [music] >> With the foam secured, the TVs are 00:06:03.200 --> 00:06:08.680 flipped onto these soft carrier pads for the rest of assembly. 00:06:09.360 --> 00:06:17.760 Now it's time for our straw men to get a brain, or a mainboard with a processor, 00:06:14.560 --> 00:06:17.760 and also a power supply. 00:06:18.680 --> 00:06:24.600 You might have noticed that each of those boards only got one screw securing 00:06:22.240 --> 00:06:28.480 them to the back panel. That is not because Hisense went to the Linus school 00:06:26.960 --> 00:06:32.280 of how to install printed circuit boards. >> This is why I usually only put half the 00:06:31.000 --> 00:06:36.279 screws in radiators. >> It's because the rest of them are going 00:06:34.120 --> 00:06:39.920 to be installed next door right here. >> [music] >> Why it made sense to divide this into 00:06:38.040 --> 00:06:42.840 two steps, I don't know, but that doesn't matter because I don't design 00:06:41.480 --> 00:06:48.120 assembly lines. Now next, we've got a very rare animal 00:06:45.280 --> 00:06:51.920 indeed, a manual step. Sorry, I'm not even going to try to do the accent. The 00:06:49.400 --> 00:06:56.000 point is that they do have a robot for speaker placement, but it is currently 00:06:53.920 --> 00:06:59.859 undergoing maintenance and trials, so they still have a person manually 00:06:57.560 --> 00:07:04.160 placing the speakers, but not for long. >> [music] >> Now it's time to install cable and 00:07:01.680 --> 00:07:07.360 wiring harnesses. As you can see, this requires three people in order to keep 00:07:06.160 --> 00:07:12.560 up with the speed of the production line. Hisense says that the handling and 00:07:10.840 --> 00:07:17.440 delicate installation of these parts is still best done by human hands, but they 00:07:15.520 --> 00:07:22.280 are researching ways to automate this, and who knows, it might not be that far 00:07:19.880 --> 00:07:22.280 off. 00:07:23.240 --> 00:07:30.040 Now we're at the end of the line, or are we? For space efficiency, Hisense has 00:07:28.480 --> 00:07:34.440 the production line laid out in a U-shape. I asked Hisense if I could ride 00:07:32.320 --> 00:07:37.680 on one of the TVs to the other side, and they said yes, but then it turns out 00:07:36.240 --> 00:07:42.960 they misunderstood my question. They couldn't imagine anyone could ask something so stupid. I tried for you 00:07:40.440 --> 00:07:46.360 guys, I tried. Next, Hisense invited me to participate in the production line. 00:07:44.880 --> 00:07:52.560 They asked me to do the internal inspection step. So I'm supposed to mark 00:07:48.880 --> 00:07:55.280 all the various connectors and tapes and 00:07:52.560 --> 00:08:00.160 screws. So this one this one. Oh, all the screws? 00:07:58.680 --> 00:08:04.480 No. There's not enough time. 00:08:02.080 --> 00:08:09.240 Which I guess was kind of their point. I guess that's why Hisense replaced this 00:08:06.080 --> 00:08:10.800 technology with this technology. They're 00:08:09.240 --> 00:08:15.800 using AI and machine learning to constantly update their capabilities to 00:08:12.920 --> 00:08:20.600 detect even the smallest errors. If an error is identified, hey, human hands 00:08:18.520 --> 00:08:23.880 are still the king, it gets fixed right next door, then the back covers get 00:08:22.640 --> 00:08:29.720 installed. Kind of a cool element of Hisense's culture is that no matter what position 00:08:27.360 --> 00:08:33.520 you apply for, if you get a job, you'll spend the day here on the final 00:08:31.800 --> 00:08:37.640 inspection line so that you can get an appreciation for what goes into these 00:08:35.320 --> 00:08:43.039 devices that you're marketing or selling or whatever it is you're doing. 00:08:40.400 --> 00:08:47.800 Before heading into QA, every panel is burned in for 10 minutes on the line to 00:08:45.240 --> 00:08:51.720 help eliminate any of those uh first part of the bathtub curve 00:08:49.440 --> 00:08:56.400 failures. At this point, our TV is basically assembled, and it's time for 00:08:53.600 --> 00:09:02.840 QA. This station behind me uses precision 3D machine vision and an 00:08:59.640 --> 00:09:05.400 eight-axis plug-in and plug-out robot 00:09:02.840 --> 00:09:09.560 with ultra-high precise force control in order to satisfy Hisense's customers. 00:09:07.480 --> 00:09:13.880 They even have a robot here that can push buttons turning the TV on. Nobody 00:09:12.280 --> 00:09:18.720 tell my wife about either of these innovations. The rear covers get screwed 00:09:16.040 --> 00:09:25.280 on, the labels get engraved, then we're off to a particular passion of mine. 00:09:22.080 --> 00:09:27.640 Packaging. After automated testing and 00:09:25.280 --> 00:09:32.800 validation, the TVs are brought back downstairs to be wrapped, padded, and 00:09:30.320 --> 00:09:32.800 boxed. 00:09:34.160 --> 00:09:40.800 This is yet another area where automation is not only a huge 00:09:37.480 --> 00:09:42.680 time-saver, but a huge back ache saver. 00:09:40.800 --> 00:09:49.400 Hisense estimates that the average weight of a consumer TV has reached 54 00:09:45.920 --> 00:09:51.640 kg. That is well over 100 lb. The 00:09:49.400 --> 00:09:55.120 solution? Have the robots move them around. Way better. 00:09:56.280 --> 00:10:02.680 What a ride, man. There's even more that we didn't get a chance to show you, like 00:10:00.600 --> 00:10:07.200 the system that monitors material supply levels at the stations and then uses 00:10:04.720 --> 00:10:12.800 these autonomous vehicles to scurry over with more screws or connectors or 00:10:10.600 --> 00:10:16.760 cardboard sleeves or whatever. And we didn't even touch on the monitoring 00:10:14.720 --> 00:10:22.160 system that shows machine health for the entire facility in real time, advising 00:10:20.080 --> 00:10:24.760 them proactively when things might need maintenance. 00:10:23.320 --> 00:10:30.920 I couldn't show you guys all that cuz they're in the process of applying for some patents, but bottom line, I think 00:10:28.480 --> 00:10:34.360 we've seen enough to know that humans we're basically obsolete in a 00:10:32.120 --> 00:10:37.840 cutting-edge production environment. Let's go somewhere that we're still 00:10:35.520 --> 00:10:41.800 needed then. The R&D center, where we can take a closer look at the RGB 00:10:39.880 --> 00:10:45.800 backlight technology in Hisense's cutting-edge TVs. I've discussed 00:10:43.640 --> 00:10:49.640 Hisense's RGB mini LED backlight technology a couple of times on this 00:10:47.400 --> 00:10:55.840 channel, both when they launched at CES and when I unpacked their 116UX at home, 00:10:53.000 --> 00:11:00.000 but I've never gotten a chance to see under the hood. Before we take a closer 00:10:58.080 --> 00:11:04.720 look though, let's do a brief history of backlight technology. Originally, 00:11:02.360 --> 00:11:09.560 backlights were designed to as evenly illuminate the back of an LCD panel as 00:11:06.720 --> 00:11:14.160 possible. This made them nice and thin compared to old-school CRTs, but they 00:11:11.880 --> 00:11:18.440 weren't the best at producing blacks. They were really more like gray. That's 00:11:16.240 --> 00:11:22.160 because even the best LCD allows a significant amount of light to pass 00:11:20.080 --> 00:11:27.880 through. The solution? Full array local dimming, which places 00:11:24.640 --> 00:11:29.440 many smaller lights across the entire 00:11:27.880 --> 00:11:33.480 back of the panel. These can be brightened or dimmed in zones according 00:11:31.960 --> 00:11:37.040 to the type of content in front of them, dramatically increasing perceived 00:11:35.080 --> 00:11:42.240 contrast. Over the years, they leveled up a lot with smaller LEDs, more 00:11:39.720 --> 00:11:46.640 numerous zones, and high-energy blue backlights that can excite quantum dot 00:11:44.400 --> 00:11:50.320 films to achieve image quality that gives even self-emissive display 00:11:48.360 --> 00:11:54.720 technologies a run for their money. But what if instead of a single color 00:11:52.440 --> 00:11:59.560 backlight, whether it's white or blue, you could have an RGB backlight, 00:11:56.839 --> 00:12:03.600 allowing you to shine red light directly behind the red pixel for the most 00:12:01.200 --> 00:12:08.440 vibrant sports car you've ever seen? That is where RGB mini LED comes in. 00:12:07.000 --> 00:12:12.640 Now, it's still early days for this technology and there is room for it to 00:12:10.320 --> 00:12:16.680 improve, especially by adding even more zones to the backlight. But Hisense has 00:12:14.760 --> 00:12:21.839 been on the forefront of development and when we measured the 116UX, we were 00:12:19.080 --> 00:12:27.120 absolutely blown away by its color gamut. Bottom line, RGB mini LED results 00:12:24.600 --> 00:12:33.160 in incredible color saturation and unreal brightness that really makes HDR 00:12:29.440 --> 00:12:35.440 content pop and it's so cool to see this 00:12:33.160 --> 00:12:40.280 side-by-side with the fully assembled unit, so you can really see how the 00:12:37.880 --> 00:12:44.000 image sausage is made. This Oh, this fire scene looks so good, right? 00:12:42.200 --> 00:12:48.600 Hisense's rise to prominence in North America has been more recent, but 00:12:45.920 --> 00:12:53.000 they've actually been around since these were current, 56 years to be precise, 00:12:51.320 --> 00:12:59.160 and are now a major player in everything from TVs, laser TVs and projectors to 00:12:56.080 --> 00:13:01.440 cloud services to fridges. In fact, this 00:12:59.160 --> 00:13:07.440 was a one of their early acquisitions, which they pointed out to me when we 00:13:03.440 --> 00:13:07.440 walked in, actually still works. 00:13:07.920 --> 00:13:13.160 Ah, refreshing. They asked me to highlight their ongoing 00:13:11.360 --> 00:13:17.120 goal of becoming a world-class provider of multi-scenario display solutions and 00:13:15.800 --> 00:13:20.920 to highlight their construction of China's first zero carbon factory. You 00:13:19.720 --> 00:13:25.400 can learn more about Hisense in the video description. And while you're down there, hey, maybe leave a nice little 00:13:23.760 --> 00:13:29.360 comment to show your appreciation for them opening up their factory so we can 00:13:27.320 --> 00:13:33.080 all understand a little bit better where our shiny gadgets come from. Speaking of 00:13:31.520 --> 00:13:41.600 shiny gadgets, if you want something else to watch, maybe check out my unboxing and first look at the 116UX 00:13:36.920 --> 00:13:44.520 116-in RGB mini LED TV. It is 00:13:41.600 --> 00:13:44.520 out of this world.