How Croma TVs are made

Idiot box? Maybe a few decades ago. But today’s TVs are smarter and more powerful than ever, being the one-stop source of entertainment in many Indian homes. From movie nights to gaming marathons, televisions are an indispensable part of our lives. But have you ever wondered how an LED TV is put together?

We took a trip to a factory to check out how a Croma 32-inch TV is made, and the process was way more interesting than we imagined! Here’s what we saw.

The entire process of a Croma TV being built from scratch can be divided into multiple sections, from the building phase to the testing phase. Here’s how they function.

LCM Assembly

First, we look at the LCM Room, where the Liquid Crystal Module, or in layman’s terms, the display of the television is assembled. Various LED Strips for the backlight and several other thin layers of plastic are first assembled onto a plastic back panel. While the LED strips function as the backlight in the TV, the various layers do the job of maintaining an even distribution of light and making sure any pictures forming are clean.

After a round of inspections, the middle frame of the TV is attached to the above section, giving the TV a sturdy structure. Next, a glass screen is added using a couple of suction pumps to ensure careful handling.

Other smaller elements like the cushion pads and the front bezels are added before sending the TV into a dark room to check for light leakage and backlight performance. Once all clearances are done, the body of the TV is ready. Now, it needs its brain.

SMT Assembly

While the external body of the TV has its layers assembled, many automated machines and technicians join forces in the SMT (Surface Mount Technology) assembly on another floor. This is where the PCB (Printed Circuit Board), also known as the brain of the TV, is made.

The process begins with a stencil that outlines where each component goes on a circuit board. This is done through several high-tech machines that are not just fast, but insanely accurate.

After adding some solder paste to the target copper parts of the bare board, small components are added to the PCB using a chip mounter. Fun fact – chip mounting machines can place components on the PCB up to 55,000 times every hour.

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The board is then checked for any issues, before entering a reflow machine that melts the solder paste, solidifying all the connections into place. One final inspection is conducted where high tech cameras will identify any possible issues with the PCB.

The PCB then enters the manual insertion line, where larger PCB components are added by hand by several skilled technicians. These components are manually placed and soldered onto the board. This is followed by some tests that ensure correct functionality of the components. Once cleared, the PCB is ready for the rest of the TV!

Final Assembly Line

The final assembly line, as you guessed it, is where the PCB and the TV body come together. It begins with the flexible flat cable being carefully connected to the PCB, after which the PCB itself is screwed in place on the TV body.

After this, the TV’s speakers are attached to it, as is the power cord. The back panel can then be closed. Following this, the TV goes through a voltage test and several other tests to ensure its optimal performance over time.

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Finally, all the labels and stickering is added to the TV body, and after a final aesthetic check, the TV is packed into a box along with accessories like the remote control, manuals, and stands. Now the TV is ready for some external testing.

Package testing

Randomly selected packed TV boxes from a batch, go through several tests to ensure functionality over transportation. A vibration test simulates the shaking on the road, while drop tests account for any accidental impacts. The TV is also exposed to sand, dust humidity and extreme temperatures to test ingress and ensuring continued functionality.

If the TV clears all of these tests, the batch is good to go, and the TV can finally be shipped to your home. That is the journey a Croma TV goes through before reaching your doorstep. Stay tuned to Unboxed by Croma for more insightful deep-dives into the making of everyday appliances.