SPC and DOE in production of organic electronics

Abstract: At Acreo AB located in Norrköping, Sweden, research and development in the field of organic electronics have been conducted since 1998. Several electronic devices and systems have been realized. In late 2003 a commercial printing press was installed to test large scale production of these devices. Prior to the summer of 2005 the project made significant progress. As a step towards industrialisation, the variability and yield of the printing process needed to bee studied. A decision to implement Statistical Process Control (SPC) and Design of Experiments (DOE) to evaluate and improve the process was taken. SPC has been implemented on the EC-patterning step in the process. A total of 26 Samples were taken during the period October-December 2005. An - and s-chart were constructed from these samples. The charts clearly show that the process is not in statistical control. Investigations of what causes the variation in the process have been performed. The following root causes to variation has been found: PEDOT:PSS-substrate sheet resistance and poorly cleaned screen printing drums. After removing points affected by root causes, the process is still not in control. Further investigations are needed to get the process in control. Examples of where to go next is presented in the report. In the DOE part a four factor full factorial experiment was performed. The goal with the experiment was to find how different factors affects switch time and life length of an electrochromic display. The four factors investigated were: Electrolyte, Additive, Web speed and Encapsulation. All statistical analysis was performed using Minitab 14. The analysis of measurements from one day and seven days after printing showed that: - Changing Electrolyte from E230 to E235 has small effect on the switch time - Adding additives Add1 and Add2 decreases the switch time after 1 and 7 days - Increasing web speed decreases the switch time after 1 and 7 days - Encapsulation before UV-step decreases the switch time after 7 days