# Presentation: 757294

## DVD Production Process &Key Factors for Quality Discs

*Verbatim, Product Marketing**Mar., 2005**Ronan Ryan**/Satoshi Wakabayashi*

## Revenue $18 billion (March 2004)

- 33,500 employees (1,500 in USA)
- Performance Chemicals, Pharmaceuticals, Petrochemicals

- 100% Subsidiary of Mitsubishi Chemical Co.
- Total Revenue   $650 million
- Optical Disc, Magnetic Media, Flash Memory

- 100% Subsidiary of Mitsubishi Kagaku Media CO.,LTD.

## Verbatim / Mitsubishi Kagaku Media Group

**Verbatim / Mitsubishi Kagaku Media Group**

**Vision & Mission**
- Verbatim / MKM is an international sales, marketing and optical technology development organization known as the innovative market leader in _removable storage media_ and related accessories providing reliable, unique technologies and products that are highly sought after and broadly distributed world-wide.
- Our mission is to develop and market high quality products that users want for storing, moving and using digital content.
**January 2004****	****	****   ****	****	****           MKM Executive Committee**

## Global Supply Chain

**Headquarters**
**Distribution**
**Manufacturing**

_**Tijuana, Mexico**_
**Floppy/CD-R**

_**Charlotte NC**_
**Verbatim USA HQ**
**USA DC**

_**Toronto Canada**_
**Canada DC**

_**Mizushima, Japan**_
**MO, UDO, Stampers**

_**Taipei, Taiwan**_
**Floppy, CD-R/RW**
**DVDR, DVDRW**

_**Singapore**_
**DVDR, DVDR DL**
**DVDRW**

_**Frankfurt, Germany**_
**Verbatim European DC**

_**Tokyo , Japan**_
**Mitsubishi Chemical Corp.**

_**Uruguay**_
**Verbatim South America DC**

_**Egham, UK**_
**Verbatim EUMEA HQ**

_**Odawara , Japan**_
**VAP DC**

_**Melbourne, Australia**_
**VAP DC**

_**Sunnyvale, CA**_
**MFD/Tape**
**Coating**

_**Hong Kong**_
**VAP DC**

_**Shenzhen, China**_
**VAP DC**

**Global Supply Chain**

_**India**_
**DVDR, DVDRW**
**CD-R**

## MKM Core Competencies

***Fast Dry Printable***

## Verbatim Product Direction

**Products are designed and manufactured for the **_**highest compatibility and reliability**_
- Technology is co-developed with hardware OEMs (designed into hardware)
- Unique manufacturing partnerships
- Specify & qualify manufacturing lines
- Tighter than industry specifications
- On site Quality Assurance and Engineering support
- Unique ID codes that insures the highest level of compatibility in the industry
**Continually**** **_**expanding**_** ****our product offering**
- Latest in core optical technology products
- Speeds (16X DVDR, 8X DVDRW)
- Layers (DVD+R and DVD-R DL)
- Surfaces (Ink-jet and thermal printable, Hardcoat)
-  Blue laser (UDO, Blu-Ray, HD DVD)
- Continue to broaden our non-optical lines (imaging, USB, accessories)
**Always **_**differentiated**_** from the competition**
- Technology and quality (AZO, SERL, Crystal, etc..)
- Product marketing (Digital Vinyl, Gold and Platinum, DigitalMovie, VideoGard, etc.)

## Verbatim Brand

**Well established brand (35 years)**
**Clearly recognized as a quality brand**
**Extremely well known & distributed brand throughout the world**
**#1 World-wide market share for DVD +/- R   **
**#1 World-wide market share for CD-R **
**#2 World-wide market share for DVD +/- RW  **
**#2 World-wide market share for CD-RW**

***Source:  Santa Clara Consulting Q4 2004***

## Major Cause of Problem

- Effect of bad media shape

- Recording layer (Dye) has problem

- Good dye, good media shape and optimized write strategy

## Production Process of R-DVD

**Inspection**

**(****Recording Side)**

**(****Dummy Side)**

*Production Process of R-DVD*

## Injection Process

*Injection Process*

-  Key factors    - quality stamper    - quality mold    - high grade polycarbonate    - optimization of injection condition       (pressure, timing, temperature)

## Mastering Process & Design of Mold

-  Mastering is the key process   - for making quality stamper
-  Key factor    - sophisticated operation of the cutting       machine    - deep knowledge/experience of        polycarbonate and injection process

-  Mold is the key material   - for injection process   - for attaining higher production cycle time
-  Key factor    - deep knowledge/experience of        polycarbonate and injection machines

## Dye Coating & Drying Process

*Dye Coating & Drying Process*

-  Key process   - to attain good recording performance   - to achieve superior archival performance
-  Key factor    - quality dye material       (ability to develop quality dye)    -  optimization of spin coater condition       (rotation speed, speed control, temperature,        humidity)    - optimization of the baking condition

## Dye is Important!

*Dye is Important!*

- Even though you optimize the process condition, you have no chance to producequality discs using wrong dye.

## Sputtering Process

-  Key process      - to attain stable recoding/reading performance   - to achieve superior archival performance
-  Key factor    - deep knowledge of forming thin metal film    - optimization of the sputtering condition    - material

## Bonding Process

-  Key process   - to attain flat media shape   - to achieve superior archival performance
-  Key factor    - quality bonding glue in terms of both       media shape and durability    - optimized process condition

- Aging Test Result for Selection of the Glue

## Inspection Process

-  Key process   - to attain consistent quality among      production lots   - to confirm expected compatibility     among major writers
-  Key factor    - Appropriate setting of defect criteria    - tight communication with major writer      manufactures

## Writing Strategy

*Writing Strategy*

- Every dye material has its own recording characteristics, so recoding power and laser exposing timeshould be optimized separately for the quality recording . (_**Writing Strategy: WS**_)

- 00100000100..

- 00100001000..

## Summary of Key Factors for Quality Discs

**Material**- Stamper, Mold, Polycarbonate, Dye, Bonding Glue- Capability of developing these materials and deep chemical knowledge are required
**Process Control**- Optimization of the process condition of Injection, Dye coating/drying, Sputtering,    Bonding process- Capability of designing each process and ample experience of the production of    optical discs are necessary
**Quality Control**- In-process control should be carefully designed and feedback procedure should be  consistently implemented to all of the production lines for quality consistency among  production lots- Strict engineering change control should be taken place
**Writing Strategy**- Ideally, optimized writing strategy should be implemented in all of major writers   before the shipment of the discs- Tight communication with major writer manufacture from the development stage   is crucial

## Verbatim (MKM) 

**Material**- one of the leading developing company of key materials like dye, stamper   and polycarbonate, and have designated chemical engineers for each material development- also a major supplier of those materials
**Process Control**- years of experience of producing all type of optical discs.   (CD-R, CD-RW, DVD+/-R, DVD+/-RW, MO and UDO)- capable of designing each process
**Quality Control**- possesses an established quality control procedure which has been refined through OEM  business with major PC, writer and other disc manufactures
**Writing Strategy**- has been in good communication with all of major writer manufactures from the    development stage of high speed (8X, 16X), high capacity (double layer) or    unique (UDO or LightScribe) writers/discs- member of the key industry organization like DVD-Forum or DVD+RW Alliance

## Bottom Line 

*We are developing discs and materials very carefully with paying attention to both recording performance and durability ** *
*We are supporting the efforts by NIST to better define archival test methods.** *

- Thank you for your time!

*Bottom Line *