business news&reviews
ten Editor in Chief Printed By Sven E. Jarby Südostschweiz Print AG (Chur, Switzerland) Managing Editor Peter Kraus, REMCOM GmbH Photography (USA / Switzerland) Michael Reinhard Photography (Herrliberg, Switzerland) Design / Layout Oerlikon Photography unless stated otherwise Darren Stacey, Doubletake Design Ltd. Comments & Information Published by Please contact us: [email protected] Oerlikon Balzers, P.O. Box 1000, Or for more information on Oerlikon visit our website: FL-9496 Balzers, Liechtenstein www.oerlikon.com systems Time Waits for No One
Dear Readers,
Welcome to TRACKS 2007: our “official” Blu-ray edition. As you have come to expect, this latest issue will update you on the latest data storage technology – and give you a close look at the real story behind Blu-ray (and PMR) disc production.
Our efforts to develop and implement the newest production technology are defined by the fact that “time waits for no one.” Especially for our industry, storage capacity for both optical and hard disks keeps expanding at a breakneck pace, but the time to implement new production solutions is continually shrinking. Being in the forefront of the newest generation of data storage media (the high capacity Blu-ray disc and the PMR-based hard disk formats), Oerlikon has taken great efforts to develop cutting edge solutions by partner with industry leaders to ensure the best production solutions possible.
Our future is Blu Oerlikon is firmly in the Blu-ray camp. In 2006, 1/3 of our revenue came from Blu-ray solutions. Since our INDIGO lines – both for single layer and double layer BD formats – are available this year (read about them on pages 16-21), expect even higher share in 2007. Our large base of installed BD lines is key to our future success, as most manufacturers will stay with a reliable supplier once the market chooses a high-density disc format. Despite the delay among consumers due to the ongoing format battle, I am confident that we will have a winner by the end of this year.
PMR progress The new PMR technology for hard disks may be an even more revolutionary technology step. Our RACETRACK system (see the story on page 44) – with production records for throughput and yield – represents the optimal solution for high-quality PMR hard disks. With almost 1/3 of the world’s hard disks already produced on Oerlikon equipment, we expect great things from this solution as well.
2007 promises to be a year of great changes – and great opportunities. All of the technology partners I have recently spoken to – and our customers – are optimistic about growth and the promise of the new storage technologies. I look forward to taking advantage of the future with you!
Peter Tinner Head of Systems, Senior Vice President OC Oerlikon Balzers Coating Ltd
Tracks 03 Contents
data storage business Oerlikon: Innovation & Diversification 5
blu-ray business partners Blu-ray Disc Association: Beyond High Definition 08 Sony DADC Leads Blu Revolution 10 GE Plastics: Developing the Perfect Substrate 12 RICOH: Blu-ray Multi-Layer Technology 13
blu-ray solutions Hans Ebinger on Blu-ray and Opportunities 15 INDIGO SL for All Single Layer BD Formats 16 INDIGO DL for Dual Layer BD Discs 20 SPRINTER for Multi-Layer Sputtering Applications 22
24:00 - A company That Never Sleeps 24
optical disc solutions MATRIX for DVD and HD DVD 27 CUBE STAR FLEX for DVD and BD-ROM 31 FUSION SL for Single Layer DVD R 34 FUSION DL for Dual Layer DVD R Formats 38
hard disk solutions 50 Years of Breathtaking Advances 41 In Pole Position with PMR 42 RACETRACK for PMR Hard Disks 44
service solutions Changing the Rules by Improving our Service 49 A Day in the Life of a Service Engineer 52
Your Oerlikon Contacts 54
04 Tracks data storage business Oerlikon – Timely Innovation & Diversification For the first time in our 100-year history, the company has a single name and logo: Oerlikon. Sven E. Jarby, Head of Marketing & Communication at Oerlikon, talks about building a diversified portfolio with a streamlined organization, a heritage of innovation, and how Oerlikon will better leverage its know-how and maintain growth around the world.
Last year’s name change was more than cosmetic. The Oerlikon Balzers Coating segment now includes not only our data storage activities, but also the Solar, Wafer Processing, and Balzers Tool Coating business units, bringing our considerable thin film know-how into a single “coating powerhouse.” Unifying these business units under a single name also points out the strategic importance of diversification for Oerlikon. “This is important to help us minimize business risks,” explains Sven E. Jarby, Head of Marketing & Communication for Oerlikon Balzers Coating. “For example, we have an optical disc industry in transition between DVD
Tracks 05 data storage business
and a new disc format. Having a Oerlikon strength. The recently For a production line product portfolio that goes far beyond announced “R&D Center” – to be optical discs helps Oerlikon fill the opened in Germany this year – will integrator, the range revenue gap during periods of strengthen the company’s focus on uncertainty”. getting more out of innovative strength of our portfolio is – to drive and ensure the future. Pushing diversification unmatched. The ability to diversify is key for all “Our new formats (such as Blu-ray, with up to 50 players in our industry. Many other R&D center GB capacity) with our new INDIGO companies have struggled and gone will extend line. And after almost three years of out of business, and some have our research intense development work on a PMR- attempted a diversified product range capabilities based hard disk system, our new but fell short. Oerlikon is probably the beyond just RACETRACK line completed final test furthest along on this path – though products and runs last year and has now proven others are moving in the same applications,” itself in the field with new records for direction. explains throughput, uptime and product Sven E. Survival in dynamic high-tech markets quality! Finally, a parallel priority to Jarby. “A means having to deal with – and innovative technology is close systematic approach to basic research accept – the inevitable and sudden cooperation with our customers and will help us take better advantage of market downturns. This is where a an improved level of customer support. emerging technology trends.” diversified strategy enables a company to channel resources like R&D, assembly, and customer support, when necessary, to other applications Delivering a replication line is only the and markets. It can make the beginning of a customer relationship. difference between remaining strong – and extinction. Having management involved The customer advantage “For a production line integrator, the Together with our “tradition of Taken together, our priorities articulate range of our portfolio is unmatched,” innovation,” the Oerlikon organization an important advantage for our says Sven E. Jarby. enables an efficient leveraging of R&D customers. As a global player, the Looking beyond a widely diversified programs into actual products and Oerlikon network of technology portfolio, Oerlikon also strives for a applications. This is possible because centers, production sites, and support more streamlined organization that “innovation” is considered an end-to- offices make it possible to maintain reflects a new management end process that involves all functions constant contact – and innovative philosophy: a renewed focus on our across the company. capabilities – with our partners. innovative strengths. These draw “Senior management is constantly “It’s what helps our customers stay explicitly from a “tradition of involved in what goes on at the successful in a fast moving global innovation.” product development level, and all our market,” concludes Sven E. Jarby. Tradition of innovation teams share an awareness, and deep Building on our history of technology understanding of the importance of innovation and the know-how and customer needs,” says Sven E. Jarby. experience of our people is a central “Integrated as part of our ongoing R&D part of the Oerlikon strategy – and efforts, this enables us to make underlines a belief in the company’s decisions that lead to new, innovative potential. By reinforcing our R&D technology and products.” teams of over 800 specialists and with The global and local priorities are clear. thousands of patents registered over Currently, a strong effort continues to the years, innovation is clearly a key fully realize third generation optical
06 Tracks blu-ray business partners
timely innovation and a shared future
in this section Blu-ray Disc Association: Beyond High Definition Sony DADC: Leads Blu Revolution GE Plastics: Developing the perfect substrate Ricoh: Blu-ray Multi-Layer Technology blu-ray business partners
Blu-ray Disc: Beyond High Definition
Frank Simonis In the late 1990’s, at the time of the Strategic Marketing Director for the successful global launch of the DVD, the Blu-ray Disc Associaton first initiatives to discuss the next step in optical digital media began. One result of the industry-wide efforts to set forth a new media standard was the creation of an open industry group: the Blu-ray Disc Association. Supported by over 170 companies, the Blu-ray Disc Association includes members from the consumer electronics, information technology, media, and software industries. Their goal was to jointly enable a Blu-ray format standard.
08 Tracks blu-ray business partners
The resulting Blu-ray (BD) standards were created acceptance, and create a new market for with an eye towards ensuring continuous advanced feature films with “right bounce” technological evolution. As a completely new content. optical disc medium with previously unthinkable storage capacity, BD offers commercial longevity The power of 50 and a consistent consumer experience in terms BD 50 GB media is the ultimate solution for the of ‘ease of use’ and a unique viewer experience high definition movie market. Recent new that goes beyond the traditional concept of high industry initiatives by Oerlikon, Singulus and Sony definition TV. DADC show that the new BD 50 is more than just a disc storage technology with lots of market potential; it’s being realized here and now and is already in the phase of acceleration. In fact, BD 50 technology is maturating and will quickly grow to become the ultimate solution for advance feature films.
During the months since its launch earlier this year, industry trends show that BD 50 has gained a strong market position. The content industry expects it to grow into a dominant market leader over the next year. BD 50 will be the ultimate feature film delight.
Total gaming experience The BD 25 GB version is a cost effective solution for applications demanding over two hours of the best quality video, with features based on the most advanced high quality audio and video Content industry revolution codes. Based on BD Java technology, the playback On top of that, the video game industry, best standards for movie viewing on Blu-ray symbolized by Sony’s PS 3 system and its BD incorporates an impressive array of features. The capabilities, is leveraging the capacity of both BD breadth of these features presents a permanent 25 and BD 50 to bring an astounding high challenge to the content providers – to keep definition games experience to consumers in a enlightening the consumer about the new way they have never experienced before. BD variations and ways to view their unique content. represents the most recent evolutionary step for a Thanks to its prodigious storage capacity, BD games industry that moved from a small screen offers consumers multiple audio channels and TV, to 16x9 standard displays, then to the multiple video and graphics planes – all of it ultimate high definition 1080p screen – bringing accessible simultaneously. The advances an extremely realistic games experience into the enabled by Blu-ray will revolutionize the content living room. industry and pose a challenge to content producers to fully exploit their potential. Simply the best All in all, Blu-ray is now emerging as the optical To ensure a flexible access to content, Blu-ray is storage standard for the next decade for the available in a 25 GB version (using a single layer content industry. This only was possible because storage configuration), and the just released 50 of the massive support by the broadest industry GB version (with a double layer disc structure). group ever brought into existence – the Blu-ray Mindful of the importance that greater disc Disc Association. The partners and members capacity played in the success of the DVD, the helped develop the enabling technologies that will Blu-ray Disc Association is confident that now ensure a cost effective solution for the end- especially the double layer version of BD will play user – and the richest high definition experience a key role in achieving wide consumer ever seen.
Tracks 09 blu-ray business partners
Leads Blu Revolution
Blu-ray DiscTM is revolutionizing today’s home entertainment market. Playstation 3 (PS3) had a fantastic launch in Europe on March 23, with 165,000 consoles sold in the UK alone (60% more than Nintendo Wii at launch). PS3 is well positioned not only as a games console but also as the future home entertainment center. Many consumers buy PS3 bundled with HDMI cables, remote control and Blu-ray movies. The best selling Blu-ray title at the moment, Casino Royale, is in the top 20 of the DVD charts (!) in some of the major territories.
Key drivers for Blu-ray are the PS3 with currently 3 million consoles, far stronger industry support from the studios (seven out of eight support Blu-ray, five support Blu-ray exclusively), the committed support from the broadest range of consumer electronics and IT companies, and a higher disc capacity of up to 50 GB. In Last year, when the dual- response to layer 50 GB Blu-ray this strong Disc was introduced demand, and it caused a stir aiming to boost among the content creation disc replication industry. This exceptionally high capacity rapidly, two storage capacity means that movie years ago Sony DADC studios can present their titles in the very best began developing High Definition visual and audio quality. manufacturing technology Furthermore, these huge capacity discs provide and production equipment for opportunities to load added value content, such dual layer Blu-ray Discs. To date as bonus material, interviews with the actors and more than 25 million Blu-ray Discs have been production team, plus rich BD-Java-based manufactured by Sony DADC in the U.S., Japan interactivity for a complete entertainment and Europe, of which 4 million were BD 50. Sony experience. DADC has agreed to share mass production technology for the 50 GB dual layer Blu-ray Disc with like-minded companies. Subsequently, all the major movie studios have announced their intentions to utilize the unique 50 GB discs and worldwide demand for ‘We are pleased that the first two companies - manufacturing capacity has soared. both system integrators of disc replication
10 Tracks blu-ray business partners
equipment - are making replication systems for replicators worldwide to manufacture pre-recorded dual layer Blu-ray Discs in a short period of time,” commented Dieter Daum, Chief Executive Officer at Sony DADC. “With our support, these companies will design and manufacture dual layer Blu-ray Disc featured studio is capable of authoring up to 30 Blu-ray Disc replication lines for mass production using experience and titles each month. With some of the most talented authors know how from Sony DADC. Production machines from around, this team can support a project creatively, advise on both companies will be available in summer of this year.” the capabilities of the format and which disc configuration best suits an individual client or project. Market leading manufacturing technology Having been closely involved with the format’s development All major movie studios have over a number of years, Sony DADC is on the cutting edge of Blu-ray Disc replication. announced their intention to
Making a BD 50 polycarbonate substrate and sputtering is utilize the (BD) 50 GB discs... identical to other disc formats: the first stage is molding a substrate (thickness 1.1 mm) in an injection molder and sputtering the first information layer (L0) with silver. Sony DADC Celebrating its 20th anniversary in Europe, Sony DADC is a The silver surface is then spin-coated with a 25 µm thick ink leading disc and digital solution provider for the layer - the so-called spacer layer. After curing this spacer entertainment, education and information industries, offering layer, the disc is placed in an embossing chamber. A world-class optical media replication services, supply chain stamper fixed on an embossing head in the chamber is solutions and software services. Sony DADC Austria is part pressed into the spacer layer ink. After the separation of of the world’s largest optical media production network, stamper and disc perfect L1 pits remain in the ink surface. which consists of 14 manufacturing facilities including sites Sputtering of this layer completes the L1 layer forming. in UK, United States, Canada, Mexico, Brazil, India, Australia, Hong Kong, Japan and China. Sony DADC offers The final phase in BD 50 production involves spin coating of global solutions with a wide variety of formats and services. a 75 µm cover layer and finally hard coating the disc surface. Every month Sony DADC produces up to 130 million DVDs, 116 million CDs, and 10 million Blu-ray discs globally. The Comprehensive Blu-ray Disc production services major investment in 2007 will be the expansion of the Blu- Recently, Sony DADC has developed its core activities ray Disc capacity as well in Europe as in the USA and beyond physical disc replication. In the field of Blu-ray Disc Japan. production, Sony DADC offers a wealth of creative and consultancy services. Among its service portfolio, Sony In response to evolving customer needs, Sony DADC DADC has developed a fast-track authoring service to Europe has established a pan-European distribution network minimize the time needed to complete Blu-ray Disc project – with distribution centers in Paris, Madrid, Frankfurt and in effect offering a ‘one-stop-shop’ solution. Enfield in UK. Sony DADC provides a one-stop-shop from authoring through to final retail order fulfillment. Since the beginning of 2006 Sony DADC has upgraded its authoring house for Blu-ray Disc Authoring. Now the fully
Tracks 11 blu-ray business partners GE Plastics: Material Solutions for a Simpler Blu-ray world
As Blu-ray heads towards mainstream production, making the manufacturing process as compact and simple as possible is paramount to ensure a smooth transition with minimum yield and up-time losses for replicators. The collaboration between Oerlikon and GE Plastics - a global leader of engineering plastic resins for the optical disc industry - provides an innovative solution to many of the industry`s current manufacturing challenges.
Gordon A. Van Dyke GE Plastics, Pittsfield, MA (U.S.A.) is the leading requires the addition of a moisture barrier coating. global supplier of engineering plastic resins widely The cover layer is a nano-based, UV-curable resin Global Technical used in automotive, healthcare, consumer that exhibits excellent coatability and abrasion- Manager electronics, building and construction, resistance properties without the need for an Media OMDC telecommunications and optical media additional hard-coat resin layer. Taken together, Manager applications. Over the past few years, GE the GE Plastics one-step Blu-ray solution allows Plastics has been developing a materials system replicators to install equipment with a smaller to solve the numerous manufacturing challenges footprint while maximizing yield and uptime by posed by the Blu-ray format ....put simply, eliminating unnecessary process steps. creating a way to minimize the number of process steps – and maximizing yield and up-time. Work Finding a partner is now complete on our one-step Blu-ray solution Fundamental to this concept is the ability to test where both the substrate and cover layer the results of our development work at our materials are applied in a single step and Optical Media Development Center (OMDC) in eliminating additional process steps (such as Pittsfield. GE Plastics surveyed the landscape of moisture barriers or hard-coat layers). Blu-ray equipment providers in search of a supplier with not only a reputation for building quality equipment with excellent functionality, but "This solution allows also a vision of making simple, compact Blu-ray replicators to install lines capable of maximizing yield and up-time. Oerlikon and its INDIGO line was the company equipment with a smaller and machine that met these criteria – not only for today’s single layer products, but also for future footprint…" dual layer products on which GE Plastics and Oerlikon have been collaborating for some time. This concept is based on Noryl PPO resin, a The INDIGO line purchased by GE Plastics is highly dimensionally-stable material ideally suited already installed and commissioned in the OMDC for use as a Blu-ray disc substrate with low water facility and will be an invaluable asset in helping absorption and swell to allow tight tilt tolerances better serve our customers in the rapidly evolving on the final discs, unlike polycarbonate, which pre-recorded and recordable Blu-ray formats.
12 Tracks blu-ray business partners
Blu-ray Multi-Layer Technology from
Unlike DVD+R, which uses spin coated dye, recordable Blu-ray discs are manufactured using multi-layer sputtering. Ricoh developed a special “BFO” recording material to ensure excellent disc characteristics and low production costs. In partnership, Ricoh and Oerlikon will market the process and production equipment.
Ricoh has a long and successful tradition in BFO multi-layer system has excellent recording Katsunori developing and manufacturing optical discs using characteristics at 1x, 2x and 4x recording Nakata multi-layer technology. Our CD-RW and speeds. General Manager, DVD+RW media are known in the industry for RMP Division, their excellent quality and benchmark status. Finally, our disc design assures that the BD disc Ricoh From the beginning, we used the SPRINTER lifespan, an important quality criterion, is well platform for our development and production beyond the expected requirements. In order to work, and are now applying our thin film know achieve these properties, we had to develop the how to develop a new recording material to be Blu-ray sputtering technology and also the used in a simple layer stack for new generation matching cover layer material and hard coating. BD R media. Accordingly, the Ricoh BD R process package consists of a thin film layer stack, a 100 micron The new “BFO” material (Bismuth oxide For two component cover layer system together with Optical disc) was specifically designed for the required special target and lacquer excellent recording characteristics and to lower consumables. production costs. Expensive or rare target elements were purposely avoided; only commonly It is Ricoh’s intention to make this BD R process available elements are used for BFO. available to recordable media manufacturers, to Furthermore, the number of sputtering layers help them to make their production fit for future required to form a functional recording medium market requirements – and save substantial R&D was reduced to the minimum of four layers. The costs and time. Our experience shows that the process and hardware are intimately related and have to match perfectly. 1x - 4x Write Power Margin Therefore, we have entered a strategic partnership with Oerlikon for 9.0 the next generation media; we use 8.5 Oerlikon’s INDIGO line and the 8.0 SPRINTER sputtering platform in our 7.5 Blu-ray development work. As a 7.0 team, we offer turnkey inorganic 6.5 writable Blu-ray technology to our 6.0 customers. This offer goes well 5.5 4x
Averaged Jitter (%) Averaged beyond conventional consumable or 5.0 2x hardware supply and guarantees our 4.5 1x customers a successful start into the 4.0 next generation disc business.
3 4 5 6 7 8 9 10 Pw (mW)
Tracks 13 blu-ray solutions
going beyond high definition in this section Hans Ebinger on Blu-ray and Opportunities INDIGO SL for All Single Layer BD Formats INDIGO DL for Dual Layer BD Discs SPRINTER for Multi-Layer Sputtering Applications blu-ray solutions
“Blu-ray? A Great Product and a Great Business Hans Ebinger Head of Optical Disc Business Unit Opportunity!”
Hans Ebinger, Head of Optical Disc at Oerlikon, answers five frequently asked questions about the future of the optical disc industry and Oerlikon’s role in that future.
How much life is left in the optical disc Why is Oerlikon suddenly a technology medium? leader in Blu-ray lines? Easily another 10-20 years. More DVDs are sold Our engineers started early with BD, already in now than ever before; the entertainment industry 2004, and worked hard to get ahead of the pack. depends on DVD revenue, and every PC has a We targeted the much tighter BD R/RE cover DVD player/recorder as standard equipment. The layer uniformity specs from the start and had a huge installed CD / DVD base and the new Blu- bullet proof cover layer process with the first ray format give the medium a solid future. systems in May 2006. It took a tremendous team effort, but the leading pre-recorded and What has certainly changed are the data storage recordable manufacturers were convinced once alternatives to optical discs. Flash memory is they saw our samples. We delivered what we small and inert; hard disks have fast access and promised. That’s why the market accepts our higher capacities. At the same time, the CD and Blu-ray systems, while others are rejected or DVD markets are maturing, which requires a requested for further improvement. different strategic thinking compared to the years of enormous growth. I assume these factors to Isn’t it much too early to enter the Blu-ray be behind the “doomsday” mood of some business? colleagues. You definitely need a clear vision and Not if you want to be a serious player in BD. All firm place in today’s market. major pre-recorded and recordable players are already positioned for Blu-ray, and mid size Will the consumer “buy into” Blu-ray? companies are timing their entry. Market demand Absolutely! Many people still think Blu-ray is only will certainly need time to develop, but you need about getting sharper images on your HDTV. BD to prepare for BD now. is much more than that. It’s also about interactivity and “multi-session” capabilities. How else do I prepare my company for the While you view, you can change the language, future? check out other pop-up windows, or tap into the As the optical disc industry matures, it’s good to Internet. That’s not possible with DVD. I’ve seen review your business portfolio. Oerlikon can help all this work – and I’m a believer. diversify your business; we are active in a variety of markets and can help you get started in new businesses. Many of our customers are evaluating opportunities and working on projects with us to carry them forward to new grounds.
Tracks 15 blu-ray solutions
product profile INDIGO SL A Timely Blu-ray Production Solution Proven cover layer process and high uptime assure reliable production.
Volker Thanks to our unique cover layer process and flexible platform Wüstenhagen Manager Process concept, INDIGO currently has the widest installed – and fully Technology customer-approved – base of any Blu-ray line. The industry’s pre-recorded, recordable, and RW market leaders all use INDIGO, the “BD system of choice.”
The final hurdle for any production line is passing Producing Blu-ray discs, with a precise 100 µm the customer acceptance tests. Once system cover layer, is a formidable technical challenge. performance is clearly demonstrated, both With ten lines installed and accepted at leading production efficiency and the process margin production sites around the world, the Oerlikon must meet specific customer requirements. This product team has obviously met the challenge; becomes even tougher when we are talking INDIGO is a proven and reliable turnkey about Blu-ray discs. production solution for all single-layer BD formats.
Blu-ray challenge The central challenge for any Blu-ray production line – and the disc manufacturer – is producing a reliable cover layer (100 µm thick) that meets stringent disc parameters:
Geometrical requirements of ±2 µm uniformity (for the cover layer) Optical requirements (for the cover layer) Large process window for operating stability Overall cost efficiency of the INDIGO system
Compared to a dual layer DVD R disc, the uniformity requirements for Blu-ray are extreme, and five times more accurate; the cover layer BD ROM Line BD R/RE Line must be optimized to ±1 µm, or ±1% of the total layer thickness! INDIGO accomplishes this feat with a refined spinning process that combines heating and UV curing (on a defined substrate The current global installed base of geometry). INDIGO lines in operation. Initially, the variations in the quality of prototype cover layer resins demanded a concentrated development effort by the INDIGO product team
16 Tracks blu-ray solutions
and the resin suppliers. The appropriate resin Hard coating / backside coating has a viscosity of 1500 and 2000 mPas (similar to The short distance between the Blu-ray disc honey!), which also demands a specific handling surface and the information layer is a further and recycling procedure to successfully apply the production challenge, as surface defects temperature sensitive material. (scratches, fingerprints, etc.) can seriously compromise the functionality of a BD disc. This The cover layer process necessitates deposition of a hard coating (only 2- To optimize cost performance, INDIGO uses a 5 µm thick) on the relatively soft cover layer one-step spin coating process for the cover layer material, a process that is extremely sensitive to that follows a three-stage sequence: contamination and requires a very clean process Cover layer formation: The UV curable environment. Finally, the hard coat lacquer also lacquer is dispensed close to the center hole of requires a subtle adjustment to the injection a substrate at low rotation speed. IR radiation molding stage, further underlining the importance heats the lacquer, which is then distributed at a of an integral approach for an ideal hard coat higher speed. The process is carefully timed to layer. create a defined temperature gradient of a few The backside of every Blu-ray disc also requires a degrees from the inside to outside of the disc. coating – a moisture barrier – to prevent any Removal of the edge bump: The disc is water absorption that could lead to warping of now spun under a UV source to gradually the disc. SiN turned out to the ideal moisture change the lacquer viscosity to prevent it from barrier because of its stable, cost efficient flowing outwards during the edge bump deposition process and no need for any removal as disc spinning increases for a short additional lacquer protection, as shown by time – ensuring a clean appearance. customer production data. As it turned out, the Curing before hard coat application: A standard SiN process (running on the CUBE conventional high power UV light source cures STAR metallizer) was fine-tuned to guarantee a the disc prior to applying the hard coat. flawless layer. Finally, the surface of the SiN layer Considerably more cost efficient than a foil needed to be compatible with a common printing bonding technique, our proprietary spin-coating process, requiring an additional effort to process follows a two-track layout in INDIGO to determine the ideal backside layer thickness. ensure fast cycle times, similar to proven DVD manufacturing processes. The IR-assisted spin coating and UV pre-curing stages also maximize recycling (>95%) of the remaining cover layer lacquer, which helps reduce disc material costs. A temperature-controlled environment enhances process repeatability.
The latest production data from selected customer sites show that cover layer uniformity achieved with INDIGO is well within the BD specifications. blu-ray solutions
product profile INDIGO SL
Average Thickness CL1 key disc manufactures and component suppliers. 107 The results speak for themselves!
105 A flexible platform for all BD formats 103 Utilizing a platform concept for all INDIGO 101 systems provides a straightforward and flexible
99 way to configure every line to meet specific Thickness (µm) 97 customer specifications – whether we are talking about a BD-ROM, BD-R, or RE line. The first 95 step is defining a reliable injection molding 93 process, followed by specifying a sputtering 0 200400 600 800 1000 process (and system), and finally adding the Disc (No.) relevant extension modules (such as the cover layer and cooling modules). Average Thickness CL2 Of course, a disc manufacturer looks beyond the 107 quality of a single disc to how general process
105 stability over time is realized. Oerlikon process specialists have amassed comprehensive 103 production data on the INDIGO lines that give a 101 valid picture of long-term system performance, 99 including the ‘cpk’ calculations that are important Thickness (µm) 97 for statistical process control.
95 The robust and compact BD-ROM line 93 Our INDIGO BD-ROM line was developed 0 200400 600 800 1000 together with key customers. Starting with the Disc (No.) cover layer module, the BD-ROM line implements all the necessary process steps – in a compact (3.2 x 4.4 m) line footprint. The process flow for The INDIGO process Dynamic disc production environment BD-ROM uses two tracks for the cover layer window (including both Typical for a new disc format, the production tracks) demonstrates process to ensure fast cycle times. Hard coating parameters initially remained in flux. While the that even after short is included as a separate step and the output INDIGO line was being readied for release, the system interruptions, stage consists of “Relaxation”, “Inspection” and the cover layer disc manufacturers were busy optimizing their “Output Spindles”. Our CUBE STAR metallizer is parameters remain Blu-ray processes – for mastering, molding, disc within the BD disc integrated for both active coating (Ag alloy) and inspection, disc signal testing, and staff training. requirements. backside coating in a single metallizer – a unique This highly dynamic environment presented a optical disc industry feature. shifting landscape of production challenges; for example, as soon as we achieved reasonable Flexibility for blank BD media yield figures the customer required new and Production requirements for the BD-R and BD-RE additional scanner settings to improve the drive formats are very different from a BD-ROM disc. compatibility of a scanner approved disc. Apart from using the much larger SPRINTER sputtering system, a BD line for blank media can During this time it was important for Oerlikon incorporate many optional processing steps to process engineers to understand the meet specific customer specifications. For performance parameters of the INDIGO example, a typical configuration starts with the replication line, but also keep the complete BD cover layer module, then adds separate cooling process chain in mind – from mastering to final and buffering module for the special cooling disc output – to end up with acceptable requirements of both the BD-R and BD-RE disc production results. This development process formats, which require a longer cooling time due required constant communication with several to a much higher surface temperature after the
18 Tracks blu-ray solutions
Variation from Reference (23mm) CL1 sputtering stage. Because of the defined hand- over position in the cover layer module, it is 5 possible to connect either a BCA unit or an 4 3 initializer. This compact solution enables complete 2 in-line manufacturing for BD-R and BD-RE discs – 1 with high process stability. 0 -1 Ready for BD DL format ± Variation (µm) ± Variation -2 The platform design of INDIGO allows a relatively -3 simple upgrade for mass production of double -4 layer BD discs. The upgrade procedure needs no -5 modifications to the existing cover layer module; 0 200400 600 800 1000 an INDIGO SL line is simply extended with Disc (No.) additional spin-coating (for the space layer) and embossing modules, the sputtering system is Variation from Reference (23mm) CL2 adjusted – and the dual layer system is ready to 5 go. The manufacturer can insert modules where 4 they are needed, allowing the investment costs of 3 the original INDIGO SL line to be dedicated 2 towards dual layer production. 1 0 Getting you a dependable solution -1
The ongoing collaboration with key customers (µm) ± Variation -2 and our technology partners (including Philips, -3 Ricoh, GE Plastics and Sony) has greatly -4 accelerated and enhanced development of a -5 reliable and high performance production solution. 0 200400 600 800 1000 Whatever is learned in the lab or the field can be Disc (No.) applied to lines around the world. The extremely tight Our robust and compact INDIGO lines provide the uniformity requirements disc manufacturer with a durable state-of-the-art for the cover layer production solution. With our reliable cover layer remain within the process, Oerlikon helps the manufacturer produce specifications, leading to the possibility using BD discs in a cost efficient and dependable way. cpk values as a statistical process control tool. blu-ray solutions
product profile INDIGO DL Bigger IS Better INDIGO DL enables production of 50 GB Blu-ray disc
The dual layer version of Blu-ray delivers impressive storage capacity (50 GB) – and requires precise production parameters. Our new INDIGO line uses Sony’s “wet embossing” technology for optimal performance and reliability. Peter Hillenbrand During the past three years, Oerlikon Added copy protection: BD features three copy Senior Product development teams worked with key technology protection components (AACS, BD ROM mark, Manager, Optical partners to build, test and optimize the INDIGO and BD+) to secure content. HD DVD Disc Business Unit replication platform for BD production. The effort implements only AACS. paid off: With the largest installed base around Interactivity & creativity: BD offers BD Movie the world, INDIGO lines now turn out BD R/RE Mode (BD MV) and a BD Java Mode (BD J) for discs across Europe and Southeast Asia, and content programming – such as with games BD-ROM discs in North America. After the and interactivity over the Internet is possible. successful launch of the INDIGO SL line, our HD DVD has a similar mode, but with limited attention turned to perfecting and implementing a programming. mass production solution for the double layer Industry support: A wide number of brands version of BD, with a staggering 50 GB capacity. offer BD players; all major movie studios (with only a single exception) intend to publish 50 GB is fabulous content on BD 50. While sheer capacity is the most obvious argument for the new BD 50 GB disc, excitement around this format is also due to:
20 Tracks blu-ray solutions
Jitter values of a double layer Blu-ray disc produced with a polycarbonate stamper. Why embossing? 10
9 Jitter L1 Injection To contrast the two production
8 Jitter L0 Molding sequences, 2P (or stamper disc process) uses an 7 additional substrate for the 6 Substrate Jitter (%) second (information) layer, Cooling 5 while wet embossing avoids 4 the extra material with a Ni
3 Backside stamper to transfer the
20 30 40 50 60 Coating information layer. Wet Radius (mm) embossing eliminates the wasted substrate and an Reflective additional injection molding Doing a double layer disc Coating Blu-ray presents numerous production challenges: a cover machine – enhancing cost layer with stringent tolerances, an optically sensitive layer efficiency. made of resins, and a molding system that produces the pit Wet embossing is similar to structured layer. Two competing technologies – 2P and wet Space Layer Application existing molding processes for embossing – were initially considered for the production of replicating pit structured layers: double layer Blu-ray discs. While 2P is still the choice for the stamper is pressed softly recordable and rewritable BD discs, wet embossing has Embossing into a thin, wet layer of a UV emerged as the clear winner for the pre-recorded BD curable resin. New in the wet format. embossing process is its Our new INDIGO DL line is a dedicated BD double layer Semi-Re-flective downstream location, rather production solution that is based on the proven INDIGO Layer than a separate (or 2nd) platform successfully used for BD single layer formats molding system. This also around the world. For example, it incorporates our allows an efficient placement of innovative spin-coating process that provided excellent any process stages next to the embossing unit in the line, thickness uniformity of the cover layer. Most recently, the Cover Layer “wet embossing” technology developed by Sony was Application further contributing to a optimized and integrated into the INDIGO production compact system footprint. process. Hard Coat The wet way Application Wet embossing advantages: The wet embossing process is straightforward. A thin layer Used for over 50% of all of a low viscosity adhesive is first applied as the embossing double layer BD discs layer in the INDIGO DL system. The stamper is then Final Disc Reduces initial investment Inspection embossed into the wet layer und UV cured before being costs separated from the disc. The disc is then sent to the next More economical running costs production line module for semi-reflective metallizing. The Output final phase is deposition of a cover layer (75 Ìm), then to the Buffer inspection station, and ultimately, off to the output spindle.
“In addition to reliability and easy maintenance, our wet embossing process also enables the fastest cycle times and low investment costs,” concludes Bernd Heinz, Blu-ray Development Manager at Oerlikon.
Tracks 21 blu-ray solutions
product profile SPRINTER The System of Choice for a Dynamic Industry The unbeatable SPRINTER platform for multi-layer sputtering applications Edgar Rauch Product Manager Still the industry standard sputtering system for rewritable disc production, the current Optical Disc SPRINTER platform features enhanced sputtering options for DC and RF sputtering with Business Unit unbeatable performance and development capabilities for BD and emerging disc formats.
With consistently high throughput (>1,200 discs / hour) far beyond other single disc sputtering systems on the market, the SPRINTER remains the leader in high-throughput production of rewritable optical discs. In addition, recent enhancements ensure full production capability for both Blu-ray and HD-DVD. With over 180 systems currently installed around the world; SPRINTER produces 9 out of 10 rewritable discs and the vast majority of the recordable and rewritable blue laser discs sold today.
The basic SPRINTER sputtering system platform is available with five, nine, and 13 process chambers to meet specific production needs:
SPRINTER-5: Based on five-process chambers, this configuration is ideal for BD-R inorganic, and a cost-effective solution for a wide range of R&D applications (for target tests, development of new layer stacks, anti- reflex coating applications, etc.).
SPRINTER-9: This 9-process chamber layout Speedy start with “UltraSpeed” is the standard SPRINTER configuration and a Our “UltraSpeed” disc handling and loader proven solution for all current rewritable disc system, enables an industry-leading throughput formats (CD-RW, DVD+RW, DVD-RW) and of up to 1,200 discs / hour, enabling the fastest emerging rewritable disc formats (BD-RE and cycle times for the disc manufacturer. With HD-DVD RW). simultaneous loading and unloading, this handling system offers more process time and SPRINTER-13: The advanced 13-process downstream handling time; this all adds up to chamber layout is conceived for DVD-RAM very high disc throughput. “UltraSpeed” is also mass production and for high throughput the interface for SPRINTER when integrated into production of all other rewritable red and blue the INDIGO line for BD R/RE production. laser disc formats.
22 Tracks blu-ray solutions
Adding cathodes chamber purge) can be realized with the new Each process chamber on the SPRINTER system “IndiCat” indirect cooling method. This new can be configured according to specific design does not influence cooling efficiency requirements and processes. The following (compared to the direct cooling method used in process stations are available: the past), making process adjustments with the “IndiCat” cooling method unnecessary. DC sputtering cathode (e.g., for reflective and phase change layers) The material world of Multi-Source RF sputtering cathode (e.g., for dielectric Our innovative Multi-Source technology allows layers) simultaneous sputtering of up to four different Multi-Source sputtering cathode (e.g., alloy target materials in a single sputtering station. The sputtering and dielectric sputtering) Multi-Source Duo (MSD) features a sputter station Cooling station with two sputter cathodes, and the Multi-Source Quattro (MSQ) features four small RF or DC For customers producing both BD-RE and DVD sputter cathodes. RW on the same SPRINTER system, it is very handy to be able to process discs in a clockwise “Multi-Source makes it possible to easily and and counterclockwise direction through the rapidly combine a wide range of materials to SPRINTER. This allows added flexibility for derive compositions that meet specific production deposition of the layer stack when different disc demands.” explains Eduard Lorenz. structures are needed. In this case, it is not The flexibility of Multi-Source to “mix and match” necessary to rebuild the system to switch Far left: between the two formats. enables an exceptionally efficient development Multi-Source Quattro process for new phase change materials (for (MSQ) can be Excellent layer uniformity – especially important rewritable and recordable inorganic disc formats) configured with when producing Blu-ray discs with higher and new combinations of co-sputtering materials four small RF or DC sputter cathodes. recording speeds – can be achieved through (before buying targets with the designated proper target positioning and rotation of the disc composition). This means a substantial saving in Below: substrate, ensuring +2% uniformity. Disc rotation money and above all, in time. Another SPRINTER during sputtering is a crucial aspect for system undergoes comprehensive unbeatable film thickness uniformity, regardless of “SPRINTER gives the disc manufacturer an added resource to create complex multi-layer tests before shipping the sputter materials used. Furthermore, the to the customer site. Oerlikon metallizer team regularly configures stacks and completely new types of thin film layer customized magnet systems for our DC and RF structures,” adds Eduard Lorenz. sputter cathodes that correspond precisely to the manufacturer’s targets.
“We tailor the magnet systems for optimal layer uniformity and utilization,” says Eduard Lorenz, SPRINTER Project Manager. “Because delivering best quality discs matters.”
Adding options The “FlexiCat” cathode control is an additional performance feature built into selected sputter cathodes to assure consistent layer uniformity over the life of the target.
In addition, fast target changes (<30-seconds after process 0
24:00 0 Every minute of every day, somewhere around the globe, Oerlikon is at work. Whether it is a thin film specialist in the lab developing the next generation technology, a service engineer maintaining production equipment on site, or a sales manager on the road: Oerlikon is a company that never sleeps.
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07:00 Moment in time: A look across the world’s 23:00 time zones gives an informative overview of selected activities at Oerlikon on a given day: 00:00 01:00 02:00 03:00 04:00 05:00 Over the Pacific: Hans Headquarters: Final Hawaii: Eric Barbian Alaska: Helfried Weinzerl LA airport: Peter Utah, U.S.A.: Steven Ebinger flies to LA after a preparations completed takes a customer call tests a new video game Hillenbrand takes a final Dentoni is on the road to Japan visit for stockholder’s during a stopover. on BD. look at his presentation. a service call. meeting. 06:00 07:00 08:00 09:00 10:00 11:00 Massachusetts: Volker Argentina: Felipe Travi is Brazil: Ricardo Schorno Over the Atlantic: Peter United Kingdom: Agency Switzerland: Sven E. Wüstenhagen is underway on site for a DVD line sets up for an on-site Tinner flies to our R&D puts the final touches on Jarby finishes a new to complete BD tests. service call. training session. lab in Florida. a BD flyer. promotional strategy. 12:00 13:00 14:00 15:00 16:00 17:00 Liechtenstein: Ralph C. Israel: Stefan Seifried Russia: Oleg Morikov is Over the Indian Ocean: Dubai: Markus Wildhaber India: Jim Bingen goes to Ohr is in the lab with discusses PMR solutions talking up technology at Janice Wilcox is flying to optimizes a CUBE STAR check the show booth RACETRACK clients. with a client. a Moscow trade show. the next trade show. process for a client. with Janice. 18:00 19:00 20:00 21:00 22:00 23:00 China: The Oerlikon Taiwan: Henfy Su closes Japan: Yasuyoshi Tamura Flying over Asia: Edgar Siberia: Egon Längle New Zealand: Markus Shanghai team finishes a another line deal. talks to Balzers about Rauch is on the way to plans tomorrow’s MATRIX Frei answers his BD customer demo. additional line sales. an Australian client. installation. Blackberry even on his vacation. optical disc solutions
covering all formats, all the time in this section MATRIX for DVD and HD DVD CUBE STAR FLEX for DVD and BD-ROM FUSION SL for Single Layer DVD R FUSION DL for Dual Layer DVD R Formats optical disc solutions
product MATRIX profile The solution for DVD & HD DVD – Because time matters
Peter With state-of-the-art performance for DVD and HD DVD production, Hillenbrand the MATRIX and MATRIX HD lines both offer a convincing Senior Product combination of high uptime, consistent throughput and low material Manager, Optical Disc Business Unit costs – helping ensure reduced manufacturing costs.
For now, pre-recorded DVD is king of the optical slowdown in growth is imminent, and already disc formats – and a big income contributor for reflected in the slow down in demand for DVD the entertainment industry. Sales of pre- replication lines. On the positive side, emerging recorded DVD in 2006 set new records again, consumer markets in Eastern Europe, India, and lines for this format still make up a large South America, and Africa, while still small part of the sales in the equipment market, with compared to the established markets, are DVD R a distant second. However, these stellar beginning to grow. numbers can’t hide the fact that key markets are increasingly mature and a optical disc solutions
product profile MATRIX
Contributing to the longevity of pre-recorded DVD provide another investment boost for the industry. is the current format battle between the two high- For the DVD manufacturer, the production line density camps, Blu-ray and HD DVD. Whatever upgrade to HD DVD is easy, thanks to a similar format eventually dominates, the superior visual physical structure to DVD with back-to-back and sound quality and greatly enlarged storage bonding of two 0.6 mm substrates. capacity of the high-density formats are sure to
28 Tracks optical disc solutions
MATRIX HD - Highest throughput and lowest cost Oerlikon prepared their production solution to address all emerging HD production challenges: molding uniformity for the metal layers, space layer performance and eccentricity. “…over 50% of all Built on a compact footprint of only 21 m2 (about 230 sq. ft.), the MATRIX HD line delivers outstanding quality current DVD-R requirements for HD DVD with 3.0-seconds cycle times and daily output of 24,000 good discs. Additional highlights dual layer discs are include: manufactured with Best process stability: Our vacuum bonding our bonding technology enables MATRIX to carry out the dual layer HD DVD requirements with only minor process parameter technology.” adjustments. The stringent HD DVD eccentricity specifications led Oerlikon to engineer a new “expandable pin” capability, (available as an upgrade).
Lowest cost per disc: the ARQ 931 cathode for DVD delivers over 1 million shots per silver target – with unbeatable uniformity across the target life. For HD DVD production, where uniformity requirements are more demanding, the ARQ 950 cathode provides a guaranteed transmission variation (<±1.3%).
The best bonding process parameters; no hardware changes are necessary. In addition: Oerlikon’s vacuum bonding has been a success across the industry. Today, Space layers conform to DVD specs 1. Lacquering 2. Spinning over 50% of all current DVD-R Dual (overall thickness specification ± 10 Layer discs are manufactured with our µm, space layer specification on track ± 4 µm) and HD DVD specs bonding technology. The bonding UV Light process is key part of disc production (overall thickness spec ± 5 µm, because the space layers for both DVD space layer spec on track ± 2 µm). 3. Vacuum Bonding 4. UV Curing (about 50 µm) and HD DVD (only 20 Optically attractive lacquer µm) are so important for the final appearance around the center hole product. Our “wet-to-wet” vacuum Bonding with MATRIX bonding process applies UV resin to Lacquering: Disc halves are placed both DVD halves; then spin coats, in the spin cups. aligns, and joins them in a vacuum Spinning: The UV resin is applied on chamber. the halves and spin coated. Particularly crucial is the space layer Vacuum bonding: Disc halves are variation on track. Compared to placed in bonding pads and conventional bonding technologies, the centered. A servo-controlled pin space layer is set at the spin coating movement ensures precise step prior to the disc bonding step. alignment and joining of the two This assures a very consistent space halves. During venting the two “Bend Bonding” layer thickness between the disc halves are pressed together at the halves (variations of only ± 1µm) center to enhance the disc’s visual Schematic view of vacuum bonding thanks to spinning without capillary appearance. forces. This process also delivers UV curing: Lid opens, and the outstanding space layer performance gripper picks up the bonded disc to for HD DVD by simply adjusting the place on the UV tray. Tracks 29 optical disc solutions
product profile MATRIX
Highest throughput: Down to 2.2 second cycle times for DVD, guaranteed daily output is now of 34,000 discs per day. “We prepared a Even with the smaller pitch and the correspondingly higher accuracy specs needed for HD DVD, throughput values for production solution MATRIX remain impressive. The individual process modules to address all are constantly evaluated together with key technology partners – also the industry’s leading disc manufacturers – emerging HD and improved where necessary. production Synonymous with highest throughput and lowest cost per disc, MATRIX HD makes no sacrifices in output, process challenges…” performance, accessibility and serviceability. Metallizing flexibility Pre-recorded DVD and HD DVD require sputter deposition of two layers: the semi-reflective L0 and the reflective L1 layers. Coating materials include aluminum, silicon, and silver alloys. The MATRIX lines use a CUBE STAR metallizer with a dual cathode setup for high throughput and the flexibility of different configurations: ARQ 931 cathode: Ideal for DVD runs, this cathode sputters L0 and L1 layers with silver alloy and aluminum targets. The silver alloy target yields over 1 million shots (L0 layers), and over 200,000 shots with aluminum.
ARQ 950 and ARQ 931 cathodes: Perfect for HD DVD, with layer uniformity of less than ±1.3% for the semi-transparent layer, the ARQ 950 deliver 400,000 discs with a single target, almost 3x more than comparable replication lines. The ARQ 931 offers outstanding performance for deposition of the reflective layer. optical disc solutions product profile CUBE STAR FLEX The “Workhorse” Picks Up the Pace CUBE STAR: The leading choice for DVD and emerging BD-ROM formats
Originally designed with a unique “twin source” layout with extremely Rudolf Bieri, fast cycle times and reliable thick layers ideal for CD-R and DVD R Product Manager, Optical Disc production, the CUBE STAR metallizer has now been upgraded with the Business Unit newest Oerlikon sputter technology for BD-ROM production.
Thanks to a layout with two sputter sources set Ready for BD around a single chamber, the CUBE STAR has a After an intense four-month development effort, proven range of flexibility to adjust to different the latest version of this versatile metallizer – the process parameters or coating materials. The CUBE STAR FLEX – was launched for BD-ROM metallizer has enjoyed notable success in DVD R, production. The new FLEX version sputters both DVD9 and CD-R production applications. For the reflective L0 layer (50 nm silver) and the new and emerging processes, the metallizer’s layout can be configured to meet specific production process specifications and the disc CUBE STAR has the handling capacity of the replication line. lowest material costs per layer and the smallest footprint…
backside coating (15 nm SiN) of the BD disc, with an added “disc flip” mechanism to turn the substrate during the transfer from one cathode to the other. The latest performance results for CUBE STAR FLEX are impressive: < 4-second cycle times for BD-ROM production. For the disc manufacturer, the metallizer also provides the lowest material costs per layer and the smallest footprint of any BD metallizer currently on the market. Overall, the CUBE STAR FLEX is the perfect solution for maintaining high throughput and reliable layer uniformity for BD-ROM production.
Tracks 31 optical disc solutions
product profile CUBE STAR FLEX
Good for new formats Finally, as our ‘workhorse’ metallizer, the CUBE STAR FLEX is also an excellent production tool for the other emerging high capacity formats – HD DVD and DVD-R DL. The flexibility of two cathodes in one metallizer enables parallel coating of the L0 and L1 layers for HD DVD, or deposition of different materials without breaking the vacuum – such as a metallic (thick 120 nm - 140 nm Ag layers) and / or dielectric layer for DVD-R DL. In preparation for future disc formats, our newest development efforts are currently focusing on Setting the DVD standard reactive sputtering of SiN on two cathodes for The CUBE STAR also sets the pace with other new applications. configurations. For example, the configuration for DVD R production features a single pivot arm and Low cost of ownership two cathodes, because sputtering of the thick For the disc manufacturer, the “twin cathode” (120 – 140 nm) silver / silver alloy layers for DVD layout is also an opportunity to reduce investment R is split into two steps to allow reduced power costs. Installing only one metallizer is less costly levels – especially important for higher recording than two conventional single cathode models, speeds (16x) – and with sufficiently fast cycle times to maintain high throughput (up to 2,000 The “twin cathode” layout discs / hour). Feedback from disc manufacturers confirms that the CUBE STAR’s process window is also an opportunity to is wider than any other metallizer on the market. reduce investment costs. For pre-recorded formats such as DVD9 (run on our MATRIX line), a parallel production sequence is used. Two discs are loaded simultaneously and it’s also easier to integrate (footprint is only and the two cathodes sputter the L0 and L1 0.6 m2, including the rack cabinet, power and layers, while the pivot arms load the next two media supplies) into the production line. discs. This parallel process delivers industry- leading throughput (up to 4,000 half discs / hour) Overall, excellent cost of ownership means high and longer load / unload times – about 0.8 throughput and bulletproof reliability for high seconds – that allow the metallizer to adapt to uptime. The components used in CUBE STAR various handling configurations. FLEX have been extensively tested and are used in hundreds of production lines around the world. The CUBE STAR has a selection of cathodes available; the ARQ 931 “throughput millionaire” for As further insurance, the CUBE STAR FLEX has unmatched material cost savings per layer, the comprehensive error tracking and performance ARQ 941 for flat targets, and the ARQ 950 for analysis capabilities to record production history tight uniformity demands. The metallizer can fulfill to pinpoint problem areas – and simplify all current and future process needs. In addition, maintenance support. This further reduces any a new cooling module option also enables active potential downtime and the length of disc cooling that is integrated in the vacuum maintenance visits. chamber.
32 Tracks optical disc solutions optical disc solutions
product profile FUSION SL Quick Cycle Times for Lower Costs Our single layer DVD R line is a productivity leader
Markus Frei Assuring lower ‘costs per disc’ without compromise on disc quality Product Manager are top priorities for the DVD R manufacturer. Our FUSION2 is a Optical Disc smaller and faster line that’s easier to operate; with 2.5-second Business Unit process cycle times and over 28,000 good discs per day.
Essentially, the FUSION platform marries an Low consumption, high productivity optimized recordable dye from Mitsubishi Kagaku FUSION is built to meet the consistently high Media with a high-performance hardware production standards demanded by the disc platform from Oerlikon to deliver the best overall manufacturing industry. Combining Mitsubishi’s disc quality. 16x production process and dye know-how with our trademark “wet-to-wet” vacuum bonder and ”Used by major replicators around the world, industry standard metallizer (single or twin- FUSION consistently delivers excellent cathode CUBE STAR) results in 2.5-second performance,” says Markus Frei. “This platform is process cycle times. Compared to previous 4- the most reliable production solution for DVD R second cycle times, FUSION represents an production, with leading performance amazing 60% productivity increase! benchmarks in uptime, use of resources, and disc throughput.” “Cost efficient production means minimized consumption; long target life, easy dye station optical disc solutions
“This platform is a true production star, with leading performance in uptime and disc throughput.”
maintenance, long service intervals and low reflectivity, and climate stability) is assured, giving power consumption,” adds Markus Frei. the disc manufacturer best line performance with “FUSION represents the finest in current easy handling and process stability. replication technology.” Standardized process sequence The stability of two molders Benefiting from an optimized process flow and During development of the FUSION, a better disc handling, both throughput speed and configuration with a third molder was initially transport stability were improved. The process considered for increased throughput. Finally, the sequence is described here in more detail: process was optimized for two injection molders by upping the cycle time – and improving process Cooling stability. Coming from the injection molders, discs are stored vertically and rotated by a unique cooling "Higher molding speeds make a line with two screw mechanism (no cooling marks!) while molding machines instead of three or four more moving through the temperature controlled economical," adds Markus Frei. “Especially for cooling area under laminar airflow. Cooling time 16x media, where it’s tough enough to control the is 100 seconds at 2.5-second cycle times, with process to obtain a consistent output with two an outstanding mechanical disc shape (tangential molders – and nearly impossible with three!” and radial deviation).
Quality and stability Dye coating The newest version of FUSION2 benefits from The dye coating station provides excellent additional production experience and repeatability. Equipped with six dye cups to enhancements (radial deviations <± 0.35° and reduce cycle time, the dye is dosed by a reliable >300 hours of climate tests) - resulting in the “pressure time” tank system and a stock tank most efficient DVD R solution in the market. that automatically maintains filling levels without line interruption. The dye coating station FUSION2 now meets all book specs and also the maintains constant temperature and humidity more demanding customer requirements. levels with optimal particle and heat Process stability (including OD stability, management. mechanical performance after drying, L0 layer
Tracks 35 optical disc solutions
product profile FUSION SL
Drying Vacuum Bonding To evaporate all remaining solvents from the dye A “wet-to-wet” vacuum bonding process applies coating, the high-capacity oven (up to 400 discs, glue to both DVD halves, spin coats, aligns, and both active and dummy) has pre-heating, heating then joins them in a vacuum chamber eliminating and cooling zones for longer drying times. any air bubbles and providing consistent space Temperatures go up to 110° C for all dye layer thickness between the disc halves processes; no transport screws are used to avoid compared to other horizontal or angled bonding disc wear. The active and dummy discs are dried techniques. separately and the homogeneous “drying through rotation” process also provides better jitter values Curing compared to competitive dryer technologies, and Developed expressly for the FUSION applications, a better mechanical shape. the new UV curing process meets the strict 16x format specifications.
Keeping production costs low Our calculations clearly Because of constant market price pressure, indicate that superior disc producing new discs on highly efficient equipment becomes key for profitability. As demonstrated to quality enables higher many manufacturers, producing superior products with high yield and high overall uptime margins and a faster on our new line is far more profitable than trying payback… to save investment costs with converted CD-R lines.
Metallizing "We keep a close eye on quality,” says Markus Sputtering deposition of the reflective DVD R layer Frei. “Our calculations at production sites around has extremely low material costs due to the long the world clearly indicate that superior disc quality target life; the ARQ 930S sputter source sputters enables higher margins and a faster payback, 85,000 discs @ 120 nm or 200,000 discs @ 50 even with a higher initial investment.” nm. FUSION offers two metallizing options – Upgrading to HD DVD R single (SWIVEL) or dual cathode (CUBE STAR) Similar to regular DVD R discs in structure, but configurations – to meet a range of sputter power with a narrower wavelength blue laser to read and level, sputter target, and cost parameters. The write information, the higher storage capacity of dual cathode configuration runs a two-step the HD DVD R format means more stringent coating process at reduced power to prevent production specifications for the disc damage to the sensitive DVD R recording dyes. manufacturer, especially for the more sensitive Edge cleaning organic recording dye. These tighter specs This design allows cleaning after the information demand low tolerances for the bonding layer and layer is coated with a silver layer and protected dye uniformity. against the cleaning solvent. The 2-cup station is "Every FUSION line can easily be upgraded to HD fed by a “pressure-time” controlled tank system DVD,” says Markus Frei. “Our development efforts for non-stop operation. look to integrate emerging disc formats."
36 Tracks optical disc solutions optical disc solutions
product profile FUSION DL Leading in Dual Layer Production Proven cover layer process and high uptime assure reliable production
Markus Frei The DL DVD +R/-R disc formats set extremely stringent electrical and Product Manager mechanical production specifications. The FUSION2 DL line features Optical Disc “inverse stack” and “2P” technologies for reliable DL production. Business Unit From the beginning, technology partnerships with “For example, the tight thickness layer uniformity Philips and MKM enabled the development and requirements for the semi-reflective silver layer optimization of key process technologies to resulted in the development of the ARQ 950 produce both types of DL disc formats. cathode, and our bonding system really shows its full potential with DL formats because of its “With a robust process, our development teams extremely consistent “spacer layer thickness” upgraded the hardware platform to meet all DL uniformity. production requirements,” explains Markus Frei. optical disc solutions
This makes the FUSION2 line the ideal platform Bonding – meets bonding uniformity for DL formats. Based on the proven single layer requirements (± 5 µm) for the current 2.4x FUSION line, the DL line for the inverse stack (IS) recording speeds, and even for the coming 8x process integrates numerous updates to meet the version (± 3 µm); bonding uniformity is essential additional process requirements: to the production window and allows a larger production window at other process stations Reflective layer – additional metallizer to sputter (such as IMM) the L1 full reflective layer Conditioning module – after sputtering L1 layer “We can’t overemphasize the importance of our and before dye coating partnership with industry technology leaders,” Dye coating – additional tanks integrated for the says Markus Frei. “And it’s an advantage that different L0 and L1 dyes works both ways, because our line serves as a Extra layers – in addition to the protective layer development platform to optimize new disc step, an extra metallizer deposits a SiNx buffer formats. This cooperation gives FUSION2 an layer unbeatable advantage in product quality, and Superior bonding system for high SLT uniformity reliability.”
Space layer variation on track at r57
4 ...with extremely consistent 3.5 “spacer layer thickness” 3 uniformity FUSION is ideal 2.5
2 for DL formats.
1.5
1 “2P” and “Inverse Stack” technologies 0.5 Double layer DVD R discs have divergent disc
Space Layer variation on track (µm) 0 structures, which translates into two different processes; either the “2P” or “Inverse Stack” 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 No. of discs processes. The 2P process uses two production lines and a separation module to separate the dummy disc from the bonding layer – to deposit Process requirements for DVD+R DL the L1 layer in a subsequent process. The Producing DVD+R DL has many critical process Inverse Stack process simply adds the L1 layer areas: stack, similar to a DVD9 sequence, which can be Metallizing the L0 layer – with <±2% R/T (abs); done inline with a single FUSION2 DL replication same as the L0 layer for DVD 9, the reflectivity line. uniformity of this layer has a significant influence on both L0 and L1 signals, as it is in the optical “Oerlikon worked with partners and customers to path of both layers optimize an inline solution based on the Inverse Homogeneous full body drying of L0 and L1 Stack process for double layer DVD+R,” adds discs – even more than on single layer DVD R, Markus Frei. “And today almost all DVD+/-R DL identical history for both discs is essential for discs currently available in the market are the practical use (such as “time dependency of produced on our equipment, – either with our the disc shape”) metallizer or our DL bonding module – or both.” Low jitter values – extended and consistent Oerlikon is the most experienced partner for DL drying time keeps jitter values low, even for the disc production in the market. tight DVD+R DL end process window
Tracks 39 hard disk solutions
going from strength to strength in this section 50 Years of Breathtaking Advances In Pole Position with PMR RACETRACK for PMR Hard Disks hard disk solutions 50 years of breathtaking advances
Last year, the hard disk celebrated its 50th anniversary. It stretches the imagination to realize that the first hard disk launched in 1956, the RAMAC, weighed 2,140 pounds and held a mere 5 MB of data on fifty 24-inch platters, and cost US $35,000 (over $ 250K in today’s dollars) to lease! Current hard disks hold an incredible 1 Terabyte on a form factor small enough to fit in your hand. As storage capacities increase, form factors continue to shrink, so that a single 1-inch drive today can store 12 GB. Since the introduction of the first commercial solution represents another technological leap – drive the hard disk drive industry has gone and creates a great business opportunity for us through 50 years of continuous innovation. The and the manufacturer.” annual increases in hard disk areal density have Although a massive technological breakthrough, averaged approximately 100% since 1997 – PMR is by no means the end of innovation for leaving Moore’s Law far behind – and the future hard disks. Future concepts, such as patterned has never been brighter. Industry experts expect media technology, show the potential for another shipments during the next 5 years to equal 10x (or greater) increase in areal density. In view the total of the past 50 years! of the company’s long-term innovation priorities, This tremendous climb in storage Oerlikon recently began working as a research capacity is a result of extraordinary partner in our second EU-funded project, this advances in magnetic recording time to address the needs of patterned media. technology, going from magneto- While flash memory has recently received resistive (MR) recording heads in the considerable press as a potential mass storage 1990’s, to giant-magneto-resistive medium, and it will definitely play a key role in (GMR) heads, to today’s perpendicular smaller form factors (such as the iPhone). But magnetic recording (PMR). PMR the reality is that flash continues to be much more enables hard disks to meet the expensive than hard drives. In addition to cost, continuing demand for increased hard disks are also better at performance, storage capacities by increasing especially in terms of write speed. the areal density of the drive by as much as 10-fold. “High-end and high-capacity applications will continue to be served by hard disks for cost The PMR magnetic storage reasons,” says Stefan Seifried. “Customers want technology is a showcase for to store the data in one place and have instant our innovative development data accessibility – that’s the key to success in team,” explains Stefan the future.” Seifried. “The RACETRACK
Photographs courtesy of Hitachi Global Storage Technologies & Seagate Technology
Tracks 41 hard disk solutions In the Pole Position with PMR
Recently celebrating its 50th anniversary, the hard disk industry – among the most dynamic and innovative of any high tech market – is going from strength to strength: a breakthrough storage technology (PMR) and an unimaginable array of popular consumer and professional applications. Leveraging over 20 years of experience in the hard disk market, Oerlikon launches RACETRACK, an all-new PMR production solution, with high ambitions. Stefan Seifried About 30% of the world’s output is produced on consoles, and a number of products we have not Head of Hard Disk Oerlikon systems such as the well-known even thought of yet. Key factors in the hard Business Unit CIRCULUS, but the market remains far from fully disk’s popularity are high-performance memory tapped. Hard disks are ubiquitous today, due to and extremely small form factors. superior achievements in cost, performance, size and reliability. Once largely confined to They have changed most aspects of both our computers, today’s hard disks are at the heart of professional and private lives. Just consider the the latest generation video recorder, MP3 players, transformation in health care, banking, shopping, flat-screen TVs, navigation entertainment, and the way in which we gather systems, ultra-flat and store information, all the way to how we take cell phones, and store photographs. Higher Internet video bandwidths allow ever-larger amounts of data to game be transported, but all this data not only has to be transported and processed, it also has to be stored.
In order to manufacture hard disks that meet the varied demands of today’s applications, it takes a first-class coating technology. It all starts with aluminum disk blanks or special glass disk blanks (substrates) anywhere from 20 to 95 mm in diameter. Cleanliness is a top priority for the production process. Even the tiniest particles in the coating can cause serious errors later during S N S N S N data writing and reading. For this reason, hard disks are made in clean rooms and under vacuum, for example, as with the new RACETRACK line. N S N S N S
Perpendicular Recording Soft underlayer“mirrors”write head and makes it possible to write domains much closer together.
42 Tracks hard disk solutions
“One of the innovations by the RACETRACK development team that I am most proud of is the system’s total accessibility, which allows much faster maintenance than anything on the market,” adds Stefan Seifried. “In addition, we have the fastest and cleanest transport available, and unique process components like a production proven multi-layer and RF cathode.”
Oerlikon Data Storage delivered the first RACETRACK system to a well-known Asian hard disk manufacturer last year. Installed and ramped-up by our local service team, which was a team effort with backup from our headquarters R&D experts and the business unit, the system is now up and running. After three months, the magnetic performance of the produced disks Cross sectional view of The RACETRACK advantage already outperformed the results from a a (15 bi layers) CoPd Dr. Stefan Seifried, Head of the Business Unit competitive line – a notable confirmation of the hard disk specimen for perpendicular recording Hard Disk is excited about RACETRACK, the new reliable RACETRACK design and technology. with soft magnetic NiFe coating system from Oerlikon. There is a good underlayer (laminated reason for his enthusiasm; after almost three “Oerlikon is now in negotiation with another with carbon) years of intensive R&D, he and his team have customer and will soon deliver a second system adapted the innovative PMR technology for hard in 2007,” adds Stefan Seifried. disks – and set new production standards at the same time. The prospects for further market success remain excellent for RACETRACK. Future storage media He exclaims, “RACETRACK beats all previous requirements will increase and more consumer production records for speed, productivity, products are being equipped with small and efficiency and flexibility!” smaller hard disks. With the PMR technology now quickly supplanting the previous LMR The RACETRACK technology also sets standards process, hard disk manufacturers will have to in ensuring faultlessly clean work processes with replace their entire production lines during the a linear layout and individual modules consisting next four to five years. of four vacuum chambers each. This configuration enables a compact setup geared to A vision of the future individual customer needs. Placed in rows, the It’s increasingly clear that magnetic storage will modules form a self-contained system with up to continue to grow as the predominant digital 24 inter-connected coating chambers (stations). storage technology for the near future. In addition to the increasing number of consumer Each blank is individually clamped into a carrier applications, new production processes – such (transport slide). This transport system features a as RF or multi-layer – and new materials will play completely new type of magnetic linear drive. a key role in helping keep this technology up with Developed for RACETRACK and operating at the unceasing demand for ever-higher storage maximum speeds, the carrier catapults the hard density / capacity. disk substrates from chamber to chamber in less than 0.7 seconds indexing time. This allows the The challenge of permanent technology disk manufacturer up to 2.9 seconds for each innovation plays to an Oerlikon strength. process stage, resulting in an hourly throughput Leveraging our experience and the know-how of 1,000 disks – world record! RACETRACK pool of our people, we can offer our customers boasts the largest throughput in the market per the bandwidth that can make collaborative R&D footprint, along with excellent process quality and the most promising way towards breakthrough unmatched efficiency. production solutions.
Tracks 43 hard disk solutions Faster and Faster with RACETRACK Our new hard disk platform enables PMR media at high throughput and future processes
Maximum output, ultra-short processing time, and quick disk transport are just three of the many superlatives to describe RACETRACK, the new hard disk coating system from Oerlikon. Built to enable production of hard disks of all formats – using PMR technology – the first system is now up and running at the Asian production site of a leading manufacturer.
Ralph-Ch. Ohr Based on a modular system concept, the innovative new “RACETRACK has Product Manager hard disk line profits from proven component technology Hard Disk derived from the company’s legacy of industry standard the highest disk Business Unit production platforms. The processes needed to produce the next generation PMR products – e.g. multi-layer throughput per sputtering, extensive heating and an improved carbon overcoat process – also contribute to the cost-efficiency of square meter the RACTETRACK system. footprint…and the “The advent of PMR has accelerated the shift to new lowest investment manufacturing platforms to produce the more complex layer stacks,” explains Stefan Seifried, Head of SBU Hard Disk. dollar per unit of “The other imperative was increasing throughput and yield so the manufacturer could meet the constantly growing throughput…” demand for media.” hard disk solutions
Customer collaboration “The needs of the disk manufacturers contributed The design of the RACETRACK system is a to RACETRACK already in the early conceptual follow-up on former company-owned designs phase of development,” adds Stefan Seifried. based on two parallel rows of horizontally aligned “The result is a platform that is both very quick, process chambers that can be expanded to meet but robust as well.” specific customer specifications. This layout Flexible layout and quick maintenance enables high throughput through the The RACETRACK system allows addition and simultaneous, double-sided deposition of all subtraction of process chambers in increments of substrate dimensions. Above: four without any special alignment procedure, up A close-up of the Production begins when the substrates arrive to a total of 24 chambers. The smallest process heating station in RACETRACK. from the clean room area and are loaded into the module uses a novel design to incorporate four system by means of a three vacuum stage process chambers with all necessary hardware Left: loading module (with a hard isolation between the services and power supplies for an easy link up Modular: The first load lock and the process chambers). and efficient use of space. RACETRACK system Possible R&D and production processes include: expands to 24 process A further priority in the RACETRACK design was chambers without any SUL sputtering to assure easy access to all relevant parts from special alignment procedures. DC sputtering the same side of the system to help reduce RF sputtering maintenance times. For example, both the Heating targets and shields – for both chamber sides – Cooling can be accessed from one side of the line. The Multi-layer sputtering gate valve can also be quickly replaced (entirely, IBD carbon or in part) without removing the entire body. Glass bias Cabling and supplies are clearly arranged for fast error diagnostics and all normal maintenance can The system layout and process sequence were be carried out without the use of pulleys or similar developed in cooperation with selected tools. technology partners / customers in extensive discussions and prototype test sessions. This A normal maintenance visit, including a regular collaborative process assured Oerlikon of a target and shield exchange (after chamber purge), solution that would address not only the technical together with inspection and cleaning of the issues of producing reliable PMR media at high chambers, takes less than 3.5 hours from system throughput levels, but also provide cost-efficiency stop to restart. through economical use of materials and high uptime.
Tracks 45 hard disk solutions
Fastest transport in the market minimize contamination at the magnetic layer With target throughputs of up to 1,000 disks / interfaces to assure good magnetic performance. hour, RACETRACK features a magnetically driven As some PMR processes require longer process transport system that is the only and also times, clean interfaces enable splitting these quickest solution for single media currently on the processes to increase throughput. Left: market. With the driving force applied solely Fast: The magnetically The disk substrate is held in a carrier during all driven transport system through the chamber walls, the linear transport process steps. The upper part of the carrier has enables throughputs of works independently for each chamber without up to 1,000 disks / hour. four notched springs (based on an improved any feedthrough. Both the drive and gate valves CIRCULUS design) and the lower part eliminates function as an integrated unit, and two lift Right: a possible source of particles with our wear Specialized: The new modules transfer the substrates from one row of resistant coating. ARQ 21 RF cathode process stations to the other. features a compact Unique cathode and process solutions design with Further system highlights include: integrated RF matching. The Oerlikon traditions of high uptime and “lowest Unique magnetic linear (chamber to chamber) cost per disk” values are maintained in drive for < 0.3-second transport times RACETRACK, exemplified by the intense Accurate and precise linear carrier positioning; development efforts for the system’s cathodes including outstanding positioning inside the and process utilization levels. chamber (accuracy < 0.2 mm) For example, both the ARQ and TRIATRON Active spring gripping eliminates ‘disk drop’ cathodes were developed expressly for current and optimizes disk transport speed and emerging PMR processes. The newly Optimized chamber design that minimizes the developed ARQ 21 RF cathode features a transport distance compact design with integrated RF matching. Newly designed gate valve with ultra-fast With over 600 similar cathodes in use for optical opening and closing times (< 0.2-seconds) disc production, the design is production proven. Outstanding 2.9-second process times thanks The TRIATRON multi-layer cathode family has to fastest transport system on the market unique DC and RF sputter capabilities for both Overall, any yield loss due to particle generation is R&D and full production applications. It is minimized by the particle management capability currently in use with several large hard disk built into RACETRACK. Based on a proprietary manufacturers. wear-resistant coating (developed by Oerlikon In addition, our IBD carbon source enables the Balzers Coating) on all guide rollers and carrier key carbon overcoat for PMR media. The IBD bars of the transport system, production tests source is self-biased (no glass bias necessary) have shown no discernible particle generation – with excellent carbon uniformity (< 3% for 65 mm even after a three-month run time. disk diameter), and its built-in self-cleaning Smooth disk processing function is a key part of the RACETRACK The substrate carrier is positioned in the chamber platform’s particle management capabilities. while the gate valves separate each process With target utilization levels of up to 60% our chamber from another. Fast transport, together processes work extremely efficiently and with excellent vacuum levels (< 5 x 10-8 mbar), especially help hold down costs in times of high
46 Tracks hard disk solutions
“Increased throughput and yield enable the manufacturer to meet the growing demand...”
target material prices (e.g. ruthenium). But the low cycle times are what really allow RACETRACK to offer the highest process utilization levels in the market. The cycle time consists of process and ‘indexing’ times. Process times can be easily lowered by improving load/unload handling speeds. However, indexing times – a sum of many parameters (chamber volume, transfer time, gate Right: valve speed, gas stabilization, etc.) – cannot be Carbon gun: The IBD easily reduced, and require major system carbon source enables the ultra-thin carbon modifications. After extensive development and overcoat for PMR testing efforts, indexing times for RACETRACK media. are now very short – for the highest process utilization levels, enhanced process flexibility and A Tradition of Excellence: Below: cleanliness. RACETRACK system specifications Versatile: The proven The new RACETRACK system, drawing from the TRIATRON multi-layer cathode provides unique “The high process utilization contributes to further manufacturing proven technologies of both the DC and RF sputter leading performance specifications found in CIRCULUS and DVD SPRINTER production capabilities. RACETRACK,” adds Stefan Seifried. “This platforms, offers a number of industry-leading includes the highest disk throughput per square performance features: meter footprint in the market, lowest investment 2 dollar per unit of throughput, and extremely low Highest throughput per footprint m cost of ownership.” Fastest transport time (0.3-seconds), resulting in 0.7-second process-to-process times Versatile software concept Excellent base pressure (< 5 x 10-8 mbar) for Drawing from the success of our CIRCULUS and clean processing DVD SPRINTER platforms, RACETRACK runs the Up to 23 process chambers; separated by PC-based WONDERWARE‘ system software. enhanced gate valves Adding, changing or subtracting Easy modular configuration allows complete components (cathodes, pumps, mass process flexibility flow controllers, etc.) is easy to do Proven technology: handling, loading and by any trained operator. Built-in processing concepts for all form factors (0.85- self-teaching modules show 3.5 inch diameters) how to manage the handling Fast target exchange time (<1 minute after and transport components, chamber purge) ensures quick return to full and all recent process production parameters (sputter Open system design with easy access to all pressure, gas-flows, maintenance relevant parts and consumables sputter voltage, etc.) can from one side of the system without any be logged – with min / special lifts or pulleys max and average values. Finally, system software updates are easily done during regular system maintenance.
Tracks 47 service solutions
keeping uptime in line in this section Changing the Rules by Improving our Service A Day in the Life of a Service Engineer service solutions Changing the Rules by Improving our Service Disc manufacturers, who depend on high equipment uptime for Bill Marsh profitability, are fed up with bad service. The most common – and Vice President irritating – scenario is a field engineer showing up at the wrong time Customer Support without the right information, without the skills or spare parts to successfully carry out an equipment repair. It’s time for a change.
There’s a saying in the field service industry that Our customers operate in a front-end supply says, “If you continue to do what you’ve always chain, where materials flow from supplier to done, then you will continue to get what you’ve manufacturer to retailer in a fairly linear fashion. always got.” However, the after-market service supply chain adds an entirely new dimension because of highly This is why Oerlikon recently stepped up its focus customized equipment configurations, unique on continuous improvement of our support production processes, a widely dispersed capabilities and ensuring that we offer the best installation base, spares depots, third-party possible service to disc manufacturers anywhere logistics providers, customs and field engineers, in the world.
Tracks 49 service solutions
and with parts and people moving around the The customer benefits because of our enhanced globe 24/7 on a moment’s notice. To ability to identify specific areas in our production accommodate today’s level of additional equipment that require improvements, based on complexity, a greater degree of training and how the system operates in the production line. sophisticated management capabilities are FRACAS also provides real-time tracking of needed. equipment downtime by our technical support group. This allows improved field and factory For mutual success response when equipment issues become To address these needs, the top priorities for urgent. Oerlikon are to develop our resources to manage the ever-evolving production technologies, and to Managing spare parts maintain an infrastructure that can efficiently As our customer service operations continue to manage our customer’s needs. We understand improve and expand, the goal of delivering better that investing the time and money in training – for service and controlling costs remains crucial. us and our customers – is vital to our mutual Traditionally, managing a global spare parts success (and profitable growth). inventory is one of the most difficult challenges. To improve our management systems we recently Despite the permanent unpredictability of parts completed implementation of the “Mobile Engine” demand, Oerlikon continually works to optimize SAP service module across all our regions to spare parts inventories. The recent assure better planning and dispatching of our implementation of a regular inventory analysis and service support teams. This module will data driven safety stock adjustments based on With today’s level of complexity, a greater degree of training and management capabilities are needed…
significantly improve scheduling, utilization worldwide product consumption will better ensure tracking, match an engineer’s skill more precisely a ready supply to our customers. Additional with job requirements, capture detailed measures for 2007 include close partnering with equipment repair information, and streamline our our customers to better understand production service order processing. requirements and spares consumption. With this collaboration, we can develop winning scenarios Responding in real-time that balance the risk and cost factors of optimal Linked to this SAP module, we have also stocking levels. developed and introduced a Failure Reporting, Analysis, and Corrective Action System (FRACAS) Managing logistics that will provide an improved process to control For every business manager working in today’s our corrective actions. A closed-loop system, ‘overnight’ economy, logistics is one of the areas FRACAS will enable Oerlikon service teams to where continuous monitoring of costs, on-time quickly collect, classify, and quantify incoming delivery, and constant efforts to improve on-time activity reports for installations, field & technical delivery rates is crucial (not to mention the new support actions, and repair data. With detailed and increasingly complex import and export analysis and a repair/performance knowledge compliance rules being implemented in most base available to all relevant teams within the countries). company, this will help us improve our With an installation base of >4,000 optical disc manufacturing quality, product reliability, and and hard disk systems around the world, Oerlikon reduce the system installation and repair times. currently works in over 100 countries. This
50 Tracks service solutions
requires increased efforts in our global logistics capabilities. We have developed a centralized logistics function that is staffed with a group of localized specialist throughout the world. In addition, we are working with the very best logistics service suppliers to help extend world-class services to our growing customer base. The lessons we’ve Tailoring programs for you learned enable In summary, 2006 was a very busy year for Oerlikon. We evaluated our internal service processes and – with the help Oerlikon to (better) of our customers – assessed the strengths and weaknesses in our service value chain. The lessons we’ve learned from meet and this review enabled Oerlikon to develop new and more exceed…customer relevant performance models and standards in the coming year – to meet and exceed both the customer expectations expectations… and our own performance goals. Our expanding training capabilities allow us to customize programs that suit a customer’s particular needs regarding equipment maintenance and production processes – from basic operation all the way to advanced vacuum and process development concepts. Please contact your local Oerlikon Service Manager or Sales Account Manager to learn more about what we can offer.
Tracks 51 24/7 24 Hours in the Life of a Service Engineer
Eric Barbian, Field “My work starts once the replication line is delivered,” explains Eric Barbian, Service Engineer for Oerlikon Field Service Engineer for optical storage customers in North America. the North America “In fact, it’s really the beginning our relationship with the customer.” region, gives a closer With a degree in Laser-electro Optics, Eric has a notable amount of experience in look at what it means the optical data storage field and has been taking care of Oerlikon customers for to “keep throughput the past five years. Responsible for keeping production lines humming as far north as Ottawa, Canada and as far south as Guadalajara, Mexico, he’s at and uptime high.” production sites for about 75-80% of his time.
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Oerlikon has a very diversified client structure across the North American region, from many small to mid-size clients in niche markets to giant replicators serving all major Hollywood studios. It’s a team effort for the Oerlikon service experts, as the field service engineers are not tied to specific customers. Regardless of the customer, every service call is different even if the general routine is the same.
Counselor and cheerleader – and more “First you listen to the problem described by the customer. Second, you try to witness the problem yourself if possible. At this point, you assess the cause and try to repair the problem,” explains Eric Barbian. “This is why you need a keen sense of observation and good listening skills in this job.” 24/7 and Blu-ray However, even with all these skills, from time to Eric adds: “We have a 24 hour on-call service time there are tough moments for a field service and offer various support packages, including engineer, for example, with a frustrated client: permanent on-site support. Some customers “Sometimes we are counselors, cheerleaders, have my cell phone number, so they can reach punching bags, and even saviors for our me at any time – and sometimes they do!” customers,” adds Eric Barbian. “A system that’s The recent introduction of Blu-ray is also behind down can always be repaired, or the process can the flurry of travel activity: “This past year a lot of be changed. But changing a customer’s my recent travel was about the new Blu-ray perception of us – that can take some time!” format and ramping up production at the various Striving for mutual success sites,” adds Eric Barbian. “The first new INDIGO Such situations are the most difficult part of the line in the world was installed in California and job and the field service team responds by Blu-ray is doing very well in our region. Because providing the best service possible. Over time, it’s also a completely new high definition disc the relationship grows with each customer, which format, it’s important to check in to make sure also improves communication: “Our job in the everything is going well.” field is not only to repair the equipment but show Strangest problems the customer that Oerlikon is dedicated to their Even with the mileage a service engineer accrues needs and their success,” says Eric. “If our during the year, a surprising amount of work is customers are successful, then we will be done over the phone. Usually the Oerlikon team successful.” is contacted at the point when no one else at the “I began with mastering systems, working in customer facility is able to resolve the problem, clean rooms and aligning lasers. From there I so they initially try to find a solution by asking a learned about repairing metallizers, and finally, lot of questions. now I am making Blu-Ray discs,” summarizes “This means that we get the strangest and most Eric. “I never have time to get bored. It’s a awkward problems,” he explains. “They can wonderful job and it’s great to work for a range from intermittent signal loss to vacuum company dedicated to being the industry leader. leaks caused a tiny hole in the swivel head. It’s That means we are constantly striving to improve always something new.” our service and our products.”
Tracks 53 Your Oerlikon Contacts
EUROPE CHINA KOREA JAPAN Oerlikon Balzers AG Oerlikon (Shanghai) Co., Ltd. Oerlikon Korea Ltd., Seoul Oerlikon Japan Co. Ltd., Tel +423 388 4870 Tel +86 21 5057 4646 Tel +82 31 785 1300 Tel +81 3 3225 9020 Fax +423 388 5426 Fax +86 21 5057 4647 Fax +82 31 785 1357 Fax +81 3 3225 9043
NORTH AMERICA SINGAPORE TAIWAN EMERGING MARKETS Oerlikon USA Inc., Oerlikon Assembly Equipment Pte Ltd Oerlikon Taiwan Ltd., Oerlikon Balzers AG Tel +1 949 863 1857 Tel +65 6303 7000 Tel +886 3 500 1688 Tel +41 81 784 4706 Fax +1 949 863 1866 Fax +65 6873 1133 Fax +886 3 583 3708 Fax +41 81 784 5426
Region Country Place Oerlikon Agent Tel No. Europe Liechtenstein Balzers • +41 81 784 4706 Germany Munich • +49 8975 505 202 The Netherlands Utrecht • +31 3024 26 320 Spain Madrid • +34 91 222 7179 Italy Alurno • +39 02 932 5744 Russia Moscow • +7 495 131 9272 Greece Chalandri • +30 210 674 8973 Asia Israel Kfar-Azar • +972 3 635 6650 Japan Tokyo • +81 3 3225 9020 Taiwan Hsin Chu • +886 3 500 1688 China Shanghai • +86 21 5057 4646 China Shenzhen • +86 755 8826 4058 Singapore Singapore • +65 6303 7000 Korea Kyungki-Do • +82 31 785 1300 India Hyderabad • +91 40 2332 413 Americas USA Irvine • +1 949 863 1857 Brasil Sao Paulo • +55 11 5097 6450 Argentina Buenos Aires • +54 11 4331 5766 Chile Santiago • +56 2 231 8877 Colombia Bogota • +57 1 335 1100 Venezuela Trinidad • +58 212 944 2010 Peru Miraflores • +51 1 445 0181 Australia Australia Milsons Point • +61 2 9954 1925 Africa South Africa Halfway House • +27 11 315 5434
Austria, Poland and the Czech Republic are covered by Oerlikon Germany. Portugal is covered by our Spanish agent. Scandinavia is covered by Oerlikon Netherlands. South East Asia is covered by Oerlikon Assembly Equipment Pte Ltd.
For full Oerlikon contact details visit www.oerlikon.com/datastorage
54 Tracks Additional photography: Cover / p26: Photodisc courtesy of Reflex Stock p 8: (Man Watching TV) Mike Watson Images courtesy of Reflex Stock p 48: © iStockphoto.com / Manfred Steinbach www.oerlikon.com