DVD Production Process

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DVD Production Process Key Factors for Quality
Discs

• Verbatim, Product MarketingMar., 2005Ronan
  Ryan/Satoshi Wakabayashi

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Revenue 18 billion (March 2004) 33,500 employees
(1,500 in USA) Performance Chemicals,
Pharmaceuticals, Petrochemicals
100 Subsidiary of Mitsubishi Chemical Co. Total
Revenue 650 million Optical Disc, Magnetic
Media, Flash Memory
100 Subsidiary of Mitsubishi Kagaku Media
CO.,LTD.
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Verbatim / Mitsubishi Kagaku Media Group

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

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Global Supply Chain
Frankfurt, Germany Verbatim European DC
Sunnyvale, CA MFD/Tape Coating
Tokyo , Japan Mitsubishi Chemical Corp.
Egham, UK Verbatim EUMEA HQ
Odawara , Japan VAP DC
Toronto Canada Canada DC
India DVDR, DVDRW CD-R
Mizushima, Japan MO, UDO, Stampers
Charlotte NC Verbatim USA HQ USA DC
Taipei, Taiwan Floppy, CD-R/RW DVDR, DVDRW
Shenzhen, China VAP DC
Hong Kong VAP DC
Tijuana, Mexico Floppy/CD-R
Singapore DVDR, DVDR DL DVDRW
Uruguay Verbatim South America DC
Headquarters Distribution Manufacturing
Melbourne, Australia VAP DC
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MKM Core Competencies
Fast Dry Printable
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Verbatim Product Direction

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

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Verbatim Brand

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

Source Santa Clara Consulting Q4 2004
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Major Cause of Problem
Recording layer (Dye) has problem
Good dye, good media shape and optimized write
strategy
Effect of bad media shape
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Production Process of R-DVD
(Recording Side)
(Dummy Side)
Inspection
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Injection Process

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

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Mastering Process Design of Mold

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

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

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Dye Coating Drying Process

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

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Dye is Important!
Even though you optimize the process condition,
you have no chance to producequality discs using
wrong dye.
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Sputtering Process

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

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Bonding Process

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

Aging Test Result for Selection of the Glue
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Inspection Process

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

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Writing Strategy
Every dye material has its own recording
characteristics, so recoding power and laser
exposing timeshould be optimized separately for
the quality recording . (Writing Strategy WS)
00100000100..
00100001000..
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Summary of Key Factors for Quality Discs

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

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Verbatim (MKM)

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

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Bottom Line

• We are convinced that we are supplying quality
  discs in terms of complete compliance with
  industry specification (DVD forum, DVDRW
  alliance) and superior compatibility with all of
  major writers
• We are developing discs and materials very
  carefully with paying attention to both recording
  performance and durability
• We are supporting the efforts by NIST to better
  define archival test methods.

Thank you for your time!