Solar Semiconductor's manufacturing facilities near Hyderabad, India are ISO 9001:2008 certified facilities for their quality management systems. The 'Fabcity' campus spawns over 50 acres with state-of-the-art manufacturing equipment and a world-class testing laboratory for internal certification and qualification. The manufacturing facility set up at this campus boasts of automation at crucial steps of the process. This campus will also fuel our future expansion into another 50 acres already allotted by the Govt. and will provide many infrastructure advantages and financial incentives. The 'Kompally' plant near Hyderabad is self-contained in terms of quality control facility & laboratory, engineering and services. We have a highly dedicated and motivated workforce with requisite experience. 

We are currently implementing various world-class lean manufacturing practices like 5S, Quality Circles, Six Sigma (SPC implementation) and also an ERP (SAP) system. Around 21 quality circles are in operation on various projects.
 

Module Assembly   Plant Capacity and Layout   Process & Important Machinery

Explore our state-of-the-art  PV manufacturing facility

Module Assembly

Both automatic and manual assembly processes are operational. In the auto mode, the assembly process may be automated and computer controlled. Incoming cells are tested for defects using vision and other systems. Defective cells are automatically sorted out before the tabbing/stringing process. The strings of cells are automatically laid up in the desired configuration (on glass and EVA cut to size) by robots that ensure proper spacing between strings. Another layer of EVA is followed by Tedlar ® back cover and the fully laid up module is tested prior to the lamination process. 

After lamination, a robotic station will trim the edges, fix a foam tape around the edges and frame the module. These modules then undergo several Quality Control checks and high voltage tests. The performance of every module is verified in a Sun-simulator and documented prior to shipment.


Plant Capacity and Layout

Solar Semiconductor operates multiple manufacturing lines at Fabcity facility and Kompally facility with an overall annual module capacity of 195 MW. The layouts of both the plants are in line with the process flow with adequate space for storage and movement. 180,000 sq ft of space is currently utilized in the 50 acre Fabcity campus for Cell & Module manufacturing, World class testing laboratory and ancillary workshops. In the Kompally facility, over 43,000 sq ft of space is allocated for module production, storage, training and office space.


Process and Important Machinery

Solar Semiconductor manages its operations through the implementation of thoroughly documented process related procedures and work instructions.

Following pre-requisites are assured for production and service provision: 

• Availability of product specifications and drawings.
   

• Availability of work instructions for process, testing and packing operations.
   

• Suitable equipment for manufacturing along with their usage instructions. 
   

• Suitable test and measuring devices with their usage instructions. 
   

• Availability of spares for servicing the customer complaints.
   

• Training of servicing personnel for field maintenance. 
   

• Record of service activities in customer complaint register. 
   

• Implementation of release, delivery and post delivery activities.

The production process of module assembly includes cell segregation, cell tabbing, cell stringing, lay-up , lamination, edge cutting & trimming, foam tape fixing, framing and junction box fixing and the other supporting material preparation activities, which include EVA cutting, TPT cutting, glass cleaning, work shop and laser cutting.