IN THE MANUFACTURE OF a-Si PHOTOVOLTAIC MODULES

The existence of a-Si as a viable technology for large s cale power generation depends to a large extent on whether the cost per watt can be sufficiently reduced. Substantial improvements have been made in the fundamental science of a-Si energy conversion. An equally compelling challenge is to incorporate improvements into a manufacturing process so that process is reliable and cost competitive. Early attempts at Solarex to transfer technology from the laboratory environment into a manufacturing line were diastrous. Yields at electrical test were routinely in the 10 to 50% range. Changes were made, sometimes several daily, to each individual process in an attempt to remedy the situation. The net effect was dozens of changes occurring simultaneously, further complicating the underlying problems and making failure analysis an insurmountable task. This paper will outline t he structure that was put into place at Solarex that allows for the smooth transfer of technology that is learned in research and development to a productive manufacturing line. The structure is composed of six basic parts manpower specialization, process control and documentation, product simplification, lot tracking, commitment to quality, and controlled experimentation. Each of these parts is essential for the system to become an effective tool for producing a reliable, low cost product. Upon formation of the manufacturing engineering group, an engineer was given responsibility f or a single or small number of