Production due diligence - Schmit Zonwering & Rolluiken Factory Audit Report.pdf · Production due...

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Production due diligence

Report of Factory Audit of

Ningbo Ulica Solar Science& Technology Co., Ltd

Version 001D

Developer:

Westerveldsestraat 81

6842 BS Arnhem, The Netherlands

[email protected]

Technical Advisor

SunChine Ltd.

Add: Room1222,Cameo Center No.2 Building,

No.16 Guangshun Nan Avenue, Chaoyang, Beijing,China 100102

Tel:+86-(0)10-64363501 Fax:+86-(0)10-84764113

Email: [email protected]

Web: http://www.sunchine.nl

mailto:[email protected]


http://www.sunchine.nl/

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Document control

Version

Version Date Comments

001A November 29, 2012 Technical report draft by Cheney Chen

001B December 4, 2012 Draft updated by Tony Wang

001C February 7, 2013 Draft updated by B. Bink

001D February 8, 2013 Final version by Tony Wang, B. Bink

Distribution list

Name Company

Tony Wang SunChine Ltd.

Cheney Chen SunChine Ltd.

Bastiaan Bink SunChine Ltd.

Rene Moerman SolarIF

Appendixes

No. Title No. Title

1 Factory Audit Announcement 11 OHSAS 18001 Certificate

2 Product Datasheet 12 Flash Test Devices Calibration Report

3 Modules TUV Certificates 13 Solar Cells Inspection Standard

4 CE Certificates 14 EVA Inspection Standard

5 MCS Certificate 15 Backsheet Inspection Standard

6 Salt Spray Test Report 16 Junction Box Inspection Standard

7 Ammonia Corrosion Test Report 17 Front Glass Inspection Standard

8 UL Certificate 18 Outgoing Quality Control Inspection Standard

9 ISO 9001 Certificate 19 Customer Complaint Response Report

10 ISO 14001 Certificate

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Contents

1. Introduction .......................................................................................................................................... 4

1.1. Disclaimer ................................................................................................................................. 4

1.2. Purpose of this document ........................................................................................................ 4

1.3. Participants of the factory audit ............................................................................................... 4

1.4. Abbreviations ........................................................................................................................... 5

2. Summary .............................................................................................................................................. 5

3. General Information about the Company ............................................................................................ 6

3.1. Company profile ....................................................................................................................... 6

3.1.1. General information ..................................................................................................... 6

3.1.2. Vertical integration ....................................................................................................... 7

3.1.3. Technical roadmap ........................................................................................................ 7

3.1.4. Project references ......................................................................................................... 7

3.1.5. Local services & Warehousing ...................................................................................... 8

3.2. Product information ................................................................................................................. 9

3.2.1. List of solar modules ..................................................................................................... 9

3.2.2. Product certifications ................................................................................................. 10

4. Module factory inspection ................................................................................................................. 12

4.1. Manufacturing process ........................................................................................................... 12

4.1.1. Manufacturing process flow chart .............................................................................. 12

4.1.2. Manufacturing process description ............................................................................ 12

4.2. Quality Assurance system ....................................................................................................... 17

4.2.1. ISO certifications and implementation ....................................................................... 17

4.2.2. Machine calibration and maintenance ....................................................................... 19

4.2.3. In-house lab-testing .................................................................................................... 20

4.2.4. Products tracking control management ..................................................................... 20

4.3. Quality Control ....................................................................................................................... 21

4.3.1. Quality Management organization chart.................................................................... 21

4.3.2. Incoming Quality Control (IQC) .................................................................................. 22

4.3.3. In Process Quality Control (IPQC) ............................................................................... 24

4.3.4. Outgoing Quality Control (OQC) ................................................................................. 25

4.3.5. Customer Engineering Services (CES) ......................................................................... 25

4.4. In-line product inspection ...................................................................................................... 26

4.4.1. Random solar modules test ........................................................................................ 26

4.4.2. Randomly selected solar modules flash test data ...................................................... 26

4.5. Conclusions of factory inspection .......................................................................................... 27

5. Comments and recommendations ..................................................................................................... 28

6. Factory audit conclusions ................................................................................................................... 29

6.1. General result ......................................................................................................................... 29

6.2. Results .................................................................................................................................... 30

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1. Introduction 1.1. Disclaimer This report has been prepared in accordance with SunChine’s factory QC audit procedures, based on

its extensive knowledge and experience in Quality Control (QC) and Quality Management (QM) in PV

industry in China.

The conclusions drawn and suggestions made in this report are based on information received from Ulica Solar (Ningbo Ulica Solar Science& Technology Co., Ltd) directly, which is assumed to be correct

and on information collected and observations made by SunChine during the factory audit.

SunChine does not allow the use of its Trademarked logo by any 3rd parties and Ulica Solar warrants

the use of this report to be solely for its intended purposes.

The receipt of this document by their addressees implies full acceptance of this “Disclaimer”.

1.2. Purpose of this document Purpose of this report is to serve as a basis for SolarIF and its insurer(s) for deciding whether or not

to make Ulica Solar module products insurable under its insured warranty insurance policy. SolarIF

and its insurer(s) may grant a certificate as proof of successful qualification. This report by

SunChine Ltd. (hereinafter also called Technical Advisors), is solely an analysis of current QM and QC

practices and if needed also contains recommendations for future improvements. The report does not

analyze the company Ulica Solar from a financial or any other point of view. SunChine has prepared

this report specifically at the request of SolarIF for a factory audit. It is based on the inspection visit

to the Ulica Solar factory on November 23, 2012 by SunChine Ltd. staff. The following factory has

been visited:

Factory address: No.181 Shanshan Road, Wangchun Industrial District, Ningbo,China

1.3. Participants of the factory audit

Name & Title Company

Quality Assurance Manager, Tony Wang SunChine Ltd.

Quality control engineer, Cheney Chen SunChine Ltd.

Chief Strategy Officer & Founder Rene Moerman SolarIF

Global sales director, Jerry Zhou Ulica Solar

Sales manager, Terry Wu Ulica Solar

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1.4. Abbreviations

Abbreviations used in the report

EL—Electroluminescence OQC—Outgoing Quality Control

IEC—International Electro-technical Commission QA—Quality Assurance

IPQC—In-Process Quality Control SOP—Standard Operating Procedure

Ipm—Maximum power current STC—Standard Test Conditions

IQC—Incoming Quality Control TS—Technology Support

Isc—Short circuit current Voc—Open circuit voltage

ISO—International Standardization Organization Vpm—Maximum power voltage

2. Summary Ulica Solar (http://www.ulicasolar.com) is a company established by Shanshan Group who is one of

the top 500 enterprises in China. It is a professional manufacturer specializing in producing solar

cells, solar modules and providing solar system integration service.

SunChine staff visited Ulica Solar factory, investigating on behalf of SolarIF whether the

manufacturing process employed by Ulica Solar and the crystalline PV modules produced by Ulica

Solar meet certain operational and technical standards respectively. This information is used by

SolarIF and its insurer(s) as a basis for deciding whether or not to make Ulica Solar module products

insurable under the SolarIF insured warranty insurance product. SunChine announced the factory

audit a week before November 23, 2012, which announcement was subsequently accepted by Ulica

Solar.

The Factory inspection took place on November 23, 2012. Audit announcement can be found in

Appendix: APP01 Factory Audit Announcement.

The factory inspection was divided into four parts: 1) Collect general information about Ulica Solar

and its factory; 2) Audit factory process & quality inspection; 3) In-line production inspection; 4)

Assist and check Ulica Solar filling in of the SolarIF “Questionnaires”, product-, quality- and

environmental- parts. During the entire audit, Ulica Solar supported SunChine in its task and was

fully prepared to answer any questions that were raised.

Ulica Solar has been operating the solar module factory from 2005, has gradually expanded

production and gained a significant market share.

In the factory, the solar cells workshop and modules workshop are organized at same location. New

and advanced automatic production equipment are used in both the cell and module workshops.

A high level Quality Management system is implemented in the factory. Ulica Solar have passed

certificated institutional audits by TUV and SGS, and are now holding ISO 9001, ISO 14001 and

OHSAS 18001 certifications. Although there are still some production and quality control issues that

need to be improved in the factory, SunChine’s factory audit shows Ulica Solar has achieved good

Quality Management level throughout its production process comparatively in the industry.

http://www.sunowe.com/

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3. General Information about the Company 3.1. Company profile 3.1.1. General information

Ulica Solar was established in August, 2005 by Shanshan Group. Shanshan Group

(http://www.shanshan.com) is one of the top 500 private enterprises in China. Its annual sales

volume in 2008, 2009, 2010 and 2011 reached RMB11.6 billion, RMB 12.8 billion, RMB 18.2 billion

and RMB 23.2 billion respectively and its current total assets amount to RMB 13 billion. The

business scope of the group covers fashion industry, renewable energy & new material industry,

investments, industry park operation & development and international trade. Now it has two listed

companies, Shanshan Share and Zhongkeyinghua which are listed on Shanghai stock market. It has

been consistently ranked as one of Top 500 Private Enterprises in China since 2002.

Ulica Solar has from the onset been devoted to Research & Development on new technology,

improving efficiency and quality and reducing manufacturing costs, with 17 patents obtained, among

which N-type mono-crystalline silicon solar cell, which was awarded the “National Torch Program”.

Ulica Solar has acquired many international certificates testifying to its high level of standardization,

such as CE, IEC 61215 & IEC 61730/TüV, UL, ISO9001, CEC and CGC-Solar. Ulica Solar is cooperating

closely with some prestigious institutions and Universities including Ningbo Material Technology&

Engineering Institution of Chinese Academy of Sciences, Shanghai Donghua University etc.

Ulica Solar has brought in the most advanced silicon solar cell manufacturing technology and

state-of-art equipment from Germany, USA and Spain. Currently its annual production capacity is

248 MW for cell and 187MW for modules. The factory is managed and lead by the CEO, which

reports to Board of Directors of Ulica Solar, led by the chairman of Shanshan Group. (Figure 1)

Figure 1 Ulica Solar company structure chart

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3.1.2. Vertical integration

Ulica Solar operates the solar industrial chain from solar cells to crystalline solar modules. Wafers are

purchased from domestic suppliers.

Wafer

Wafers used at Ulica Solar for making cells, originate from three manufacturers. They are ReneSola

Ltd with a share of 60%, Solargiga Energy Holdings Limited which takes 30% and Winsun New

Energy Co., Ltd which takes 10%.

Solar cell

Ulica Solar produces solar cells matching their own full capacity modules production. Extra solar cells

are sold to others Chinese module manufacturers. The cells efficiency improves continuously and

now the efficiency has reached 17.8% (Mono crystalline) and 17.1% (Poly crystalline).

3.1.3. Technical roadmap

Ulica Solar has its own Research and Development (R&D) team. They show a strong focus on PV

technology and environmental protection. Its technical roadmap is strategically focused on PV

products with higher and more stable performance whilst simultaneously lowering its costs.

Ulica Solar’s key technical milestones are listed as follows:

Solar cells efficiency reached over 15.0% in 2005;

N-type mono-crystalline silicon solar cell was awarded the National Torch Program in 2008;

Applied for 23 patents and so far 17 patents have been awarded;

Successfully developed the highly efficient 190Wp mono-crystalline module in 2010;

R&D department continuously improves the technology of cells. In the next two years, the

efficiency of mono- and polycrystalline cells will reach 18.4% and 17.2% respectively by using

new materials to increase the fill factor in 2013, and 18.8% and 17.6% respectively by

improving solar cells diffusion process in 2014.

New generation of cells with ”Selective Emitter” technology and “N-type” solar cells technology is

being developed; this strategic development is supported by the local government.

3.1.4. Project references

France

Location: France

System Size: 1.2MW

Installation: Nov, 2010

Italy

Location: Roma

System Size: 1.0MW

Installation: Aug, 2010

Germany

Location: Germany

System Size: 4.266MW

Installation: Jun, 2010

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Denmark

Location: Denmark

System Size:5KW

Installation: Jul, 2012

China

Location: Ningbo

Capacity: 700KW

Installation: Jun, 2008

Italy

Location: Turin

Capacity: 200KW

Installation: May, 2012

3.1.5. Local services & Warehousing

As a globally operating company, Ulica Solar provides local customer pre-and after-sales engineering

services. If clients have any question, they can contact Ulica Solar local branch/office or contact

directly with Chinese headquarters. They can offer quick response to client questions. The customer

completed records have been checked by SunChine during the audit.

The following table lists the service contact points:

Regions Local services

Asia

Headquarters

Ningbo Ulica Solar Science& Technology Co., Ltd Address:

No.1 Shanshan Road, Wangchun Industrial Area,

Yinzhou District, Ningbo, China. P.C.：315177

Sales Department: Tel: +86-574-28828976

[email protected]

Israel Office

Address: Zurit 20104,

Israel

Tel: +972 4 9990 3336

[email protected]

Japanese Office

Address: 11-1 Shimotaomotekaeba

Kitakawashi Ikawa Minamiaakita Aktia

018-1512 Japan

Tel: +81 18 874 3252

[email protected]

Europe

German Office ：

Address: Karlstr. 1, D-74405 Gaildorf,

Germany

Tel: +49 7971 21245

[email protected]

Polish Office :

Address: 68-200 Zary, Wroclawska 2,

Poland

Tel: +48 789 100 600

[email protected]

Greek Office:

Address: 8, Kifisou Av. , Athens, 121 33,

Greece

Tel: +30 210 57 49 501

[email protected]

Malta Office:

Address: Mdina Road Qormi QRM 9011,

Malta

Tel: +356 21 466668

[email protected]






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USA

US Office:

Address: Storke Rd,Goleta,CA 93117

Tel: +1 805 570 4386 [email protected]

Regions Local Warehouses

Asia

Queensland Warehouse, Australia

Address: Interport 97 Freight Street Lytton QLD 4178

Tel: +61 73262 5552 Fax:+61 73262 5568

E-mail: [email protected]

Europe

Hamburg Warehouse, Germany

Address: Dratelnstr. 18 21109 Hamburg

Tel. 0049 40 75277-176

Fax 0049 40 75277-276


Brussels Warehouse, Belgium

Address: Avenue de Vilvoorde, 200,

Vilvoordselaan B-1000 BRUSSELS

Direct Phone: + 32 2 421 99 23


Felixstowe Warehouse, UK

Brinor Warehousing & Distribution Ltd

Address: Unit J Central Avenue Ransomes

Europark Ipswich, Suffolk IP3 9SL

Tel : 01473 726500

Contact :Darren Medland Any time/day

except 2nd May – he is off


Manchester Warehouse, UK

Address: Leestone Road, Sharston

Industrial Estate, Sharston,Manchester,

M22 4RB

Tel:+44 (0) 161 998 3212 (Direct)

Fax: +44 (0) 161 945 2750 (Direct)


Piraeus warehouse, Greece

Address: Thesi Mandri Logotheti or Chavosi Georgiou Genimmata Avenue- Magoula

Tel.: +30 210 5552555 Fax. : +30 210 5553290


3.2. Product information

3.2.1. List of solar modules

Ulica Solar Modules List

Mono crystalline modules

Model Normal Power(Wp) Tolerance Module

Efficiency Cells

Specification

UL-155D-72 Power classes 155-200,

in steps of 5Wp 0～+3% 14.9%～16.1% Mono 125×125





UL-190M-54 Power classes 190-240,











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Poly crystalline modules

Model Normal Power(Wp) Tolerance Module

Efficiency Cells

Specification

UL-180P-54 Power classes 180-235,

in steps of 5 Wp 0～+3% 14.2%～15.3% Poly 156×156





Solar module datasheets in Appendix: APP02 Product Datasheet

3.2.2. Product certifications

TÜV certification

Issued by Reference No. Expiry Date Certificates cover Model range

TÜV

Rheinland

PV60029185

(Basis IEC61215)

March 5,2015

UL-190D-54(190 to 225 increment of 5)

UL-165D-84(165 to 200 increment of 5)

UL-235D-96 (235 to 270 increment of 5)

UL-210M-60(210 to 250 increment of 5)

UL-250M-72(250 to 300 increment of 5)

UL-230M-54 (230 to 240 increment of 5)

PV60029186

(Basis IEC61730)



UL-180P-54 (180 to 235 increment of 5)



Mono/poly crystalline modules TUV certificates in Appendix: APP03 Modules TUV Certificates

CE Certification

Issued by Reference No. Issued date Certificates cover Model range

TÜV

Rheinland

AN 60038288

0001 March 16,2011

UL-155D-72 (155 to 200 in 5 steps)

UL-165D-84 (165 to 240 in 5 steps)

UL-235D-96 (235 to 270 in 5 steps)

UL-190M-54 (190 to 225 in 5 steps)

UL-210M-60 (210 to 250in 5 steps)

UL-250M-72 (250 to 300 in 5 steps)

UL-180P-54 (180 to 210 in 5 steps)

UL-200P-60 (200 to 240 in 5 steps)

UL-240P-72 (240 to 285 in 5 steps)

Mono/polycrystalline modules CE certificate in Appendix: APP04 CE Certificates

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MCS Certification

Issued by Certificates No. Expiry Date Certificates cover Model range

TÜV

SÜD BABT 8532 R1 January 13,2014

UL-155D-72 (155 to 200 in 5 steps)

UL-165D-84 (165 to 240 in 5 steps)

UL-235D-96 (235 to 270 in 5 steps)

UL-190M-54 (190 to 225 in 5 steps)

UL-210M-60 (210 to 250in 5 steps)

UL-250M-72 (250 to 300 in 5 steps)

UL-180P-54 (180 to 210 in 5 steps)

UL-200P-60 (200 to 240 in 5 steps)

UL-240P-72 (240 to 285 in 5 steps)

Mono- and polycrystalline modules MCS certificate in Appendix: APP05 MCS Certificate

Salt Spray Test

Issued by Certificates No. Issued Date Comments

Intertek SH11061208-V1 June 30,2011

UL-165D-72 (165 to 200 in 5 steps)

UL-205D-84 (205 to 240 in 5 steps)

UL-235D-96 (235 to 270 in 5 steps)

UL-190M-54 (190 to 225 in 5 steps)

UL-210M-60 (210 to 250in 5 steps)

UL-250M-72 (250 to 300 in 5 steps)

UL-180P-54 (180 to 210 in 5 steps)

UL-200P-60 (200 to 240 in 5 steps)

UL-240P-72 (240 to 300 in 5 steps)

Mono and polycrystalline modules test report in Appendix: APP06 Salt Spray Verification

Ammonia Corrosion Test

Issued by Certificates No. Issued Date Certificates cover Model range

TÜV

Rheinland PV 60075719 March 6, 2012

UL-155D-72 (155 to 200 in 5 steps)

UL-205D-84 (205 to 240 in 5 steps)

UL-235D-96 (235 to 270 in 5 steps)

UL-190M-54 (190 to 225 in 5 steps)

UL-210M-60 (210 to 250in 5 steps)

UL-250M-72 (250 to 300 in 5 steps)

UL-180P-54 (180 to 235 in 5 steps)

UL-200P-60 (200 to 260 in 5 steps)

UL-240P-72 (240 to 315 in 5 steps)

Mono and polycrystalline modules certificate in Appendix: APP07 Ammonia Corrosion Test Report

UL Certification

Issued by Certificates No. Issued date Certificates cover Model range

UL E311825

(Basis UL1703) June 2,2011

UL-150D-72 (150 to 230 in 5 steps)

UL-195D-84 (195 to 225 in 5 steps)

UL-230D-96 (230to 260 in 5 steps)

UL-170D (170 to 300 in 5 steps)

UL-190P (190 to 300 in 5 steps)

Mono- and polycrystalline modules UL certificate in Appendix: APP08 UL Certificate

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4. Module factory inspection

4.1. Manufacturing process

4.1.1. Manufacturing process flow chart

Ulica Solar operates according to a complete production management system. A complete

manufacturing process has been implemented in the workshop divided into 9 parts. Figure 2 shows

the detailed flow chart and description of the process. Before stringing of the cells, Ulica also

implements the raw material preparation process, including interconnection soaking, EVA/Back

sheet cutting, solar cell color and electrical pre-selection, etc. Also, double step 100% Electrical

Luminescense (EL) tests are implemented before and after lamination process.

Figure 2: Ulica solar production process flow chart

4.1.2. Manufacturing process description

Incoming materials inspection and preparation:

Raw materials are inspected by IQC inspectors before entering the warehouse. Products are

marked with IQC confirmation labels that also mention the responsible IQC inspector;

Note: Key materials such as EVA and backsheet are prepared in a separated room, but the

cutting time of EVA and backsheet are not marked on the materials; this is not easily identifiable

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for materials handing out the correct materials;

Raw materials are prepared under required condition, the prepared materials quantity is

according to daily production plan, only the same brand and type materials will be used per

batch, so as to prevent invalid combinations and mixed materials issues from happening.

Solar cell sorting:

Solar cells are sorted by both efficiency rate and color. The sorting is implemented in cells

production workshop but not in module’s production workshop;

Solar cell sorting SOP files are placed close to the workstation. Workers displayed a clear

understanding of the SOP and standards;

Defective cells are marked and placed into separate plastic trays in order to prevent mixing them

with qualified cells;

Gloves and uniforms are always used by workers. No cells are directly touched during the entire

sorting process;

The sorting process has an associated product flow chart.

Cell soldering and stringing:

All cells soldering and stringing are implemented by machines, 4 automatic soldering machines

from Spanish Gorosabel group are used in-line and the parameter setting of the machines

match the guided parameters form(From SOP requirement);

Auto soldering machines are operated by workers and supervised by technician. The soldering

quality is good and no defective issues were found during the audit;

After auto soldering, all cells strings are inspected and if necessary repaired before layout;

All modules are tracked from this station; the serial numbers and all tracked information is

input into computer in digital version.

Layout:

Workers wear gloves and uniforms. No materials or bare finger are directly touching cell strings

during the layout process;

In-house designed model boards are used in order to efficiently fix the cell matrix layout;

Rulers are regularly used by the workers to measure the distances between strings;

Matrix array and soldering iron temperature match SOP file parameters;

Note: There is no sign or record to mark the different brands EVA/back sheet after cutting

during the layout process;

Visual inspection is well implemented at the work stations, confirmed by IPQC inspector and

recorded on IPQC inspector check list;

100% EL test (Half way test):

For halfway module manufacturing test process, a visual inspection and an Electroluminescence

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(EL) test are both implemented for every module;

The EL test is performed two times:1) before the laminating process station and 2) before the

flash test station;

EL test machines routine checking and maintenance records are clear and updated at regular

intervals;

Defective modules’ are removed from production lines, put onto separate shelves while photos

are separately saved for analysis. The ratio of cells showing significant defects as part of total

tested cells is about 1.5‰ according to the record during the audit day. All cells showing defects

will be replaced at the repair workstation after the auto soldering;

Remark: Normally, the 1.5‰ defect rate is not regarded very high during modules production.

Ulica Solar has a very strict management for micro-crack issues and all the micro-cracked cells

identified during the production by double EL test will be replaced.

One of the operators was observed to have cut the finger protectors off from his gloves in order

to feel more flexible for working, but this is of course not allowed.

Lamination:

Laminator routine checking and maintenance records are placed near or on the equipment. The

checking process follows SOP requirements;

Laminator parameters are set according to SOP depending on different EVA/Back sheet

combinations and checked by IPQC inspector. Operators are not allowed to change these

settings;

Modules’ cooling is done by automatic fans after lamination, and the modules stack limitation is

20pcs which guideline is strictly followed.

Silicone sealant filling & framing:

Silicone sealant filling and framing process are performed by machine; the process and

parameters setting matches SOP guidance;

Machines routine checking and maintenance records are well kept and checked by IPQC

inspectors;

Between modules’ frame and back sheet fill silicone sealant by hand after framing assembly,

silicone sealant molding by hand is in good condition;

Junction box is fixed onto the module by hand and well encapsulated;

Sealant curing and cleaning:

After framing and junction box assembly, modules are placed in separate area for more than

eight hours to allow the silicone sealant to cure. However, the designated area is not a separate

room, so it will be hard to control the humidity and temperature during silicone curing; [ Rec. to

be improved! ]

The silicone sealant curing time is recorded and marked clearly on module’ frame, so that every

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module’s silicone solidity can be ensured.

NOTE: Modules for silicone curing are normally put into a separate room; Ulica Solar has no

separate room for the process because now they are producing in one big workshop area.

However, they plan to set-up new and standard solidification rooms in their new workshop

which they are planning to build.

Second 100% EL test and Insulation test:

After the curing process, 100% EL testing is implemented for modules. At the second EL test

station, the ratio of cells showing defects is very low, only one cell shows defect in 88pcs of

modules inspected during the audit;

Insulation test is implemented for every module and test conditions match IEC61215/61730

requirements;

Insulation testers are calibrated by a third party organization; the tester daily check and

maintenance records are clear and well filled-in;

Testing process is randomly inspected and documented by IPQC inspector.

IV testing (Flash testing):

Flash testing takes place in a separate room prepared for maintaining Standard Test Conditions

(STC, AM=1.5,1000W/m2,25ºC。);

Reference modules are stored in a dedicated closed box. There are two types of reference

modules: ‘mother’ or ‘golden’ reference modules provided by TÜV that are used once a month to

check/calibrate the daily used ‘silver’ reference modules used on a daily basis copied from TÜV

mother module;

All daily used reference modules have proper calibration records; the Spire sun simulator is

calibrated 2 times for each shift and the record is documented;

Packaging and Outgoing Quality Inspection:

Standard carton box has a capacity of 24pcs, for detailed package, please see Table 1. The

packaging information is printed on the carton box;

Packaged modules are randomly unpacked and inspected by OQC inspector before final loading;

OQC inspector has the right to stop shipments in case of quality issues;

During the audit, no Original Equipment Manufacturer (OEM) orders for other customer were

found in the factory. It was confirmed with management that indeed policy of Ulica Solar is to

fully focus production on its own brand.

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Modules standard packaging quantity specifications

Item description Modules

Solar cells 6 x 12 cells of

125 mm x 125 mm

6 x 10 cells of

156 mm x 156 mm

6 x 12 cells of

156mm x 156 mm

Module size 1508mmx808mmx46mm 1637mmx997x46mm 1953mmx997x46mm

Pcs per pallet 50 48 48

Pallets per 20” / / /

Pallets per 40GP” 14 / /

Pallets per 40HQ” / 13 11

Table 1: Solar modules standard packaging quantity specifications

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4.2. Quality Assurance system

4.2.1. ISO certifications and implementation

ISO 9001 Certification

Valid Until April 27, 2013 Certificate No. CN0700224

Certification Company Detail

Issued by SGS United Kingdom Ltd Systems and Service Certifications.

Items Inspection process Comments

ISO9001

Certificate

ISO Standard

Procedure for

Production

During factory audit, the following ISO

documents were checked:

A--Company Organization

B--Worker’s Standard Operating

Procedure

C--Device Management

D--Process of Production Control

E--Warehouse Management

F--Raw Materials and Module Inspection

Standard

G--Purchase Control Management

H--Correction and Prevention Measures

I--Customer Complaint Management

J--R&D or Engineering Change

Management

K--Environment and Occupational

Health and Safety Management

L--Safety and Fire Control

All the ISO documents were found to

have been updated frequently and

confirmed by all the relevant

departments;

Three months records have been

checked and all the records are clear

and well recorded.

Remark:

Ulica Solar ISO9001 management stystem is complete and well implemented in the whole factory;

During the audit, we checked the documents of the manufacturing-, quality-, technology-,

purchase- and human resources- departments. The sales- and finance- departments were outside

the scope of SunChine factory audit but were checked by CEA;

ISO9001 Certificate can be found in appendix：APP09 ISO9001 Certificate

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ISO 14001 & OHSAS 18001 Certifications


ISO 14001

Certificate

Valid Until December 01, 2014 Certificate No. 12 104 41984 TMS

Certification Company

Issued by TÜV SÜD

OHSAS 18001

Certificate

Valid Until December 01, 2014 Certificate No. 12 116 41984 TMS

Certification Company

Issued by TÜV SÜD

Remarks

ISO 14001 and OHSAS 18001 management systems are implemented in the whole factory, and

related records are clear;

The factory operations management for waste handling, cleaning and fire-prevention are well

implemented;

ISO 14001 and OHSAS 18001 certification are listed in appendices: APP10 ISO14001 Certificate

and APP11 OHSAS18001 Certificate

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4.2.2. Machine calibration and maintenance

Main Machines for Production or Quality Test

Machine Name Inspection process Comments

Auto soldering machine

4 Automatic soldering machine lines

are running for cells soldering and

stringing, no manual soldering

operations for modules production

in workshop;

Maintenance and daily checking

records are clear, and hanging close

to the machines.

Brand:

Gorosabel

Type: SL-200

Origin:Spain

Laminator

5 laminators with the same brand of

Senco are used in workshop, and

the laminators make the capacity is

about 180MW per year for Ulica

Solar;

Device parameters match SOP file;

Records of routine maintenance and

checking are clear;

Brand: Senco

Type：

CYY-3623DGM

Origin: China

Sun-simulator

For flash test with one Spire test

machine, the tester is daily

calibrated by the manufacturer with

reference moduels;

Modules’ calibration, maintenance

record and daily checking are clear.

Brand: Spire

Type:5600SLP

Origin: USA

Remarks:

During the audit, all main production and test devices are checked. Calibration and routine

maintenance status is recorded, according to ISO 9001 standard on a daily basis;

All the devices have professional person in charge and with factory inner managed numbers;

All main test devices have been calibrated by third parties: the National Institute of Metrology

P.R.China and Ningbo Institute of Measurement and Testing. The flash test device calibration can

be checked in appendix, APP12 Flash Test Devices Calibration Report;

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4.2.3. In-house lab-testing

R&D Department and In-House Lab-Testing

Type of Lab-Testing

Lab-Testing Process or Records Comments

Conventional lab-testing

The test belongs to conventional

lab-testing, it is done everyday or

for each batch EVA to check whether

the materials match each other;

For each batch, EVA/Back sheet

cross link rate tests must be carried

out before production.

EVA gel content

lab-testing

Wet leakage

current

lab-testing

The test is done at set intervals, or

for experimental requirements;

Note: The calibrated date of

insolation tester was invalid (15 Nov

2012) during audit.

Specialized lab-testing

In factory internal lab, most of

IEC61215/61730 test items can be

implemented;

Specialized tests sometimes can take

more than 2 months. Such tests are

carried out according to an annual

plan;

Customers can also require Ulica

Solar to carry out certain IEC tests

for their orders.

UV radiation

lab-testing

Remarks:

In factory internal lab has facilities for: Mechanical load test and Thermal cycling test;

All specialized tests comply with IEC61215/61730 requirements;

During the audit, all test machines were verified to have proper maintenance records;

Note: The calibrated date of insolation tester was invalid (15 Nov 2012) during audit.

4.2.4. Products tracking control management

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Products Tracking Control


Bar code

tracking system

The electrical bar code tracking system

is a ‘work in progress’, under

implementation. Now half of the

production parameters and records

still need to be typed into the system

manually. Then all the data can be

tracked by the system. The next step is

that automatic bar code scanners will

be implemented for all the production

process for the tracking system in the

new workshop.

Remark:

Tracking system is well implemented in the production under tracking SOP guidance;

The bar code digital management can track PO number; worker; raw materials; modules’

testing or inspection status etc.;

Fully automatic and direct digital input for the tracking system is still under construction.

4.3. Quality Control

4.3.1. Quality Management organization chart

Ulica Quality Management department is under the leadership of Management Representative. It

operates in parallel with production department, but is lead by a different director. The Quality

Management chart can be found in Figure 3.

The Quality Management system includes three sections: System Supervisor, Quality Assurance

Supervisor and Quality Inspection & Control Supervisor. Each section has different responsibility.

About 80 QC people work in the department in the whole factory. The QC engineers and inspectors

have received timely and appropriate training. Training records have been checked during the audit.

Responsibilities of each section are as follows:

System Supervision:

The section includes two parts: Document clerks and System monitoring staff.

Quality Assurance Supervision:

The section includes three parts: Quality Engineers, Supplier Engineers and Metric administrators

(Measure Engineer). They mainly focus on supplier auditing and evaluation, inspection standard

confirmation and audit, and measurement device calibration and maintenance.

Quality Inspection& Control Supervision:

The section includes four types of jobs: Incoming raw materials inspection & control, Cells inspection

& control, IPQC inspection& control and Module/ Outgoing inspection& control. They mainly focus on

production process inspection and control, deal with materials confirmation, technical processes

improvement and finished product inspection.

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Figure 3: Ulica Solar Quality Management structure

4.3.2. Incoming Quality Control (IQC)

Key Raw Materials List and Inspection Standard

No. Key materials TÜV approved Suppliers Inspection Standard

1 Solar Cells Ulica Solar 156Mono/125Mono /156Poly APP13 Solar Cells

Inspection Standard

2 Encapsulation

material Hangzhou First F806 thickness=0.5mm

APP14 EVA Inspection

Standard

3 Back Sheet

3M Film17 thickness=0.35mm

Isovolta AG 2442 thickness=0.32mm

SFC SS-320 thickness=0.35mm

Toko Aluminum K.K. W250 thickness=0.369mm

APP15 Backsheet

Inspection Standard

4 Junction Box

Ningbo Zhonghuan PV-ZH009/PV-U009Zhejiang

Chuanyuan PV-U802-M

Zhejiang Jiaming PV-U801

APP16 Junction Box

Inspection Standard

5 Front Glass

Henan Ancai Tempered glass 3.2mm Beijing Huamei Tempered glass 3.2mm China South Group(CSG) Tempered glass 3.2mm

APP17 Front Glass

Inspection Standard

6 Aluminum Frame

Zhejiang Dingfeng 6063-T5 Thickness=50mmm Thickness=46mmm

Yixing Qiaosheng 6063-T5 Thickness=46mmm Checked at spot

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Warehouse Condition and IQC Inspection


Warehouse

Conditions

Warehouse management is according to

ISO document guide;

Raw materials storage condition

according to management guidance, but

the temperature is not according to

requirement. Note: Checking result is

18.7℃, not in the range of 25±5℃.

[ To be improved! ]

The key materials, like EVA, backsheet,

silicone sealant and cells are stored in a

separate room with suitable condition;

Warehouse cleanliness and neatness is

good;

Records of materials entry or exit can be

tracked;

IQC

Inspection

and Record

Inspection process of raw materials is

according to IQC SOP;

Each type of material has related

inspection standards for IQC inspector;

IQC inspection records for recent 3

months of production have been

checked in factory. All the records are

clear and traceable.

Suppliers

Classification

Suppliers management and evaluation

according to ISO management guidance,

each supplier has a score for annual

evaluation;

Suppliers of main raw materials such as

solar cells, junction box, EVA, back sheet

and front glass match the list of

IEC61215/IEC61730 test report.

Remarks:

All the raw materials in the warehouse and in the production lines match TÜV CDF file;

Raw materials from the warehouse are placed on a FIFO (First in-First out) basis;

Raw materials are marked before and after IQC inspection and placed in separate areas;

Supplier management and evaluation, materials inspection and storage have complete ISO

guidance documents.

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4.3.3. In Process Quality Control (IPQC)

IPQC Inspection


IPQC

Inspection

Record

IPQC inspector checking is based on

quality management SOP guidance;

Inspection records are clear and contain

initial product confirmation; workers

actual work details at each process work

station; device calibration records and

other production related information;

The records/ tables can be tracked for

more than one year after the

production;

Manufacturing

Process

Quality Control

In order to communicate aims and

status of Quality Management, an

information board provides daily

updates. It is placed in the public area

for workers and management teams;

IPQC inspectors randomly inspect every

process station, in case of statistically

higher than normal rejected products,

inspectors will immediately inform the

factory manager to stop the production

Remarks:

Every IPQC inspector is in charge of several production process stations in production lines;

Initial product and Bill of Material (BOM) inspection records are crucial items on IPQC routine

checklist, they are checked by inspector and confirmed by QC engineer;

Production process quality inspection and control has been efficiently implemented by IQPC

inspectors.

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4.3.4. Outgoing Quality Control (OQC)

OQC Inspection

OQC Inspection Standard APP18 Outgoing Quality Control Inspection Standard


OQC AQL

Standard

OQC Random inspection is carried out

according to the GB2828-2003 (The

standard is based on ISO 2859-1:1999).

Module inspection normally uses general

inspection level Ⅱ, AQL1.5.

E.g. If one batch consists of 150pcs of

modules and random inspection selects

32pcs; If the inspected lot has more than

one module showing a major deficiency,

the whole batch will be rejected.

OQC

Inspection

Reports

Each order has separate OQC inspection

report and the OQC engineers select two

modules from each pallet;

OQC inspection report is based on OQC

inspection standard and delivery

notification.

Remarks:

OQC inspector randomly selects modules according to AQL standard for each order, if the batch

inspection shows fail, it will be rejected and can’t be delivered;

For Ulica Solar OQC inspector, the AQL requirement is just reference, QA inspector don’t permit

defective product passing into delivery batch during final inspection. If QA inspector finds defects

during inspection, they will reject the batch.

4.3.5. Customer Engineering Services (CES)

Ulica Solar have a special technical team for providing global customer service. They offer full

service for customers.

Customer service is an important part for Ulica Solar. For example, when receiving a complaint from

a customer, they immediately offer the analysis & improvement report. APP19 Customer

Complaint Response Report

Note: This report is not an international standard 8D report, but an Ulica version report;It is

suggested the Ulica version to be upgraded to international standard.

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4.4. In-line product inspection

4.4.1. Random solar modules test

Electrical Functional Test

Items Inspection record Inspection comments

Wet leakage current test

Test apparatus:

AC/DC/IR Hipot tester

Type: CS9922BX

Origin: China

Normally, QC inspector randomly select

modules for the test;

During the audit one module with serial

No. U610MS1204Q3956D passed the

testing procedure.

Setting:

VDC =1000V

ILC=50uA

(leakage

current)

R=40MΩ

T=120s Passed ○ Fail

Flash test

Test apparatus:

Spire Sun Simulator

Type:5600SLP

Origin: USA

Flash test reference module

specifications are copied from TUV

approved mother module;

Flash test is implemented on 10

randomly selected modules.

Setting:

T=25℃

Irradiance

1000W/m2

Standard

pressure

(AM1.5

spectrum)

Passed ○ Fail

4.4.2. Randomly selected solar modules flash test data

Serial No. Pmax (W) DP(w) Voc (V) Isc (I) Vmax (V) Imax (I)

Type UL-250M-60 RIT PTR

RIT PTR RIT PTR RIT PTR RIT PRT

1 U610MS1204Q3949D 254.16 254.48 -0.31 37.38 37.49 9.01 9.01 29.80 29.85 8.53 8.52

2 U610MS1204Q3954D 253.09 253.17 -0.08 37.44 37.51 8.97 8.94 29.68 29.70 8.53 8.52

3 U610MS1204Q4022D 255.39 255.62 -0.23 37.53 37.57 9.06 9.02 29.56 29.72 8.64 8.60

4 U610MS1204Q3971D 254.02 254.47 -0.45 37.45 37.49 9.12 9.08 29.43 29.69 8.63 8.57

5 U610MS1204Q3917D 254.97 255.09 -0.12 37.48 37.52 9.03 9.03 29.64 29.67 8.60 8.60

6 U610MS1204Q3952D 253.74 254.11 -0.37 37.52 37.54 9.05 9.01 29.71 29.92 8.54 8.49

7 U610MS1204Q3946D 253.08 253.09 -0.01 37.22 37.37 9.07 8.99 29.47 29.59 8.59 8.55

8 U610MS1204Q3916D 250.54 250.08 0.46 37.34 37.13 9.02 8.95 29.23 29.47 8.57 8.49

9 U610MS1204Q3932D 251.17 251.33 -0.16 37.29 37.31 8.98 8.98 29.21 29.42 8.60 8.54

10 U610MS1204Q3913D 255.01 254.57 0.44 37.49 37.52 9.04 9.05 29.69 29.57 8.59 8.61

Average Output Pmax 253.52 253.60 -0.08

Remark：RIT- Random Inspection Test , PTR-Production Test Record, DP-Deviation Power of RIT minus PTR

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4.5. Conclusions of factory inspection

Ulica solar operates its PV module production with 100% complete production process

implemented according to IEC61215 standard; Separated solidification room is still missing, but

improvement is now integrated into the design of their new factory;

ISO 9001 standard is well implemented in the module factory. A complete set of production

process SOP’s has been implemented. All the SOP files are well implemented and updated daily.

ISO 9001 related tables and records are properly filled in and routinely checked. Environment

and occupational health & safety system ISO 14001 (and OHSAS 18001, outside the scope of this

audit) has also been implemented in the whole factory;

Standard Operating Procedures (SOP’s) are used as the guiding standard for production and

inspection. Workers and inspectors were observed to comply with SOP requirements,

implemented records are traceable for more than one year;

Supplier management and evaluation standards are implemented according to ISO files guidance.

Raw materials inspections comply with materials inspection standard. Key raw materials, like

EVA, back sheet and silicone store in the separate room but the room temperature is around 2

degrees Centigrade lower than the required temperature;

IPQC inspectors are responsible for the daily quality inspection of production lines. They have a

very good understanding of the entire production process. Routine inspections normally take

place every 2 hours. IPQC inspectors have the right to report to the factory manager and stop

production. inspection results are shown at public places within workshop;

All maintenance and calibration records of production equipment as well as test devices are

placed close to the machines and they were found to be up to date. Each piece of equipment has

a professional person in charge and factory internal management number;

OQC inspector random selection covers each pallet, and inspection requirements follow the OQC

inspection standard. For each batch of manufactured products an outgoing product inspection

report is available;

Customers service or after-sales service is strongly supported by factory, so if any problem is

reported from a customer, they can get a fast response and will receive systematic support; The

response from Ulica Solar is not yet according to international standard “8D” report, suggested

to be improved.

Product tracking system is complete in factories. Every module is traceable by bar code. All

tracking information is typed into the system manually and the tracking and auto scanning

system is now under construction/ implementation;

Product in-line random inspection result by SunChine is good. Modules safety test is in line and

the flash test result shows a small tolerance compared with nominal value.

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5. Comments and recommendations Item Issues Remarks

Warehouse and raw material

1 Temperature control in warehouse is out of range;

not according to requirement.

Temperature management should be

according to ISO file guidance.

Production technology process portion

1

There is no sign or record to mark the different

brand EVA/back sheet and cutting time after

cutting during the layout process.

Key materials should be marked

during the production with detailed

information after unpacking

2 Silicone sealant of modules is cured not in a

separate room, but in the workshop.

SunChine suggests to put module

into a separate room for curing.

3 The calibration date of wet leakage current tester is

invalid.

Tester should be calibrated on

schedule.

4

One of the operators has cut the finger protectors

off for his gloves in order to feel more flexible for

working, which is obviously not allowed.

IPQC inspector shall take

responsibility to prevent this kind of

personal decisions potentially

causing quality issues;

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6. Factory audit conclusions

6.1. General result

Factory General Inspection Result

Certification Valid Under

application None

ISO 9001, ISO14001 and OHSAS18001 √

TÜV or VDE √

Others (MCS/UL) √

Production insurance √

Product warranty √

Production procedure and implementation Good Satisfactory Unsatisfactory

Production technology process √

Workers’ Standard Operating Procedure(SOP) √

Quality Management organization √

Raw materials inspection √

Inspectors’ Standard Operating Procedure(SOP) √

Outgoing product inspection (OQC) √

Devices calibration and maintenance √

Supplier management and evaluation √

Customer complaint management √

In house lab-testing √

Products inspection in-line √

Tracking system √

Factory environment conditions Good Satisfactory Unsatisfactory

Raw material warehouse √

Production workshop √

Workers operation, training and skills √

Overall rating (0～10)

Unsatisfactory (0～<6) Satisfactory (>=6～8) Good(>=8～9) Excellent (>=9～10)

√

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6.2. Results

According to:

Audit results for the implementation of IEC61215/61730, ISO9001 and 14001;

Audit of Standard Operating Procedures for quality control and production processes;

Audit of documents and materials provided by Ningbo Ulica Solar Science& Technology Co.,

Ltd;

Completeness of manufacturing process and independent QC function;

Mutually agreed inspection standards between SolarIF and SunChine Ltd.

SunChine audit result of Ningbo Ulica Solar Science& Technology Co., Ltd:

Good* ( 8.0)

Valid certificates will have to be provided to SolarIF.

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