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Sixth-generation glass substrates, used for the first time in the world at Kameyama Plant No. 1, measure up to 1,500 x 1,800 mm, but the eighth-generation glass substrates used at Kameyama Plant No. 2 are as large as 2,160 x 2,460 mm, even though they are only 0.7 mm thick. If both sides of an eighth-generation glass substrate were held up, the center of the substrate would sag more than 30 cm. Moreover, substrates are extremely delicate; even the smallest excessive load can cause micro cracks, rendering the substrate unusable. What’s more, the surface of glass substrates is 2,000 times smoother than that of ordinary glass. If a substrate is carelessly touched, dust stuck to the surface will result in sub-standard products and, ultimately, will affect yield rate.
To transport delicate glass substrates without damaging them, Sharp developed original transporting technology. At the Kameyama Plant, driverless transport cars loaded with a number of glass substrates travel around the huge factory, ensuring the well-timed delivery of those substrates to the next process. The actual transporting, loading, and unloading is carried out quickly but gently with proprietary Sharp glass handling technology. As a result, Sharp can input 60,000 glass substrates per month into the manufacturing line (at Kameyama Plant No. 1), making it possible to produce a stable and highly efficient supply of large LCD panels.