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AMERISOLAR PV MODULES
PROTOS S.P.A. Società di Controlli Tecnici e Finanziari
WORLDWIDE ENERGY AND MANUFACTURING (NANTONG) CO., LTD.
PV MODULES FACTORY – NANTONG, JIANGSU PROVINCE - CHINA
TECHNICAL ADVISORY
GENERAL AUDIT REPORT
PRIVILIGED AND CONFIDENTIAL
PEER REVIEWS
Rev. data/date redatto/drawn verificato/checked approvato/approved
0 29/03/11 Ing. Antemina Del Vecchio Ing. Giorgio Saraceno Ing. Giorgio Saraceno
Codice commessa/job code 557/10
Nome file/file name 290311-1235-General Audit Report Amerisolar.doc
Ns. Riferimento/our reference 1235/11
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TABLE OF CONTENTS
1 SCOPE OF THE DOCUMENT AND LIMITS 5
1.1 GENERAL INFORMATION 5
1.2 DOCUMENTATION 6
1.3 SCOPE OF WORK 7
1.4 LIMITS 8
2 THE COMPANY 10
2.1 OUTLINE 10
2.2 HISTORY, MISSION, PERSPECTIVE 11
2.3 ORGANIZATION 13
2.4 COMPANY MANAGEMENT 14
2.5 COMMERCIAL STRUCTURE 16
2.6 AMERISOLAR REFERENCES AND TRACK RECORD 17
3 THE PRODUCTION FACTORY 22
3.1 OUTLINE 22
3.2 TRAINING OF PERSONNEL 23
3.3 MANUFACTURER CERTIFICATIONS 24
3.3.1 ISO 9001 Certification 24
3.3.2 ISO 14001 Certification 27
3.4 EXTERNAL AUDITS AND INSPECTIONS 29
3.4.1 ISO 9001 Factory Inspection 29
3.4.2 ISO 14001 Factory Inspection 29
3.4.3 IEC 61215 Factory Inspection 30
4 WORLDWIDE ENERGY AND MANUFACTURING (NANTONG) CO., LTD FACTORY VISIT 32
4.1 INCOMING GOODS TESTING PROCEDURE AND STOCKING 34
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4.2 WAREHOUSING 34
4.3 COMPLIANCE OF THE MAIN MANUFACTURING STEPS WITH QUALITY PROCEDURES 35
4.4 R&D LABORATORY 39
4.4.1 Technical Specifications of the main R&D equipments: 41
4.5 IMPROVEMENTS AREAS 46
5 THE PRODUCTS 47
5.1 NUMBER AND TYPE OF COMMERCIALIZED PV MODULES 47
5.2 MODULES DESIGN PARAMETERS 50
5.3 WARRANTY CONDITIONS 52
5.4 LIST OF SUPPLIERS 56
5.5 IMPROVEMENT AREAS 57
6 CONCLUSIONS 58
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1 SCOPE OF THE DOCUMENT AND LIMITS
1.1 General Information
Worldwide Energy and Manufacturing USA, Inc. is an international manufacturing and
engineering firm founded in September 1993 and focused on photovoltaic modules and on
contract manufacturing services in mechanical, electronics and fiber optic products.
Worldwide Manufacturing, USA Inc is traded publicly in the United States (OTCBB: WWMU)
and has the headquarters in California, USA and offices in China, Spain and Italy.
From 1993 the Company service customers primarily in Europe, South Korea and United States: since
2005 the Company started the direct contract manufacturing continuing the subcontracting of only a
portion of the entire business.
Although the Group is historically focused on manufacturing components for high tech industries, in
2008 they decided the expansion into the solar module markets.
The company designs, develops, manufactures, and markets solar modules under the
AmeriSolar brand with a range in rated power output from 165 watts to 240 watts per
module.
Worldwide Energy and Manufacturing USA, Inc. intends to penetrate the Italian market of
the big photovoltaic plants, financed following Project Financing schemes, and in such
context intends to propose to the banking system their products through a General Audit of
the productive processes carried out by an Independent Technical Consultant.
In this framework, the company has requested to Protos to support the Company itself to
accomplish a General Audit of the Worldwide Energy and Manufacturing (Nantong) Co., Ltd.
Factory located in Nantong, China.
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1.2 Documentation
The Worldwide Energy Factory Audit has been worked out on the basis of documentation
made available and listed below:
> Additional test report
> Amerisolar 2010 shipments to main customers
> Amerisolar Presentation
> Attachment 2-Chart of department duty in quality
management system
> Calibration procedure
> EN 61730 test report_15040367.001
> Facotry organization structure
> Factory inspection report
> IEC 61215 test report_15040366.001
> IEC 61730 certification
> Inspection manual
> ISO 9001 report
> ISO 14001 report
> Items
> limited warranty
> List of Machinery
> List of qualified suppliers
> List of R & D equipments
> Qualified Supplier Evaluation Report Sample
> Quality organization structure
> Requisition sheet of raw material inspection Sample
> Supplier Quality Assurance Ability Questionnaire Sample
> Training Program
> Updated product quality warranty
> Work flow chart
> Standard purchase agreement
> Certificate of product quality warranty
IPffifiT*S
cefificate of products liability insurance
IEC6l2lScertificate
ISO14001 Ceftification
ISO 9001 Certification
2011 2nd stage
r 1wEt4u zott!-.--J'
r* )WTMU SALES CONTRACF 2011\-- )
1.3 Scope of Work
The Scope of Work of the assignment includes a General Audit of the Worldwide Energy and
Manufacturing USA, Inc. Factory located in China, Nantong, and, more in detail, all the
activities hereinafler described.
The service will aim at analysing the following issues:
Verifu the manufacturer ce*ifications, pafticularly:
ISO 900i Ceftification;
IS0 9001 reports on periodical inspection by Qualifuing Body;
ISO1400 1 Certifi cation;
Analyse the commercial structure, particularly:
Analyse the production assessr?lent, mainly:
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> Compliance of the main manufacturing steps with quality procedures;
> Number and type of commercialised PV modules with relevant classes of power;
> Tolerance on Pn;
> Capacity of PV module selection in sub-classes (Pm, Vm, Im, Voc, Isc, FF) and
relevant tolerances;
> Training of personnel.
Analyse the procurement and warehousing structure, particularly:
> List of suppliers;
> Procurement specifications;
> Performance of quality control on in-going materials;
> Compliance of quality control with quality procedures; Warehouse inspection;
> Compliance of stock management with quality procedures;
> Compliance of warehousing conditions with specification by suppliers and quality
procedures.
1.4 Limits
This document is subject the following limitations:
our analysis was based on information provided by the Sponsor and included into
official documentation provided by such, which are listed in the above Chapter
“Documentation”. PROTOS takes no responsibility for the reliability and
completeness of the information used to carry out our work, as we merely
analyzed the feasibility of the main theories and information provided to us. Our
activities do not take into account the possibility of events of an extraordinary and
unforeseeable nature occurring. According to the managers of the Sponsor, no
elements beyond those we received that could have a significant effect on our
conclusions were available.
our work is of a consultancy nature and is neither binding nor obligatory; the
appointment and the results deriving thereof were provided to support assessment
and verification of the Project by the Sponsor and may not be used for activities
and objectives other than those of which we are aware.
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this document is strictly confidential and may not be reproduced and may only be
used by the Sponsor for the aforementioned purposes; it may therefore not be
copied or made available to any other third parties.
the conditions of our appointment involve no review of the results we obtained due
to events occurring after the date of release of this report; observations regarding
this document may be forwarded within 20 days of its release and we undertake
to make any necessary changes.
we may in no way be held responsible for damaging consequences including those
forwarded by third parties for any reason whatsoever, except in cases of intent
and gross negligence.
our appointment did not involve carrying out any estimates or audits on the
Balance Sheets of the Companies involved in the operation.
while effecting the activities involved in writing this report, we carried out no tests,
trials, measurements, controls using instruments, laboratory analyses, surveys,
etc., nor any other kind of verification that may involve using special technical
tools.
under no circumstances will Protos undertake any managerial, organizational or
coordination functions within the Sponsor to the purposes of this appointment, as
our work has an exclusively external nature that is strictly consultancy-related.
let it be clearly understood that our Company may in no way be considered equal
to, overlap or interfere with the activities assigned as the exclusive competence of
the subjects responsible for controlling, revising, verifying and certifying to the
purposes of the Law (Director of the Board of Auditors, Safety Director, Auditors,
etc.).
the theories set forth in this document may undergo variation, including substantial,
in view of multiple variables or factors that are currently unforeseeable.
The present document includes the results of the analysis carried out on the basis
of the documents received up to date and above listed.
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2 THE COMPANY
2.1 Outline
Worldwide Energy and Manufacturing USA, Inc. is an international manufacturing and
engineering firm founded in September 1993 and focused on photovoltaic modules and on
contract manufacturing services in mechanical, electronics and fiber optic products.
Worldwide Manufacturing, USA Inc is traded publicly in the United States (OTCBB: WWMU)
and has the headquarters in California, USA and offices in China, Spain and Italy.
From 1993 the Company service customers primarily in Europe, South Korea and United States: since
2005 the Company started the direct contract manufacturing continuing the subcontracting of only a
portion of the entire business.
Although the Group is historically focused on manufacturing components for high tech industries, in
2008 they decided the expansion into the solar module markets.
The company designs, develops, manufactures, and markets solar modules under the
AmeriSolar brand with a range in rated power output from 165 watts to 240 watts per
module.
The company was formerly known as Worldwide Manufacturing USA, Inc. and changed its
name to Worldwide Energy and Manufacturing USA, Inc. in February 2008 to reflect its
expansion into the solar energy industry.
Worldwide Energy operates by means of the following subsidiaries:
Solar Division - Amerisolar
> Worldwide Energy and Manufacturing (Nantong) Co., Ltd - “Amerisolar” Brand PV
modules
> Worldwide Energy and Manufacturing (Shanghai) Co., Ltd - Design, Installation, and
Consulting for Solar Power Systems.
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Manufacturing Division
> Shanghai Intech Electro Mechanical Products Co., Ltd – Engineering and Quality
control arm for Worldwide
> Chengde Science & Technology Co. - Air conditioning units for automobiles
> Shanghai Intech Electronics Manufacturing Co., Ltd - PC boards, cables, coils,
chassis, etc.
> Shanghai Intech Precision Mechanical Products Manufacturing Co., Ltd – die casting
and machining components for automobile, home appliances and wireless
telecommunications industries.
Figure 1: Worldwide Energy Business Areas and Subsidiaries
2.2 History, mission, perspective
Worldwide Energy solar business started in 2007 with the Solar Division set-up.
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In 2008 the Amerisolar PV modules obtained the TUV certifications and in 2009 the UL
certification.
In 2008 the Company started the mass production in the Factory located in Ningbo;
nowadays the production is being moved from the Ningbo factory to the new Nantong
factory which began the module’s manufacturing in July 2010.
Figure 2: History of Worldwide Energy Group ‘Solar Division’
The Company's Nantong facility has a current manufacturing capacity of 100 megawatts
(MW) per year and is located on a site large enough to accommodate two building
expansions in order to increase, when completed, its total manufacturing capacity to 300
MW per year. The Research & Development centre, located in Nantong facility, is focused on
increasing system and module efficiency and is led by a team of experts in PV solar
technology.
Worldwide Energy focuses his attention on R&D and describes its mission as:
> To develop and enhance our photovoltaic modules technology to provide the most
reliable, clean and affordable solar energy in the market.
> To gain complete control over its manufacturing business from sales, to
engineering, production, quality, delivery and customer service.
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The Company is currently implementing the following measures:
> Expansion into new geographic regions and develop strategic distribution alliances
to better support the burgeoning growth that the PV Solar Markets are experiencing
> Increase manufacturing capacity and improve profitability due to better economies
of scale
> Increase operating margins by becoming vertically integrated through further
upstream offerings either by joint venture or acquisition
> Expand solar sales and distribution globally, particularly in the U.S.
> Provide systems integration services to complement high-quality PV solar modules
2.3 Organization
In the scheme below the Company structure diagram is shown.
Figure 3: Worldwide Energy and Manufacturing Organization Structure
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2.4 Company Management
Here following Worldwide Energy and Manufacturing USA, Inc. Management Staff is
described:
> Jimmy Wang, Chief Executive Officer
Mr. Wang has over twelve years experience in a wide range of component
manufacturing. From 1996 to the present, Mr. Wang has been President, CEO and
director of Worldwide Energy and Manufacturing USA, Inc. (California). In 1990, Mr.
Wang earned a Masters Degree in Applied Economics from the University of Minnesota,
and in 1982 received a Bachelors of Science Degree in Economics from the Shanghai
Institute of Foreign Trade.
> Jeff Watson, President
Mr. Watson has over 25 years of manufacturing experience supporting a variety of
industries and markets. He started his career as an engineer in the power transmission
industry with Fasco Gearmotors, a vertically integrated design and manufacturing
company producing gear-motors, linear actuators and the supporting electronic controls.
Mr. Watson earned a Bachelor of Science Degree in Mechanical Engineering from the
University of Missouri.
> Mindy Wang, Secretary and Treasurer
Ms. Wang has over twelve years of accounting and financial management experience with
Technology Power and Worldwide Manufacturing. From 1996 to the present, Ms. Wang
has been Secretary and Treasurer of Worldwide Energy and Manufacturing USA, Inc. Ms.
Wang earned the equivalent of a Bachelors Degree in International Business from the
University of California at the Los Angeles Institute of Economics and Management in
Beijing.
> Philip Zhang, Vice President Operation
Mr. Zhang concurrently functions as the VP of Operations for Worldwide U.S.
headquarter, and the General Manager for all China operations since April of 2001. He is
responsible for directing the company’s manufacturing and supplier chain management in
China. Mr. Zhang has many years of experience in engineering modification, quality and
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delivery control and production line management. He attended the China Textile
University in Shanghai and graduated with a Bachelor’s in Mechanical Engineering in
1982. He completed a Masters Degree in Computer Science at the San Francisco State
University in 1988.
> George Wang, Vice President and CEO of Solar Division
Mr. Wang has more than 10 years of manufacturing experiences in electronics and solar
industries, and he joined in Worldwide Energy and Manufacturing USA, Inc in June, 2008.
In 2006, he joined in Solarfun Power Holdings, one of the major players in the Chinese
solar energy industry. He held the positions as Special Assistant to Chairman of the
Board and Director of Sales and Strategic Accounts. He played a very active and
important role in the process of Solarfun’s IPO on NASDAQ and in the brand promotion
of Solarfun’s solar modules all over the world. Mr. Wang earned a Bachelor of English
Education from Nanjing Normal University and a Master Degree of Law from Law School
of Jilin University. In 2004, he finished his post-graduate program Comparative Legal
Research between Chinese law and American law from Johns-Hopkins University in the
United States.
iflffistfiS
2.5 Commercialstructure
Worldwide Fnergy and Manufacturing Solar Division design, manufactures and sells
Amerisclar Brand PV modules in f;urope, South Korea, Australia and North America,
shown in the following figure:
The Company is present with its photovoltaic products in the ltalian and European markets,
through the following distributors:
its
as
rE
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FROTffi
-- in uK
The standard terms and times of delivery in Europe are the following: cIF European maln
port & FoB shanghai poru wiilrirffter signing contract and receiving deposit
2,6 Amerisolar references and track record
In this paragraph a general track record of the Company is presented'
Here following is a list of the main customers to which worldwide Energy and Manufacturing
supplied PV modules in 2010 in Europe, both as oEM supplier and with Amerisolar Brand
nnodules:
?L J zor'lw
:l/lvl vvh---J{ -llfuw,--___*..-a4MW
'(J'tmwGermanY
C---:- soMw
I.ql
-:-- I: 6MW
-'fl2'wSwiss
- 2 ---:7MW4
€:3MWFrance
Canada
,f:1MW
-(
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Manufacturing USA, Inc'
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Amerisolar PV modules have been installed, among the others, in the following European
sites:
1.6 MW, Schlanstedt / Saxony-Anhalt, Germany
800KW, Donori, Italy
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66KW, Corso Vittorio Emanuele Li, Italy
50KW, Nichelino (TO) Italy
81KW, Warwickshire, UK.
fl fiTss
Moreover, at the end of 2010 Worldwide Energy and Manufacturing USA Co, Limited has
entered into four -i the supplying of Ameriselar PV modules:
A5-5M monocrystalline modules * 9 MW
AS-6P polycrystalline modules - 21 MW
(deliverip" '-"-*' :rorfl Jarii.t*ry 2011)
A5-6P-30 polycrystaliine modules - 14,5 MW
(February, March and April Deliveries)
. italy-AETM monocrystatiir ri rrrc..;uies
AS-6P polycrystalline modules
100KW, Matthew Arnold School in Oxford , UK.
\..
90KW, Henley on Thames, UK.
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PMffi#S
(Total Supply euantity 7 MW - deliveries starting from December20l0 until April
2011)
contract for the supplying of up to 40MW of the Amerisolar AS-sM, AS-6M and AS-
6P modules
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3 THE PRODUCTION FACTORY
3.1 Outline
The factory is located in Nantong, near the coast of the East China Sea, about 120 miles
North of Shanghai. Nantong is known as the economic hub of the Jiangsu Province and is
easy to be reached from Shanghai by means of the motorway.
Figure 4: Factory Location
Before the beginning of the operation in the Nantong Factory, the production was entirely
located in the Ningbo Factory, South of Shanghai. Then, since May 2010, the Company has
been moving the production from Ningbo to Nantong; this transferring will be concluded
within 2011, in order to have the time to build and put into operation the new facilities in
Nantong. In fact, unlike its leased facility in Ningbo, the Company owns the Nantong facility
outright, as well as the parcel of land on which it is situated, for a total surface of more than
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40,000 m2, on which the Company has planned to build two new buildings that would bring
the total manufacturing capacity to 300 MW per year. A Research Centre has also been built
in the Nantong manufacturing plant, for the research and development of the "Amerisolar"
solar technologies.
The second building is now under construction and is supposed to start the production within
the end of 2011, reaching a total production capacity equal to 200MW.
The planned production facilities are described in the following table.
3.2 Training of personnel
The training of personnel is based on a ‘training on the job’ activity and on detailed training
programs.
Periodical training course are organized for internal use by the Factory’s Departments.
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In the following table the schedule of the internal courses which have been planned for the
next months is shown; the Managers of the HR, QC or Engineering Departments are the
Speakers of the Training Sessions and the Audience is the Controller of the Department or all
the Department’s staff depending on the topic of the course.
3.3 Manufacturer certifications
Here in this paragraph the Manufacturer quality certifications owned by Nantong Worldwide
Energy and Manufacturing Co, Ltd Factory are presented.
3.3.1 ISO 9001 Certification
ISO 9000 is a family of standards for quality management systems maintained by ISO, the
International Organization for Standardization and is administered by accreditation and
certification bodies.
The rules are updated, as the requirements motivate changes over time.
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Some of the requirements in ISO 9001:2008, one of the standards in the ISO 9000 family,
include:
- a set of procedures that cover all key processes in the business;
- monitoring processes to ensure they are effective;
- keeping adequate records;
- checking output for defects, with appropriate and corrective action where necessary;
- regularly reviewing individual processes and the quality system itself for effectiveness
and facilitating continual improvements.
A company or organization that has been independently audited and certified to be in
conformance with ISO 9001 may publicly state that it is "ISO 9001 certified" or "ISO 9001
registered". Certification to an ISO 9001 standard does not guarantee any quality of end
products and services; rather, it certifies that formalized business processes are being
applied.
Worldwide Energy and Manufacturing Co., Ltd. detains the ISO 9001:2008 Certification
for Design and Production for Solar Modules issued on August 3rd 2010 and valid until
August 2nd 2013.
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3.3.2 ISO 14001 Certification
The ISO 14000 is a standard for environmental management systems that is applicable to
any business, regardless of size, location or income.
The aim of the standard is to reduce the environmental footprint of a business and to
decrease the pollution and waste a business produces. The most recent version of ISO
14001 was released in 2004 by the International Organization for Standardization (ISO)
which has representation from committees all over the world.
The ISO 14000 environmental management standards exist to help organizations minimize
how their operations negatively affect the environment. In structure it is similar to ISO 9000
quality management and both can be implemented side by side. In order for an organization
to be awarded an ISO 14001 certificate they must be externally audited by an audit body
that has been accredited by an accreditation body.
Worldwide Energy and Manufacturing Co., Ltd. detains the ISO 14001:2004 Certification
for Design and Production of Solar Cells and Modules issued on December 2nd 2010
and valid until December 1st 2013.
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3.4 External Audits and inspections
Protos has been provided with the Audit Reports carried out by Guangdong Zhongjian
Certification Co., Ltd aimed at the issuing of the ISO 9001 and ISO 14001 Certificates.
Guangdong Zhongjian Certification Co., Ltd has been founded in 1993 by Guangdong
Economy & Trade Committee with the qualification of a Third Party independently legal and
multinational certification body; it is accredited by China National Accreditation Service for
Conformity Assessment (CNAS – Member of IAF International Accreditation Forum), ANSI-
ASQ National Accreditation Board (ANAB) and United Kingdom Accreditation Service (UKAS).
The Company is mainly engaged in performing certification of Quality Management
System(QMS), Environment Management System(EMS), Occupational Health and Safety
Management System(OHSMS), Food Safety Management System (FSMS), Good Agricultural
Practice(GAP), and Organic Products.
Moreover the IEC 61215 Factory Inspection has been provided.
3.4.1 ISO 9001 Factory Inspection
The factory inspection has been carried out on July 17th 2010. At the time of the visit the
factory was in a start-up phase but, as stated in the Audit Report, the Company’s Quality
Management System had been correctly organized to meet all the regulations to be
respected by each Company’s Department.
The Audit’s result was positive with the exception of some minor corrective actions to be
performed to adequate the Factory to the Quality Requirements; in particular, the controls
on the production process and the product inspection should have been strengthened.
Next Factory Inspection is recommended by the Audit Team of Guangdong Zhongjian
Certification Co., Ltd for June 2011.
3.4.2 ISO 14001 Factory Inspection
The factory inspection has been carried out on November 12nd 2010.
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The company has collected and confirmed applicable laws and regulations, which have been
achieved through implementation of assessment principles and management plans in
various functional departments according to requirements of environment principles.As
regards the control measures drafted by the company according to main environment
factors, the relevant operation instructions and the operation manuals have been compiled
and are basically effective.
The Audit Team of Guangdong Zhongjian Certification Co., Ltd recommended to plan next
Factory Inspection for October 2011.
3.4.3 IEC 61215 Factory Inspection
PROTOS has been provided with the Report of the factory inspection (Report
N.15040132.001) performed by TUV Rheinland (Shanghai) on November 25th 2010 as part of
the photovoltaic module qualification according to IEC 61215.
In the TUV factory inspection the following production areas have been inspected:
> Cell line
> Solar Cell tabbing
> String connection
> Lay-up station
> Lamination
> Framing
> Electrical connection
> Power measurement
> Packaging
The ambit of the inspection has covered the production of polycrystalline modules AS-6P-30-
220W series (with 156*156 polycrystalline cells) and of monocrystalline AS-5M-180W series
(with 125*125 monocrystalline cells).
The result of the inspection is good with regards of all the Production line with the following
remarks from the TUV inspector mainly on the materials specifications and testing equipment
calibration:
jpffiffi#5
€enerql;
Thls tq sn inltlal Fl ffir Worklwide =rergy
6ild Manufucturing (Neniqngl fro., [-td. Th+ uuprkEhop and ,anare-
houe€ are in*pe*led; relevEnt dmcuments are fihecfted.
During tfie Fi a srfi,Bfi quantitf A$-6F3&,fi20w aHil As$?dt 'f *0w rflodule$ efBrs produsBd dnd wo{t6,r'ldedaclaied thstth6 wortting process flnd p*rsffist€r*fcr allth# msdul$* $ret+ltE $afire.
Selsw llried Eorne deviations in the produclion prosess and quality eonbcl.
Worldwid* n*eds to nand in tha coffcstiry| repon trrdtlin t weah* effer r*criving ihis feporl,
Froduetion ilr€+essiNo malor d*vieliun* rr*se foundi *$r det#ls pte*s€ r*fer to Beslidfi f-
Sualify ctntnd *nd quality *csurailc*:
llere *nly some deviatlofis ars li6ted, fs{ detsil+ pl*a$€ r6fer to s6st,$n 7 snd 8.
L
trical and sther infsrmation.. no cell type designatien; xo adequale eles-
2. ?he type designation tf the materials drould be clcar in the perchasing ccntract. let*il technical docu-ment$ shsufd be provlded by th€ s{rppller te-g. the dlode r:lanutegturer, s8uls type are not nrentloned in
th6 c{rltrfict}3. Tkere sh+uld be s wf,rk insbucJiEn far Huxi*g agent using: haw to treat it with the cell and string csnnec-
tor, hcw tong to replace i* hsut ts hardte th* vrra*,ter lluxing agent'
d" Lffsni.€taorx Frsce$$: '!l th*re'$ no neintenance manufil; $ th+ gel-conas:]t ts.$t frequency shsuld beqe#find"
$. lnouletian snd lri-pst test: 1) l-{i-pul teti should be 100}4 oonduatedi 2} tlre par*metere fcr hi-pol testsh*uid be speclf,ied i$ ridod{ insfiucti*fi; 3} test resulte shdilld be rs60rded: 4} tfia ruet te*trtage test *houldb+ regular{y eanisdeut in the future; 4) there *r*uld bea daily funcli***l clteck far hi-poi tetter
s. Hi-potie*ler and lR sensar in module *irnulat€r slrssld be calibrated.
7, Fifl$l*utput p0ffer ms&$ffienlent step: 1] ln TIF$'$ calibreti*n tepr{ he measurernent unaertatnty is natgiven, *r:d wrong *landard *as apptied; ?] lhe setting of Temp" Correction kclcr is fr*rn the default sehting hut not lhe e*tual value of their madul*,: 3) lhe tearyoral stability of the simulatar is nol giuen hy suppfiier; 4] tlre supplier s*ould also pru'r*le ttle atc&ptanss r€lsrt 0f ths *irnulat${ $} hdfsfr# m*a8hre$€fii,msdulss arc stored untif raaffi S'lg sfiLriafit teffperaiure; dorage br deflft€d.
8. War*hou, e: 1) The r*quir6#r rri *houfd b* Ful en the wall essy {a ge&oh: ?} terfi-p*rafure and hururidiiy ar* Rsl rccprd4d.
tVorldwide Energy andManufacturing USA, Inc.
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Worldwide Energy and Manufacturing USA, Inc.
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4 WORLDWIDE ENERGY AND MANUFACTURING (NANTONG) CO., LTD
FACTORY VISIT
Protos performed a Factory visit on January 12th 2011.
The factory is located in Nantong, near the coast of the East China Sea, about 120 miles
North of Shanghai. Nantong is the economic hub of the Jiangsu Province, reachable from
Shanghai by means of the motorway.
The Company owns all the parcel of land on which the Nantong facility is located, for a total
surface of more than 40,000 m2; the construction of two new buildings that has been
planned for 2011 and 2012, will bring the total manufacturing capacity to 300 MW per year.
In particular, the first new workshop is now under construction and is supposed to start the
production within the end of 2011, reaching a total production capacity equal to 200MW.
The total installed capacity is actually 120 MW a year (2010).
The commercialized PV modules with relevant classes of power (Guaranteed tolerance on Pn
equal to 0/3%) are:
> Monocrystalline Panels: AS-5M-185W; AS-5M-190W; AS-5M-195W.
> Polycrystalline Panels: AS-6P30-230W; AS-6P30-235W; AS-6P30-240W; AS-6P30-
245W.
At the time of our inspection, the Staff employed for the Production area was made up of
120 people, working on 2 shifts rotation for the soldering lines and 3 shifts for the
lamination.
The production area was protected and secured with safety and security measures and every
worker was properly dressed, wearing smocks, gloves, safety masks and caps. Moreover,
every production area had its own Quality inspector.
The layout of the machinery is correctly organized according to a vertical production line.
The list of the Process Equipments is detailed in the following pictures:
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Figure 5: List of Machinery
Some of the Machines have been moved in Nantong Factory from the Ningbo Factory: this
new installation has been carried out by the Machines supplier and the original Warranties
for all the Equipments are still valid.
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The tools and machinery are located in wide spaces with no interference of the different
activities or interference of the workers among them.
4.1 Incoming goods testing procedure and stocking
A visual inspection of the incoming goods is carried out by the internal Staff in accordance
with adequate instructions prescribed by the Quality Control department.
In particular, the Solar Cells are 100% visual inspected and each 5 cells per lot are tested
(Power measurement) and checked for their dimensions (Thickness measurement).
Suppliers are monitored continuously regarding their delivery and quality performance. All
incoming goods are checked by the Warehouse staff to verify whether or not they match the
bill of loading and labeling, e.g. correct dimensions, product markings and other visual
characteristics.
All inspections on incoming raw material are registered by compiling specific documents
which have to be signed by the Logistic Department and the QC Department.
A Supplier Evaluation Report is compiled for the Qualification of each supplier by the
Purchasing Department.
4.2 Warehousing
Warehousing conditions and stock procedures were found compliant with the standard
procedures, with separate regions dedicated to material stocking and no overlapping areas
of activities, possible causes of unwilling damage to the products.
Some materials were not stored in the main warehouse due to the lack of space: in
particular the solar Cells were stored in a different room, next to the offices.
Moreover, some materials were stocked in the Production workshop: Worldwide Energy staff
explained that this is a temporary storage procedure, which will be changed after the
construction of the new facilities when all the available production and warehousing space
will be reorganized.
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In fact, a new warehousing structure will be included in the new facility which will be built
within the 2011, to increase the current storage space which could not be sufficient for the
expected increase in production.
Sampling test are performed by Worldwide Energy personnel on incoming goods. The
sampling rate is changing according to the kind of materials.
At the time of the inspection the control on the incoming goods was not yet based on a
electronic system. As future approach, Protos advises to consider bar-code reader for the
incoming packages in order to manage more easily the information flows.
A new warehousing area has also to be arranged in the future for the packaged modules
which are now temporary stored in the production area.
4.3 Compliance of the main manufacturing steps with quality procedures
In Nantong factory Protos visited the PV modules manufacturing workshop, where assisted
to the entire production chain process, from quality controls on solar cells up to storage of
packed modules.
Mono and Polycrystalline modules are produced by means of manual module assembly line,
With the work flow chart shown in the following figure:
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Figure 6: PV modules work flow chart
Quality procedures are performed continuously along all the modules manufacturing process,
from the visual inspection and power testing on the Solar cells supplied, up to the final visual
inspection of modules before packing (the Quality Control Points are represented in the
figure with a triangle symbol).
The Company executes its Quality Control by checking the conformity of materials, the
respect of assembling process, and the specifications of the final products.
Worldwide Energy perform quality checks on the incoming goods through its Quality Control
System, according to high quality standards.
Protos has been provided with the Inspection manual which states all the inspection
procedures and the minimum requirements to be verified by the Quality Inspectors of the
various Departments during the production process.
In the following figures the Quality Organization Structure and the chart of Department Duty
in Quality Management System are shown.
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Figure 7: Quality Organization Structure
Figure 8: Chart of Department Duty in Quality Management System
The production steps for modules production are outlined in the following figure.
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The process starts by welding the cells with bus ribbon to meet required output power in
series.
The components are laid up and assembled with EVA film and Back Sheet to encapsulate the
strings in order to protect them from external environment and prevent water infiltration
(lamination process).
Follows trimming process and sealing of Junction-Box for electrical connection and then
frame installation is performed to ensure mechanical strength (Framing process).
Electroluminescence tests are performed on each module before (intermediate test) and
after the lamination process (Flash test).
Electroluminescence testing is a powerful tool for a fast in-line imaging of electronic and
mechanical properties on wafers, cells and modules, allowing for a fast detection of process
faults and handling errors, in particular for highly automated production lines, enabling a
quick feedback (with a proofing image) to the suppliers of raw materials and production
equipment.
After the production process is completed, quality control is performed and module
maximum power output, temperature and other relevant parameters are measured and
modules are classified accordingly to the power output (Simulation).
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4.4 R&D Laboratory
Protos was led into the R&D lab where quality testing procedures, as damp heat, thermal
cycling and humidity freeze, are continuously performed.
The R&D department is able to perform all the tests required by the IEC (International
Electrotechnical Commission ) rules on new Products.
Before starting any commercial production, the reliability and compliance of every
component will be tested in the R&D laboratory.
In case of positive results of the test performed then the modules are sent to TUV and UL
laboratories in order to achieve the certifications.
Protos has been provided with an Additional Test report regarding all the tests which have
been carried out on samples of Amerisolar PV monocrystalline module on November 26th
2010. The following tests have been performed to check the reliability and safety of
Amerisolar modules:
> Insulation test
Test equipment: Hi-pot tester (Model: CS9922I)
DC voltage source, with current limitation, capable of applying 500 V or 1000 V plus
twice the maximum system voltage of the module.
> UV preconditioning test
Test Equipment: UV preconditioning test chamber (BR-PV-UV)
The equipment is capable of maintaining the module temperature at 60℃± 5℃
measuring the irradiation of the UV light produced by the UV light source at the test
plane of the module, within the wavelength ranges of 280 nm to 320 nm and 320 nm
to 385 nm (with uncertainly of ±15 %).
> Thermal cycling test
Test Equipment: High and low temperature alternating damp heat test chamber
(HRW4024F)
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A climatic chamber with automatic temperature control and free circulation of air
inside to minimize condensation on the module during the test, capable of subjecting
one or more modules to specific thermal cycles (accuracy ±1 ℃).
> Humidity-freeze test
Test Equipment: High and low temperature alternating damp heat test chamber
(HRW4024F)
> Damp-heat test
Test Equipment: High and low temperature alternating damp heat test chamber
(HRW4024F)
Protos remarks how the Worldwide Energy’s R&D facilities do respect the highest standards
in photovoltaic technology.
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4.4.1 Technical Specifications of the main R&D equipments:
> High and low temperature alternating damp heat test chamber
Model: HRW4024F
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> UV proconditioning test chamber
Model: BR-PV-UV
> Salt water spray test chamber
Model: BR-SST-90
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> Universal material tester
Model: BR-P2
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> Hi-pot tester
Model: CS9922I
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> Solar cell tester
Model: XJCM-9
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4.5 Improvements Areas
> Incoming goods stocking and control procedures could be optimized, also
accounting for increasing volume of 2011.
> IT procedure could be implemented throughout the chain in order to help keeping
record of production process.
> Module sorting could be implemented as a standard procedure at the end of the
production line, with the creation of 2-3 sub-classes of modules within the same Power class,
in order to provide for additional services to the final customer.
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5 THE PRODUCTS
5.1 Number and type of commercialized PV modules
Worldwide Energy and Manufacturing (Nantong) co., Ltd currently produces the following
Amerisolar Brand PV modules:
> Monocrystalline PV module 72 cells: AS-5M-xxxW (185W÷195W).
> Polycrystalline PV module 60 cells: AS-6P30-xxxW (230W÷245W).
Worldwide Energy and manufacturing (Nantong) Co., Ltd detains the following PV
modules certifications:
Modules : AS-5M-xxxW (170W÷205W in increment of 5W)
AS-6P30-xxxW (210W÷250W in increment of 5W)
Certificates:
> IEC EN 61215 - TUV Rheinland Certificate N. 50194421
Issue date: December, 27th 2010
> IEC EN 61730 - TUV Rheinland Certificate N. 50194884
Issue date: December, 27th 2010
Worldwide Energy and Manufacturing USA, Inc. detains the following PV modules
certifications:
Modules : AS-6P-xxxW (250W÷285W in increment of 5W)
Certificates:
> IEC EN 61215 - TUV Rheinland Certificate N. 50191250
Issue date: November, 3rd 2010
> IEC EN 61730 - TUV Rheinland Certificate N. 50191251
Issue date: November, 3rd 2010
Modules : AS-6P30-xxxW (60 Poly Cells - 200W÷240W in increment of 5W)
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Certificates:
> IEC EN 61215 - TUV Rheinland Certificate N. 50193526
Issue date: December, 17th 2010
> IEC EN 61730 - TUV Rheinland Certificate N. 50193527
Issue date: December, 17th 2010
Modules : AS-5M-xxxW (190W÷210W in increment of 10W)
Issue date: April, 14th 2010
AS-5M-xxxW (220W÷250W in increment of 10W)
Issue date: November, 26th 2010
Certificates:
> IEC EN 61215 - TUV Rheinland Certificate N. 60029800
> IEC EN 61730 - TUV Rheinland Certificate N. 60029801
Amerisolar PV modules are supplied with a Nominal Power tolerance equal to 0/+3%
The tolerance on peak nominal power is a percentage related to the quality of
manufacturing; it usually ranges from ±2% up to ±5%. The smaller the tolerance, the more
predictable will be the electrical performance of the module.
A low modules tolerance range reduces the mismatch effect (which can occur when modules
with different electrical specifications are connected) improving the energy production of the
PV Generator.
The tolerance is an important value to assess the commercial policy of the manufacturers.
The top class manufacturer are those using:
• A reduced negative tolerance for nominal peak power
• A zero overlapping area between different classes of the same product
Here below the Amerisolar PV modules nominal peak power grouped per class of product is
shown:
Monocrystalline PV module 72 cells
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160
170
180
190
200
210
220
Polycrystalline PV module 60 cells
200
210
220
230
240
250
260
270
Protos favorably remarks how Amerisolar PV modules presents a plus-only power tolerance
and a reduced tolerance range in respect to the market (between 0 and +3% for all
commercialized modules).
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5.2 Modules Design Parameters
The Technical Specifications of the Amerisolar Monocrystalline PV modules are shown in the
following table:
Figure 9: AS-5M – Monocrystalline 72 Cells
The Mono modules’ efficiency ranges from 13.32% up to 15.67%; these values can be
considered as medium-high performing within market standards.
NOCT (Nominal Operating Cell Temperature) is the cell temperature when irradiance is
800 W/m2, ambient temperature is 20°C and wind speed is 1 m/s at a module tilt-angle
equal to 45°. Technical values are ranging from 41 °C up to more than 50 °C. The NOCT is a
very critical parameter: for maximum power output of the module, lower operating
temperatures (and higher irradiance) are needed.
The NOCT of the Amerisolar Solar modules (mono and Poly modules), which is equal to
47±2°C, is aligned within market standards.
The Technical Specifications of the Amerisolar Polycrystalline PV modules are shown in the
following table:
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Figure 10: AS-6P30 - Polycrystalline 60 Cells
The Poly modules’ efficiency ranges from 12,23% up to 14.68%; these values can be
considered as medium performing within market standards.
Related to the nominal operating cell temperature are the Temperature Coefficients for
Pmax, Voc and Isc. These coefficients represent the variation of electrical output of the
module, and hence its performance, with respect to an increasing in the operating
temperature.
A high quality, crystalline silicon solar cell, at 25 °C cell temperature, may produce 0.60 volts
open-circuit (Voc). The cell temperature in full sunlight, even with 25 °C air temperature, will
probably be close to 45 °C, reducing the open-circuit voltage to 0.55 Volts per cell. The
voltage drops modestly, with this type of cell, until the short-circuit current is approached
(Isc).
Maximum power (with 45 °C cell temperature) is typically produced with the 75% to 80% of
the open-circuit voltage and 90% of the short-circuit current. This output can be up to 70%
of the Voc x Isc product.
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The short-circuit current (Isc) is nearly proportional to the illumination, while the open-circuit
voltage (Voc) may drop only 10% with a 80% drop in illumination. Lower-quality cells have a
more rapid drop in voltage with increasing current and could produce only 50% Voc at 50%
Isc. The usable power output could thus drop from 70% of the Voc x Isc product to 50% or
even as little as 25%.
For similar modules, actual observed values of the Temperature Coefficient for Pm range
from 0,38%/°C up to 0,50%/°C.
The value 0,47 %/°C shown by Amerisolar Solar modules is comprised within market range.
All the tolerance are correctly indicated in the technical data sheets; their value depend on
measurements accuracy that is considered more than acceptable and aligned with higher
technological standards for this type of application.
5.3 Warranty conditions
Worldwide Energy (WEMU) provides its customers with the following warranties:
• Limited Product Warranty - Ten-Year Repair or Replacement.
• Guaranteed peak Power Limited Warranty.
WEMU warrants its Photovoltaic Modules, including factory-assembled DC connectors and
cables, to be free from defect in materials and workmanship under normal application,
installation, use and service conditions, for a period of 10 years (Limited Product Warranty)
from the date of sale as shown in the Proof of purchase to the Buyer.
The Product Warranty for PV Modules(s) covers:
> Failure due to defective manufacturing:
o Failure due to oxygenation/distortion of aluminum frame;
o Cracking of the front glass surface due to foreign objects inside the glass;
Note: This warranty shall not apply to cracking of glass caused by external shock from flying
objects or by external stress.
> Failure due to defective materials: defective or malfunction of the junction factory-
assembled cables and male/female connector;
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> Non-conformity to specifications due to faulty production and/or inspection
processes.
If its modules fail to conform to this warranty, Worldwide Energy will, at its option, either
repair or replace the product, or refund the purchase price paid by the customer.
Worldwide Energy warrants that, for a period of 10 years from the date shown in the
commercial invoice to the Buyer, the power output of its modules will not fall below 90% of
the of the minimum “Peak Power at STC” as specified in WEMU’s Product Flash Datasheet
and that for a period of twenty–five (25) years it will not fall below 80% of Pmin (Limited
Power Output Warranty).
The “Limited Product Warranty” and “Guaranteed peak Power Limited Warranty” cover only
the transportation cost for reshipment of any repaired or replaced PV Modules(s) to the place
of installation, and do not cover any transportation charges for the return of PV Module(s) to
WEMU, customs clearance or any other costs related to installation, removal, or reinstallation
of the PV Module(s).
Moreover, the “Limited Warranties for PV Modules” are applicable only to Buyer who has
purchased the PV Modules directly from.
In order to provide a reliable 25-year warranty, on January 12th 2011 Worldwide Energy and
Manufacturing (Nantong) Co., Ltd. signed an agreement (valid to January, 11th 2013) with
Alltrust Insurance Brokers and Risks Consultants Co., Ltd., a China nationwide insurance
brokerage company headquartered in Shanghai which was established under the approval of
Chinese Insurance Regulatory Commission.
Alltrust has launched the first long-term (up to 25 years) quality warranty insurance
specifically dedicated to the solar photovoltaic products by mean of alliances with
international financial groups and re-insurance groups.
The insurance plan provided by Alltrust has gained recognitions from large foreign
purchasers, financial institutions and governments.
Alltrust product quality warranty insurance provides cover for payments under the following
warranties given by Worldwide Energy and Manufacturing (Nantong) Co., Ltd.:
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> Any defect of modules in materials and/or workmanship under normal conditions
within a period of two years from the date of delivery to customer.
> A module output power no less than 90% of the rated power within ten years from
the date of sale to the customer.
> A module output power no less than 80% of the rated power within twenty-five
years from the date of sale to the customer.
The repair or replacement of the power shortage costs liable to Worldwide Energy and
Manufacturing (Nantong) Co., Ltd. as well as transportation cost, will be compensated by
Alltrust.
Protos considers favorably this policy since it can significantly reduce business risk concerns
of the insured and risk management costs.
By reducing the foreign trader’s risk the interests of both buyers and seller can be protected,
promoting Amerisolar PV modules into the international market.
In the following figure the Certificate of Product Quality Warranty issued by the Company
Alltrust Insurance Brokers and Risks Consultants Co., Ltd. is shown.
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ffiffi0s
5.4 List of suppliers
The Amerisolar PV modules are assembled using different suppliers and materials. protos has
been provided with the following list of Qualified Supplier in which, for each material, one or
more Supplier have been identified.
All the manufacturers selecLed for the supply of the main module components can be
considered in the top-rated suppliers.
1n particular: Motech is one of the largest solar cell manufacturers worldwide in terms ofproduction capacity and output; TIANJIN SECD GLASS CO., LTD. is a leading supplier in
China for special glass designed also for photovoltaic applications; Bridgestone is known as
the world leader company in the production of EVA sheet and is to increase production ofthe adhesive film to a manufacturing capacity by 1,200 tons of Ethylene Vinyl Acetate (EVA)
film.
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Worldwide Energy andManufacturing USA, Inc.
AMERISOLAR PV modules
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Worldwide Energy andManufacfi;ring USA, Inc.
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6 CONCLUSIONS
Worldwide Energy and Manufacturing USA, Inc. is an international manufacturing and
engineering firm founded in September 1993 and focused on photovoltaic modules and on
contract manufacturing services in mechanical, electronics and fiber optic products; it is
traded publicly in the United States (OTCBB: WWMU), with the headquarters located in
California, USA and offices in China, Spain and Italy.
Although the Group is historically focused on manufacturing components for high tech
industries, in 2008 they decided the expansion into the solar module markets. The company
currently designs, develops, manufactures, and sells PV modules under the AmeriSolar brand
in Europe, South Korea, Australia and North America.
The Company, already present with its photovoltaic products in the Italian and European
markets, intends to enter in the Italian market of the big photovoltaic plants, financed
following Project Financing schemes; in this framework, the support of Protos has been
requested to accomplish a General Audit of the Worldwide Energy and Manufacturing
(Nantong) Co., Ltd. Factory located in Nantong, China.
The Company owns all the parcel of land on which the Nantong facility is located, for a total
surface of more than 40,000 m2; the construction of two new buildings, that has been
planned for 2011 and 2012, will bring the total manufacturing capacity to 300 MW per year.
In particular, the first new workshop is now under construction and is supposed to start the
production within the end of 2011, reaching a total production capacity equal to 200MW. The
total installed capacity is currently equal to 120 MW per year (2010).
Protos described the business process, by referring for its evaluation to high-rated market
standards recorded for similar Companies and has performed an onsite visit in order to check
the appropriateness of the production procedures and to verify their compliance to the
Quality standards.
jPRfiTOS
puring the inspections, Protos appreciated the highly professional skills of the management,
the organization, and the safety procedures shown.
At the time of our inspection, the Staff employed for the Production area was made up of
120 people, working on 2 shifts rotation for the soldering lines and 3 shifts for the
lamination. Protos assisted to the entire production chain process: from the Quality controls
on solar cells up to storage of packed modules.
The production area was protecLed and secured with safety measures and every worker was
properly dressed, wearing smocks, gloves, safety masks and caps. Moreover, every
production area had its own Quality inspector.
Warehousing conditions and stock procedures were found compliant with the standard
procedures, with separate regions dedicated to material stocking and no overlapping areas
6f activities, possible causes of unwilling damage to the products,
Quality procedures are performed continuously along all the modules manufacturing process,
from the visual inspection of raw materials up to the final inspection of modules before
packing,
Suppliers are monitored regarding their delivery and quality performance: all incoming goods
are checked by the internal Staff, in accordance with the instructions prescribed by the
Quality Cantrol department, in order to verifli whether or not they match the bill of loading
and labeling, e.g. correct dimensions, product markings and other visual characteristics.
Worldwide Energy and Manufacturing Co., Ltd. detains the IS0 900ft2O08 Ceftificationfor Design and Production for Solar Modules, issued on August 3'd 2010 and valid until
August lnd 2A!3, and the ISO 140$1:2004 Certification for Design and Froduction of1-Solar Cells and Modules issued on December Znd 2010 and valid until December l't 2013.
From the analysis of the technical specification of both mono and polycrystalline modules,
Protos confirms that their main electrical parameters can be considered in the medium-high
market range.
A few Improvement Areas have been identified throughout this report"
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