Jonsa Antennas: COMPANY REPORT Satellite Dish Manufacturer Jonsa, Taiwan

COMPANY REPORT
Satellite Dish Manufacturer Jonsa, Taiwan
JONSA
Antennas
Teil des JONSA
Fabrikationsgelndes
in Nantou in Taiwan
exports satellite dishes worldwide for 25 years

guarantees consistently high quality even with
extremely large volume production
one of only few manufacturers of Ka band
antennas
produces all dish moulds in-house
ready to manufacture special-purpose dishes,
e.g. for multi-satellite reception with multi-LNB
holder
98 TELE-audiovision International The Worlds Leading Digital TV Industry Publication 09-10/2014 www.TELE-audiovision.com
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99
COMPANY REPORT
Satellite Dish Manufacturer Jonsa, Taiwan
Major providers of pay TV via satellite usually give their subscribers the
necessary reception equipment free of
charge, or to put it in a more realistic way the price is included in the
monthly subscription fee. In most cases, those components are not manufactured by the content providers themselves, but rather are sourced from
third-party manufacturers which act as
OEMs or ODMs.
If youre in the OEM business and are
looking for a steady flow of orders and
revenue from content providers, one
of the key requirements is consistently
high quality. JONSA is an excellent example for that. The Taiwanese company was founded in 1988 and has been
producing satellite antennas for leading
satellite pay TV providers around the
world. What made JONSA such a major
player? There is only one way to find
out and so we embarked on a journey
to Nantou in Taiwan. Nantou is a rather
small town close to Taichung in western Taiwan, yet it is here that JONSA
has set up its administrative offices and
huge production halls.
The business was founded by David
Lin in 1988 and up to this very day he
is owner and chairman of JONSA. Originally, JONSA was in the business of
erecting large halls or more precisely
of producing metal walls for setting
up halls. So come to think of it, it was a
pretty small step from straight walls to
parabolic shaped antennas.
The first model introduced by JONSA
was a 120cm dish which at the time
was lathed from a single sheet of metal.
Initially, production volumes were tiny:
JONSAs monthly output was roughly
Nantou,
Taichung,
Taiwan
David Lin is
founder, owner
and chairman of
JONSA.
Main entrance
to JONSA.
Quality antennas
for the worlds
largest content
providers
101
Visitors are welcomed to

the JONSA headquarters.
ten antennas, Mr. Anthony fondly remembers the companys pioneering

days. He is the person in charge of the
companys sales team and responsible
for communication with key account
customers. While the first JONSA dishes were made for C band reception, export of Ku band antennas also began
as early as 1989. Our first export year
saw shipment of approximately 24,000
antennas, Mr. Anthony recalls with
pride.
These days, however, JONSA plays
in an entirely different league: We
produce about 15 million dishes per
year. Which satellite bands are covered today? 80% of our output are
Ku band antennas, 10% are designed
for C band reception, 5% for the S and
L bands and another 5% take care of
the Ka band. This latter segment is on
an enormous upswing, however, since
JONSA is one of only a select few manufacturers worldwide capable of manufacturing antennas for this rather tricky
frequency band. And if youre in such a
position of strength the prospects for
an additional increase in Ka band sales
are looking excellent.
Most of JONSAs satellite antennas
are purchased by large pay TV providers or in the case of Ka band dishes
providers of Internet via satellite. Since
this is currently only offered in North
America and Europe on a larger scale,

those companies are rare and far in between. So chances are the Ka band antennas they use are manufactured by
JONSA. We have concluded non-disclosure agreements with all providers,
so were not in a position to give you
their names, Mr. Anthony explains the
high level of confidentiality maintained
by JONSA.
JONSA has a markedly global strategy, and the numbers Mr. Anthony provides lend impressive proof to that approach: 70% of our production output
is shipped to the Americas, with North
America the final destination for half of
those antennas, and Central and South
America for the other half. 10% go the
Middle East and 5% reach Europe. We
notice that Africa is not on that list at
all. True, but it is a market for which
JONSA envisages enormous potential
for development and expansion, which
is in the process of being launched.
Our local agent does excellent fieldwork, particular in sub-Saharan Africa,
which we have earmarked for strong
business growth. The South American
market is also set to embark on continuous expansion, not least due to the
Olympic Games in Brazil that will take
place in 2016. Demand for Ka band
antennas also experiences promising
growth, Mr. Anthony reveals, and be-
tween 2006 and 2013 we have shipped

a total of six million Ka band dishes
with 66cm and 75cm to North America
alone.
Those figures are truly impressive,
and they also hint at the fact that JONSAs Nantou production premises are
not able to handle all that demand on
their own. Here in Nantou we focus
on Ka band and Ku band antennas. We
set up an additional production facility in the Chinese city of Nanjing as far
back as 1993, where we manufacture
all panel antennas and C band dishes. As a matter of fact, the Chinese
workforce already outnumbers that in
Taiwan. 500 staff work for JONSA in
China, while the corresponding number
in Taiwan stands at 400. At the Nantou
headquarters of JONSA there is also
the administrative building for some
35 employees, the sales and marketing
team with 17 members of staff and
first and foremost the R&D department with a workforce of 25.
When it comes to antenna production, we never stop improving. Whats
more, the demands placed on manufacturers are always rising as well. The
Ka band, in particular, requires a great
deal of attention to detail and excellent
precision all through the production
chain, Mr. Anthony explains and adds:
While the accuracy tolerance in Ku
band antenna production may exceed

0.5 mm RMS (root main square), for Ka
band dishes it must be lower than 0.25
mm. This is also one of the reasons
why JONSA has set up a top-notch quality lab for continuously evaluating and
ultimately improving the quality of its
satellite antennas.
This is our secret of success, and
there are some pay TV providers which
have been cooperating with us for the
last 20 years. This can only work if
the quality is right, if it is permanently
checked and if our customers can rely
on consistently high production and
product quality.
Inside the JONSA showroom,
where some of the antenna

models of the JONSA range are
presented.
105
1. Moulds are required for pressing individual

satellite antennas. This machine cuts a new
mould for a 150cm satellite dish according to a
pay TV customers bespoke specifications.
2. The finished moulds undergo post-treatment
here and are then inserted into the press tools.
3. The companys warehouse hosts a large
variety of moulds for different sizes and types of
antennas.
4. Small 60cm antennas are pressed here.
JONSA operates a total of 11 large presses at
its main location in Taiwan, and another 13 at its
Chinese productions facilities.
4
2
8
5. This is how antennas are pressed: The roll on
the left consists of endless sheet metal, with a new
roll of 0.8mm sheet metal weighing 2,200kg. The
metal is fed from the roll to the large press fully
automatically. Next, antennas are put into shape
from that sheet metal with a pressing force of up
to 600 tonnes. Large presses like this one have an
hourly output of up to 500 antennas with a diameter
of 60cm.
6. View of one of the production floors where
mounting components for satellite antennas are
manufactured.
7. View of the production floor with large presses,
which make antennas out of pre-cut metal. These
presses are perfectly suited for the production of
smaller antennas, such as the 45cm variant.
8. Feedarm holder production: Pre-cut tubes are
ready for assembly.
6
109
11
10
12
9. The tubes need to be

placed into the feeding
section of the machine.
10. The machine then grabs
one tube after the other and
bends it according to predefined specifications.
11. The holders leave the
bending machine.
12. The mounting holes are
then punched out manually.
13. Complete mounting
systems are punched at this
production line.
13
14. It would take one hour to travel one entire journey from beginning to end on this
400m endless conveyor belt. It goes without saying that JONSA only uses non-toxic
and RoHS-certified paints.
15. All finished satellite antennas and mounting components are spray-painted with
weather-proof paint at this huge spray-painting facility. JONSA runs four of those
painting facilities where 22,000 individual pieces are painted in a two-shift operation.
16. Clad in an overpressure suit a JONSA member of staff refills one of the paint
chambers.
17. Random sampling takes place at the end of the conveyor belt to make sure enough
paint is applied to antennas and components.
18. All finished components for a satellite antenna complete with all mounting
components are packaged here and made ready for despatch to customers in the
case of JONSA these consist of large pay TV providers and major national distributors.
14
15
16
17
18
113
19
20
25
Quality Assurance at JONSA
22. Specimens of all accessory components like clamps and

pole holders are stored here. Components from the actual
production chain are checked for accuracy against these
specimens on a regular basis.
23. The result of an optical 3D check. The calculated
measurement results are compared with the corresponding
value of the production plan to determine the manufacturing
tolerance.
24. An optical 3D device is used to determine the accuracy
of components such as clamps and pole holders.
25. The quality assurance library hosts all sample plans for
production.
26. An electron microscope is used to have an in-depth look
at the surface of an antenna component.
27. The surface of components is checked with this x-ray
device.
28. How do components made of plastic (such as LNB
holders) react to continuous exposure to sunlight? This
UV test unit gives the answer. Components or parts
thereof are mounted on slots and exposed to UV radiation.
Exposure over 1000 hours is equivalent to a real-world
exposure of one year. JONSA tests its components for a
service life of eight years.
29. Stretching and punching: The robustness and
sturdiness of antennas can be tried and tested with this
machine. It stretches and punches components and at the
same time measures how much the tested material gives
way under pressure.
19. Mechanical components such as pole holders and feedarm holders

must be attached to the antenna in a way that guarantees similar
durability to that of the dish itself. A saltwater test lab is used to
evaluate the quality of the components (screws, nuts, clamps, etc.)
by spraying them with saltwater for 100 hours. This corresponds to
roughly 5 to 7 years of actual outdoor use.
20. Individual antennas are taken from the production chain on a
regular basis and checked with a precision laser to make sure their
form and shape is up to specifications. These spot checks are carried
out automatically. The only thing a JONSA employee has to do is put
the antenna in place and initiate the checking process.
21. A laser scan with manual operation is available to check larger
antennas as well.
21
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29
22
24
26
27
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32
30. Carl Chen is the head of Supply Chain
Management. His position is paramount
for guaranteeing a flawless production
process and maintaining consistently
high quality.
31. Stanley Chiang is production
manager at JONSA and has the entire
production operations under his control.
32. Jimmy works as product manager and
is responsible for product development.
33. Theres no shortage of technical
challenges at JONSA. At the moment
all eyes are on the Ka band with
its extremely detailed and precise
requirements. Rick Tseng is the manager
in charge of the R&D team. Here he is
seen in the test lab, looking at a Ka band
feed made by JONSA.
34. 17 members of staff in the Sales Team
act as interface between JONSA and its
customers. Among them are Paula Chen
(left), who is in charge of marketing, and
Conny Chen (right), head of Sales.
31
34
117

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COMPANY REPORT

Satellite Dish Manufacturer Jonsa, Taiwan

exports satellite dishes worldwide for 25 years

www.TELE-audiovision.com 09-10/2014 TELE-audiovision International

Satellite Dish Manufacturer Jonsa, Taiwan

www.TELE-audiovision.com 09-10/2014 TELE-audiovision International

Visitors are welcomed to

ten antennas, Mr. Anthony fondly remembers the companys pioneering

America and Europe on a larger scale,

tween 2006 and 2013 we have shipped

band antenna production may exceed

Inside the JONSA showroom,

where some of the antenna

www.TELE-audiovision.com 09-10/2014 TELE-audiovision International

1. Moulds are required for pressing individual

www.TELE-audiovision.com 09-10/2014 TELE-audiovision International

9. The tubes need to be

Quality Assurance at JONSA

22. Specimens of all accessory components like clamps and

19. Mechanical components such as pole holders and feedarm holders

www.TELE-audiovision.com 09-10/2014 TELE-audiovision International

www.TELE-audiovision.com 09-10/2014 TELE-audiovision International

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