エンジニアチームは、ポーランド工場を訪問し、出来事が満載な6月なりました。特に、ポーランドでの高品質プラスチック部品製造の開発においては、ポジティブな結果を証明する出来事となり、ここからさらに生産工程を進め、段階的に量産に近づけることができるとわかりました。プラスチック部品を作る準備は、容易ではありませんでしたが、ついにこのハードルを克服することができました。

プラスチック部品については、ある程度入手できましたが、想定していた数よりも少ないものでした。 これは、オーディオ品質ゲートで見つかった不具合によるもので、私たちは、最良の耳栓だけを採用した為です。その為、採用率についても低いものとなりました。このことにより、私たちはより高品質のマイクに切り替えることにしました。

ノイズキャンセル性能は、原音に正しくマッチするかどうかに左右されます。 そこで、現在は、新しいマイクを使った一連の耳栓を作っています。それは、感度がより絞られた許容範囲を持っています。 また、チューニングパラメータの新しいセットも用意できています。これは、マイク感度の変化を補正するために、信号レベルを2dB上げるパラメータセットです。

先週、新しいコンポーネントを受け取り、テスト設定を実施、また慎重に分析もしました。 テスト結果には明らかな改善が見られ、目標値に戻っています。 ただし、この変更により、前回までに想定していた出荷日程に間にあわせることができません。新しく改良されたオーディオエレクトロニクスが高速生産に利用可能になるのには、ここから2週間かかります。 それに伴って、製造スピードは、段階的に上げていきます。 この変更にもかかわらず、少ない数ですが、6月中に少量のシリーズを製作することができました。7月からは、フルスピード生産を達成するための立ち上げが求められます。

今後のアップデート情報でも、製造工程においての重要な詳細をご報告し、またイベントや展示会からのニュースや調査結果についてもご報告していきます。

(最新情報詳細については、下記英語版をご覧ください。)

June has been an eventful month for us, in which our engineering team visited the factory in Poland again. Especially the establishment of the high-quality plastic part production in Poland has been a positive milestone for QuietOn, which enables the manufacturing to progress and allows us to gradually approach the phase of mass production. This plastic part manufacturing set up has been a struggle but finally we managed to overcome it 😊

In the following update, we will share with you the important details of our production process as well as news and insights from ongoing events and exhibitions.

 Here are some insights from the plastic part manufacturing:

Our mechanical engineer Tero is checking the plastic part manufacturing machine in Poland.

A brief introduction of the machine functionality:

First, the mold parts are pushed together, then the plastic grains feeder pumps into the material, the machine heats it up and pushes it through the cylinder with high pressure. The solid plastic gets in the final shape when it is cooled down, then the molds are opened and the parts get out.

The metallic and very precisely manufactured molds are pushed together.

The plastic parts were carefully analysed and manufacturing parameters were adjusted to get the high quality. Those parts were then sent to product assembly from where we got the final approval that they were working perfectly.

The mechanical assembly is confirmed to be completely doable at a high level of accuracy by the well-trained and experienced operators. They are able to assemble the speaker gasket, and top cover with its gaskets reliably. You can refer back to the manufacturing process in this update.

Status

Even though we finally got the plastic parts we were able to produce only smaller quantities of the products than targeted, due to the identified variations in our tight audio quality gate, as only the very best ones were accepted. Hence, the yield was too low. For this reason, we decided to switch to higher quality microphones.

The noise cancelling performance depends on a how accurately the signal matches the original noise. That’s why we are assembling a test batch of the earplugs with a new microphone that has a tighter tolerance of sensitivity. We have prepared a new set of tuning parameters, i.e. sets of parameters that boost the signal level by 2 dB to compensate the microphone sensitivity change.

We got the new components last week, made the test build and analyzed it carefully. The test results show significant improvements so now we are now back on track. However, due to this change, our previous estimation of delivery could not be reached.

This picture shows a close up of the audio responses in certain frequency space. The colored curves represent different devices measured. The lower colored curves in the picture show a group of devices with the improved audio setup. We can see that the variance is much smaller, which means we have higher quality devices.

It will take two weeks to get the new improved audio electronics for a full-speed manufacturing. Subsequently, the manufacturing speed will increase step-by-step. Despite this change, we can still produce a small batch in June. From July on, the ramp up is then targeted to reach the full speed. We aim to produce 3000+ pieces during that month.

 Recent feedback of the product

We have received again a lot of positive feedback from various people who have been testing the device. Perhaps the most significant feedback was the best Good Sleep Award from Japan Sleep Exhibition.

Jurors of the Good Sleep Award and visitors of the Sleep Expo 2019 in Japan were eager to test the earplugs and were delighted and impressed by their effectiveness.

Even if you turn over during sleeping, the products are completely wireless, it will not get annoying or distracting to wear the earplugs. They specialize in sleep, making them different compared to other noise canceling products and very effective.” – Mr. Shogo Fujii, Director of the Medical Health Lab/ Deputy director of Nikkei BP Intelligence Group

People who are troubled with sleep first search for new pillows and other bedding, but QuietOn Sleep functions as a sleep supporter.” – Mr. Norihito Yasuda, Chief editor of Dime from Shogakukan

Apart from that, we got great feedback from Simon Hill, reporter of Digital Trends, specialized on new technology:

QuietOn Sleep did a remarkable job of blocking out noise. It’s most effective against low frequency noises, like snoring, traffic, or airplane engines.”

 We are particularly delighted about the positive comment concerning the audio performance in both hearing and silent mode:

The QuietOn earbuds were very effective at blocking certain noises, so I could be in the room with a robot vacuum and hardly hear it, but when my wife spoke to me, the sound was crystal clear.

For people who crave absolute silence, QuietOn will work best.“ – Digital Trends

Last week, QuietOn exhibited at FTE’s Ancillary Revenue Show in Istanbul. We have welcomed a good stream of visitors from airlines and industry players who have been impressed by QuietOn Sleep’s ability to create silence.

Since we want to ensure the best possible quality, we keep our quality control gate high. Thus, the audio test round has to be done at a maximum accuracy. We have sent our engineers to work onsite with the operators in the factory. So overall, there are some delays, but the project has been progressing in manufacturing and we’re still very confident that you’ll get your investment back at its best returns!

We have been sending out the first dozens of devices to backers and our distribution partners and QuietOn Sleep is getting great reviews, which motivates us strongly in this challenging journey. We continue working hard to get it to you as soon as possible.

We cannot thank you often enough for your support. The uplifting words we keep reading from you help and motivate us on this long road to the completion of QuietOn Sleep. We are endlessly looking forward to finally providing all our supporters with their key to a restful and relaxing sleep. Please stay tuned with us!

Lots of love,

QuietOn team

 

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