Hello our dear customers,
Perhaps the Finnish summer can never be hotter than the question “When can I get my QuietOn Sleep?”. We do understand and are happy to know that our product will help solve your problem. So let’s catch up with the project’s status.
As many have recommended to put the delivery updated information right at the beginning of the update, we’ll put it right here for you. However, please finish reading the whole update to have a more holistic view on the project development.
“When will I get my product?”
After discussion with our manufacturing partner, we decided to have more operators in the team to work in three shifts (so including the night shift as well), to make sure we can produce as many as we can. Every week, the engineers from QuietOn fly to Poland to work closely with the team there (operators, product manager, quality control manager…) to ensure everything goes well, spot the unexpected errors, fix them right away, and make immediate decision if needed.
The planned manufacturing speed is: 100 devices/ shift * 3 shifts/ day * 70% yield*5 days/ week = 1000 devices/ week.
It’s very expensive for us to run our manufacturing at 70% yield. However, we want to be committed to delivering this product to you as soon and quick as we can, and at the same time, not to compromise our quality standard. Also, we are surely improving the yield percentage in the coming weeks.
For some of you that haven’t read the update in April, we just copied here some parts of it, which explain the role of the operators and the yield percentage. Skip this part if you already read the update in April.
How are the earplugs made in the mass production process?
SMD process is applied in our earplug mass production. SMD is the abbreviation of surface mount devices, a device assembled using surface mount components and technology.
The process used in QuietOn earplug manufacturing is described in detail as below:
A PCB (printed circuit board) panel is manufactured. It is a board about the size of an A5 sheet of paper. It contains 40 PCB modules, each used in one earplug. The blank panels arrive at the factory and our contract manufacturer assembles the components on it.
Firstly, the solder paste is screen printed on one side of the PCB. Then the “pick-and-place” robot automatically puts components on the surface of the PCB which then goes into a reflow oven where high temperature melts the solder paste. The components become physically and electrically attached to the PCB. The panel is flipped around, and the process is repeated for the other side.
0.6 x 0.3 mm is our smallest component, and they have to be picked and placed with an ultra-accuracy.
There are other two components that can’t be assembled with the automated pick-and-place robot: the speaker and the battery holder. They are, therefore, soldered manually. The following steps are completed with the aid of a microscope and tweezers.
The first test step is done at this phase. The proper level of air leak is measured from the pressure relief channel with a semi-automated tester. Those devices with a too high or too low leak are rejected and the speaker gasket assembly is repaired.
The battery is slid into the battery holder. Other mechanical parts are put in their positions, and the PCB is lowered on top of them. The plastic top cover is put over the PCB carefully, aligning the gaskets around the charging contacts. This step has to be handled with caution, in order not to crease the gasket. Additionally, in this phase, the speaker wire has to be routed safely so it doesn’t get pinched between the plastic covers.
The top cover is attached permanently with the ultrasonic welding machine and a foam filter is inserted into the audio tube. This step finalizes the assembly of the earplug.
The earplugs are then numbered to go through different tests and to be analysed.
The process involves some delicate works that need an extreme care and caution from human labour, which can’t avoid errors . After an earplug is assembled, it has to go through the three tests (Audio test, Air leak test, and charging test). More details can be found here.
If the earplug doesnt pass any of the tests, we have to open it, examine and spot where the problem is. There are some errors here and there in the assembly process, but all have been improved. Our newly trained operators have managed to get the yield increased.
New audio component, Tuning, & Depaneling
In the previous update, we mentioned the new audio component with adjusted parameters (more details), we got them and they work perfectly well, and also the tuning.
The lazer cut system for depaneling comes in use, which speed up the manufacturing process and reduce quality risks.
One extra mile for a better understanding:
We have shared with you from the designs, the manufacturing process, to where the problems arise and how we manage to hack through all these. Making the technology and the electronic components 40% smaller than the first product requires our investment in totally brand-new infrastructure and components. Your investment has been invested in an innovation that will help solve many problems regarding the sleep-related health concerns. We are no end obliged to your contributions and be our company till the end of the development, we’ll deliver what’ve been said.
Much love from QuietOn team!