Engineering

for
Speaker System
31 / Aug. 2001 in SSI
 Contents
1. Construction of Speaker System

2. Assembly Process of Speaker System

2.1. Typical Assemblying Process

2.2. Wooden Process : Wrap Board Cutting

2.3. Wooden Process : Cabinet Shaping (Folding)

2.4. General Assemblying Process

2.5. Sub Assemblying Processes

3. Acoustical Key Parts

3.1. Duct

3.2. Acoustic absorbent

3.3. Network
4. Measurement of Speaker System

5. Specification Chart of Speaker System

6. Often Occuring Problems

7. Inspection for Speaker System

8. Regular Checking in the Production

9. Basic Rule for Serial Numbering

10. Cost of Speaker System

11. Construction of Speaker Unit

12. Production Spots of SONY Speaker System

13. Designing and Production Standard for Speaker System

 1. Construction of Speaker System
A-0123-456-A : SS-DPxxxx//Q(A)(CE7)

A-1234-567-A : Overall A’ssy

A-2345-678-A : System (L) A’ssy

A-1234-567-A : Speaker cabinet A’ssy

4-123-456-01 : Back panel

4-123-457-01 : Wrap

4-123-458-01 : Baffle board

4-123-459-01 : Duct

4-123-490-01 : Triangle corner block x2

A-1234-568-A : Front panel (L) A’ssy

4-234-567-01 : Front panel (L)

4-234-568-01 : Cosmetic ring

4-234-569-01 : Catcher x2
 A-1234-569-A : Grille frame A’ssy

4-345-678-01 : Grille frame

4-345-678-01 : Grille cloth

4-345-679-01 : Sony emblem

4-456-789-01 : Packing

1-234-567-11 : Speaker (5 cm)

1-234-568-11 : Speaker (15 cm)

4-456-790-01 : Acoustic absorbent

1-234-569-11 : Terminal board

1-234-570-11 : Speaker cord with capacitor

7-123-456-01 : Screw +3.5 x 14 x8

A-2345-679-A : System (R) A’ssy

A-1234-568-A : Packaging and Accessory Gp

4-567-890-01 : Individual carton

4-567-891-01 : Polyethylene bag x2

4-567-892-01 : Cushion

C-1234-567-1 : Printing Instruction for Carton

 2. Assembly Process of Speaker System

Typical Assembly Process

Adhesive apply onto Wrap

Baffle board

Folding
Speaker unit Terminal board

Wire kit

Wire connecting
Front panel
Screws
Cosmetic ring
Speaker unit fixing
Front panel A’ssy Catch

Front panel A’ssy push in

Grille frame A’ssy Grille frame

Grille frame A’ssy attach Grille cloth

Sony emblem
Acoustic & Visible check
Carton & Cushion Model number label

Packaging
Wooden Process : Wrap Board Cutting

PVC Lamination
PVC (roll)

Chipboard or MDF

Rough size cutting

V-cutting

PVC surface

V-cut Machine
Tenoner
Wooden Process : Cabinet Shaping (Folding)

Baffle board
Front panel

PVC : t 0.15∼0.20

Wrap
Back plate

Final Joint
Sub Assembly Processes

Front panel A’ssy

Cosmetic ring

By welding pins from back side

Front panel
Catcher (4 pcs)

Just push in

Grille frame A’ssy

Grille cloth

By welding all around

Grille frame
Sony emblem

By welding pins from back side

 4. Measurement of Speaker System

Measurement
1m

Sine wave (20 Hz∼20 kHz , 1 W)

Frequency curve

Sound Pressure Level

xx dB / 1W・1m

Impedance

xx Ω
 5. Specification Chart of Speaker System

Speaker system : 2 way

Speaker units : Tweeter : 5 cm Cone type

Woofer : 12 cm Cone type

Enclosure type : Bass reflex

Rated impedance : 6 Ω

Maximum input power : 80 W

Magnetically shielded : Yes

Input type : Terminal

Grille frame : Detachable

Dimensions (mm) : 145 x 255 x 210

Weight : 2.7 kg / pc
 6. Often Occuring Problems

Acoustical No sound Mis-connection of wires

Buzz sound Non enough glue on Cabinet

Speaker unit problem
Non correct assembly of Cosmetic parts

Air leakage sound Non enough glue on Cabinet

Incorrect position of Packing

Appearance Big gap between Bending of Front panel

Cabinet & F.Panel Non enough pushing of Front panel

PVC rough surface Non enough polish before PVC lamination

Rough corner edge Non enough maintenance of wooden tools

of Cabinet
 7. Inspection for Speaker System

In line (all)

Acoustic check * Sweep test

・ 1 , 3 or 5 W
・ 20 Hz ∼ 20,000 Hz for 2 ∼ 4 sec
・ Buzz , Air leakage , Flying noise

* Polarity check : by phase checker

* (Impedance check : by auto sweeper)

Appearance check * General

* Gap between panel and cabinet

* Stain on PVC surface

QA outgoing (sampling)
Acoustic check * Sweep test

・ 1 , 3 or 5 W
・ 20 Hz ∼ 20,000 Hz for 10 sec or longer
・ Buzz , Air leakage , Flying noise

* Polarity check : by phase checker

* Music test

・ Connect to the combined amplifier

・ Equalizer : Max or pre-set position
・ Volume : Max (no distortion)
・ Play back “Billy Jean” (Michael Jackson)

Appearance check * General

* Gap between panel and cabinet
* Stain on PVC surface

Packaging check * Condition

* Accesaries
 8. Regular Checking in the Production

Glue onto wood

Cabinet Adhesive Specification

==> To clarify :
*Type of Glue
*Volume of Glue
==> Confirm between Engineering and Production

Daily Adhesive Check Sheet

==> To check and record :

*Type of Glue
*Volume of Glue
*Position of Glue
Dimensions of wooden cabinet

Check sheet for Dimensions in Horizontal V-cut Machine

==> To check if wrap board V-cut is correctly processed

==> Important dimensions are to be measured 3 times per day

Check sheet for Dimensions in Tenoner

==> To check if back board is correctly processed

Check sheet for Dimensions in Vertical V-cut Machine

==> To check if wrap board groove is correctly processed

==> Important dimensions are to be measured 3 times per day

Maintenance of tools

Standard for Changing timing of Tools for Wooden Machinery

==> To clarify :
*How often condition should be checked
*How often tools should be treated
==> Confirm between Engineering and Production

Tool exchange timing check sheet

==> To check if tool maintenance is properly done

 9. Basic Rule for Serial Numbering

Normal pair packaging Center & Surround packaging

L R C S S
x,x00,001 x,x00,001
x,x00,002 x,x00,002
x,x00,001 x,x00,002 x,x00,003 x,x00,003
x,x00,003 x,x00,004 x,x00,004
x,x00,005 x,x00,006 x,x00,005
Any 1
--uneven-- --even-- x,x00,006

Any 2 --------
x,x00,001
x,x00,003
x,x00,005 x,x00,003 x,x00,002

--L number-- --C number-- x,x00,003 x,x00,006

Bar code label Bar code label
 10. Cost of Speaker System
Material cost Direct material Indirect material

Back panel PVC sheet included

Glue

Wood
Wrap Material of Wood
Paint
Triangle corner block

Baffle board
Mecha. Parts

Duct
Plastic parts

Front panel Out-soursing

or
Cosmetic ring
In-house molding Resin
Grille frame
Paint
Sony emblem

Catcher

Packing
Others

Grille cloth Out-soursing

Acoustic absorbent

Screw +3.5 x 14
 Direct material Indirect material

Speaker (5 cm)
Electro Parts Speaker (15 cm)
Out-soursing
Terminal board

Speaker cord with capacitor

Individual carton
Packaging

Polyethylene bag Out-soursing

Cushion

Manufacturing cost

Wooden process

Injection
In case of “In-house molding”
2 nd treatment

General assembly

Sub assembly
 11. Construction of Speaker Unit

Edge (Surround)
Frame (Basket)
Cap Diaphragm

Lead wire
Damper (Spider)

Voice coil
Plate (Top plate)
(Main) Magnet
York (Bottom plate)

Back cover Cancel magnet

 12. Production Spots of SONY Speaker System

BHD , SK 2nd
Malaysia SEM Kedah-Plant BH , SAVE Wood Molding process

Yakushin CL Wood

FPI BH Wood SP unit

Tatara B Wood

BH , LBT 2nd
Indonesia Dai Hwa BG
Wood Molding process Cushion

2nd
AST 2002 LBT Wood Molding process Cushion

LBT 2nd
KEP Cen & Sur
Wood Molding process
 BHD , SK 2nd
Thailand Tatara BH , Value Wood Molding process

SPS BG Wood

2nd
China Dai Hwa BG , Micro Wood Molding process Cushion SP unit

2nd
Foster Micro Wood Molding process SP unit

2nd
GHD (Tatara) Micro Wood Molding process SP unit

Japan Kibo-kogyo BH , SA-VE Wood

Hungary 2nd
Videoton BG , Value Wood Molding process

EAG Wood
13. Designing and Production Standard for Speaker System

Designing Standard

D-001 J/E : Designing Standard for Serial Number and Bar code label

D-002 J/E : Designing Standard for Model Number Label

D-003 J/E : Designing Standard for Power Handling Test of Speaker System

D-004 J/E : Designing Standard for Color of Speaker Cord

Production Standard

P-001 J/E : Production Standard for Gluing onto Speaker cabinet

P-002 J/E : Production Standard for Tools of Wooden Machinery

P-003 J/E : Production Standard for Dimensions of Wooden Process

P-004 J/E : Production Standard for Adhesion Test of Lamination Sheet

P-005 J/E : Production Standard for Power Handling Test of Speaker Unit