I really enjoyed this story since it addresses the real world issues of manufacturing. It's fine to design something on a CAD program, but somewhere along the line, the actual parts have to be assembled and that, it turns out, is every bit as important and the design itself. Attention to detail, proper assembly techniques, training and clear work instructions all matter. Thanks.
I spent a lot of years as a club musician and speakers were tossed around quite a bit, not like Pete Townsend, but things get dropped, bounced around on the stage, and in vans. I've heard voice coils rub, seen them melt, and shatter (titanium horns). I've seen surround dry rot and fatigue, but I've never seen a magnet fall off, not even on the big 20lb magnet JBLs. This sounds like a pretty low quality vendor.
Scott, that is a good point. This reminds me of a number of situations I have seen with small manufacturers over the past few years. The problem was parts testing over time (life testing). You really need to trust your supplier or have a good warranty program. On the other hand, even with a good warranty the failure often leaves a bad taste with the consumer.
This story exemplifies the importance of good work instructions. A good system will account for a new employee and still make quality product. Documentation of task steps and quality risks on each step is important.
And in this case it sounds like someone forgot to check and see if the glue would give the product the life it needed. Could have been one of those cost out ideas. Or more than likely, someone just thought it would work as good as the other stuff.
I agree with the use of good instructions or standard operating procedures. However, I don't like the idea of standard operating procedures being, "bring it to me and I'll fix it with some baling wire and twine."
When a 15$ radio fails because of poor quality components it's my fault for buying rubbish in the first place. But if I buy a top quality audio product, maybe a radio from a company whose name sounds like an Italian dish, or a term in trigonometry, or the capital of a US state, I don't expect it to fall apart because someone saved a few pennies in production, or sold "quality" at "quality price", without actually verifying the quality of the product. In the long run, the cheap mass produced products have more stringent manufacturing procedures and automated final test methods, and are more reliable.
The 100% solar-powered airplane Solar Impulse 2 is prepping for its upcoming flight, becoming the first plane to fly around the world without using fuel. It's able to do so because of above-average performance by all of the technologies that go into it, especially materials.
With major product releases coming from big names like Sony, Microsoft, and Samsung, and big investments by companies like Facebook, 2015 could be the year that virtual reality (VR) and augmented reality (AR) finally pop. Here's take a look back at some of the technologies that got us here (for better and worse).
Good engineering designs are those that work in the real world; bad designs are those that don’t. If we agree to set our egos aside and let the real world be our guide, we can resolve nearly any disagreement.
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