Cracking the pain point of "labor-intensive + low productivity" -Magnetic circuit + soft integration of automotive speaker automated production line to achieve double the efficiency per capita

Client Background
A car audio manufacturer specializing in the production of 3.5- to 8-inch car speakers previously operated its production line using a “manual dispensing + manual assembly + air-drying” process, which presented three major issues: 1) Magnetic circuit assembly (T-core, magnet, and basket assembly) required 6 workers per shift, while soft component assembly (suspension, cone, and voice coil assembly) required 8 workers per shift, with labor costs accounting for over 30% of total costs; 2) Uneven manual adhesive application caused component misalignment after drying, resulting in a defect rate of 51%; 3) Natural drying took over 1 hour, limiting daily production capacity to only 8,000 units, which was insufficient to meet OEM order demands.

Jumbo Solutions
To address these pain points, we have customized an integrated production line comprising an “automatic magnetic circuit assembly line + diaphragm machine + multi-layer automatic oven.” The core configuration is as follows:
Automatic magnetic circuit assembly line: Integrates a four-axis dispensing robot (accuracy ±0.05 mm), an automatic loading mechanism, and a blow-and-suction dust removal module to achieve a fully automated process—“automatic T-iron placement → automatic dispensing → automatic magnet placement → manual pot frame attachment → automatic drying”—replacing four manual workers;

Diaphragm Machine: Equipped with a universal positioning turret, it supports automatic dispensing of adhesive for the outer ring and center of voice coils and the outer ring and center of paper cones. Combined with manual assistance for inserting voice coils and placing paper cones, it replaces five workers. Additionally, only positioning parameters need to be adjusted during changeovers, reducing costs by 60%;
Multi-tier Automatic Oven: The B/C-stage oven features a 4-tier design, with each unit capable of holding 651 speakers. with electric heating and temperature control (adjustable from room temperature to 45°C). Drying time in the magnetic section is reduced to 12 minutes, and in the soft section to 38 minutes, completely replacing natural drying.

Effectiveness of implementation
Labor costs: The number of workers per shift was reduced from 14 to 5, resulting in monthly labor cost savings of over 80,000 yuan;
Production Efficiency: Hourly production capacity has increased to 1,000 units, and daily production capacity has exceeded 18,000 units, meeting the OEM’s order requirement of “15,000 units per day”;
Product Quality: The accuracy of automatic dispensing has been improved to ±0.05 mm, and the defect rate due to component misalignment has been reduced to 0.81 TP3T.