Case study | 8 processes for making wired headsets in the factory

By justchinait
February 2, 2021

The earphone is a pair of conversion units that accept the electrical signal from the media player or receiver and convert it into audible sound waves by using a speaker close to the ear. In fact, the structure of the headset is very simple; let’s introduce the production process of the wired headset:

1. Production of earphone shell:

①Producing the shell: through the shell mold, the raw material is injection molded.

②Printing logo: After injection molding, the plastic parts are sprayed with oil. After spraying, they need to be baked. After the paint is dry, screen printing and bronzing are performed.

2. Production of earphone wires

3. Cable assembly

4. Production of the speaker unit

5. PCBA production

① PCB production: PCB is an important electronic component, a support for electronic components, and a carrier for electrical connection of electronic components. Because it is made by electronic printing, it is called a “printed” circuit board;

②SMT (SMT): SMT mounter installs chips, resistors, capacitors, inductors and other components on the PCB in order;

③Post soldering (repair soldering): After the plug-in is pulled up, the circuit board after tin immersion and some electronic components have not been tinned well. At this time, post soldering is needed to solve it.

6. Assembly: Combine the wires, pins, housing, speakers, and PCBA together.

Soldering pin

Welding speaker

7. Test

①Headphone/MIC measurement frequency response curve

②Headphone listening test, MIC listening test

③Control box button function test

④Check the appearance of the headset

8. Packaging

①Pack the finished products according to customer requirements

②Labeling: stick barcodes and price stickers on products according to customer requirements.

③Packing: Pack the products into cartons according to the packing specifications, and pack them for easy transportation

The above is the general process of producing wired headsets. But usually, these processes are not completed by a factory. The production of a headset requires the cooperation of multiple factories.

At present, many headset manufacturers believe that SMT is a non-core manufacturing process, which is more cost-effective through outsourcing, especially for small-scale production. In addition, electronic component manufacturing and mold manufacturing are two other production processes that are outsourced by more and more companies. Therefore, the production focus of general headset manufacturers is basically focused on the cables and speakers that determine the headset’s quality. Therefore, most of them also have their own cable and speaker exciter assembly workshops. In addition, many companies may also import earphone wires and high-quality speakers according to buyer requirements.

The specific operation depends on the scale of the project. Because the strength determines the production links the factory is responsible for:

After receiving an order, a small factory is usually only responsible for a small part of the production process (assembly + testing + packaging). PCBA, earphone shells, wires, speakers, electronic components, and packaging materials are all outsourcing. Outsourcing refers to purchasing from factories that specialize in this part.

How to distinguish the difference between a large factory and a small factory?

The medium-sized factories do most of the links themselves: wire + shell + assembly + testing + packaging.

Outsourcing: PCBA + speakers + packaging materials

Large factories are responsible for the core links: wire + shell + PCBA + assembly + testing + packaging.

Unimportant parts are usually made by a cooperating factory or small factory: speaker + packaging materials.

Therefore, the supplier will try to extend the delivery time as much as possible when quoting and delivering. Sometimes they are not sure how long it will take.

Because the production of a product is completed by multiple suppliers, the order’s delivery date is often delayed. As long as a supplier has a problem, the order cannot be produced as planned.

The most serious is the small factory, where all the core materials are purchased out, and I am only responsible for assembly and packaging. Therefore, the quality of the product is difficult to guarantee.

Therefore, you must evaluate the supplier before choosing a supplier. If you need to find a reliable supplier or perform a supplier evaluation, please contact us.

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