|Introduction||History||Philosophy||Manufacturing||Support & Education||Global Reach|
Building Great Products One Detail At A Time
Meyer Sound products are made at its Berkeley factory, where every aspect of manufacturing can be supervised and controlled directly by John Meyer and senior engineering and production staff. This constant interaction allows Meyer Sound to continuously analyze production methods and implement improvements immediately.
Products are subject to rigorous 100-percent testing and warranted for a full three years. Every major component undergoes multiple test procedures; both before installation and as part of the finished system, to ensure Meyer Sound products meet or exceed all stated specifications and provide long-term reliability and complete consistency from unit to unit.
Meyer Sound products often must be virtually built-to-order due to the number of options required by customers. At the same time, those orders typically need to be filled very quickly, posing a conflict with the time normally incurred in semi-custom manufacture and quality assurance procedures. At Mars, Meyer Sound’s 65,000-square-foot loudspeaker production facility, drivers are assembled with the electronics, cabinets and other components in a Meyer Sound loudspeaker. All processes have been optimized for speed and efficiency, while still meeting the same demanding quality control standards. Residing in the landmark H.J. Heinz Building (former factory of the ketchup makers), Mars's fluid and flexible production floor reflects the lessons of decades of uncompromising loudspeaker manufacturing, and enables the company to build and test large orders in a matter of days.
At Meyer Sound, endless prototyping, power testing and failure analysis are employed to determine the methods that produce reliable results. It is this reliability that gives professionals complete confidence that Meyer Sound products will continue to perform faithfully under the rigors of constant use.
Driver Design and Assembly
Drivers used in Meyer Sound loudspeakers are manufactured on site in the company’s Saturn and Phoebe driver fabrication facilities. Using custom-designed and highly modified machinery, the company makes its own paper cones from custom-formulated raw paper stock and creates its own magnetic assemblies starting from unmagnetized slugs.
Core component manufacturing processes are performed in house, including forming diaphragms, building phasing plugs, individual optimization of each compression driver, and even formulation of many key adhesives and compounds. Less critical components are made to Meyer Sound’s tight specifications and subject to exhaustive quality control.
Meyer Sound’s driver engineering lab is located in the fabrication facility itself in order to facilitate a close working relationship between those designing and those building the drivers.
Having a complete fabrication facility also provides Meyer Sound with the ability to do small runs of prototype designs, allowing fast iteration in the development process. Further, by the time a new driver design is finalized, its manufacturing process is already established.
Every aspect of driver manufacture is not only tightly controlled, but also assiduously documented. This has many benefits: it enables the achievement of extremely high levels of consistency and reliability in the drivers, makes possible ongoing detailed analysis and improvement of processes, and allows issues that arise to be traced back through every step of manufacture.
Having driver manufacturing on site allows Meyer Sound to establish and maintain quality and consistency impossible to attain when key processes are outsourced.
Product Testing and Quality Assurance
Consistency is paramount at Meyer Sound, and it can only be guaranteed by quality control and testing. In order to reach and maintain the level of quality required in Meyer Sound products, quality control must be exhaustive, including thorough and repeated testing.
It starts with incoming materials and parts, which are subjected to thorough batteries of tests and evaluations. Meyer Sound’s Quality Control department maintains elaborate measurement laboratories for incoming parts that often exceed the capabilities and precision of the parts’ manufacturers. Critical components are often hand-graded and –matched, and detailed procedures imposed at every stage of the loudspeaker manufacturing process check each component and subsystem multiple times.
Component Quality Testing
Every transistor, every transformer, every cable, every circuit board, and every driver traverses layer upon layer of documented procedures designed to guarantee that each component meets and maintains specifications.
Rigid test procedures are performed at each step of assembling components into subsystems and subsystems into complete systems. Specifications are tight and nothing is allowed to “slide through” by being merely close to the mark; it must meet spec to be accepted. SIM® audio analyzers are employed at numerous stages to insure that each unit being measured matches stored curves of reference units.
Enforced adherence to design specifications results not only in amazing consistency from unit to unit, but also promotes reliability. If a problem arises in the field, the consistency of Meyer Sound products enables customers to replace assemblies or parts in the field and return the loudspeaker to service without need for any alignment procedure. When timing is critical, this efficiency provides the fastest method of restoring users anywhere in the world to full functionality.
Behind the Innovations