Stein Automation supplied a workpiece carrier transport system for the final assembly of loudspeakers. Since this has been in use, throughput times have become significantly shorter and output has increased considerably.

Founded in Berlin in 1924, Beyerdynamic moved to Heilbronn in 1948. Today, 500 employees there generate an annual turnover of around 100 million euros. The portfolio includes headphones, microphones and communication systems for use on stage, for live radio and television broadcasts and headsets for conferences. End consumers are also supplied via a worldwide dealer network. Around 1.3 million headphones leave the Heilbronn plant every year.

Beyerdynamic exclusively equipped the Beatles' first tour of Germany in 1966 with its microphones, and in 1987 all reporting stations at the Olympic Games in Seoul, South Korea, were equipped with headsets from Heilbronn. Since 2008, conference technology from Beyerdynamic has been used at the Organization for Cooperation and Development (OECD) in Paris. In 2019, the Sydney Opera House equipped its tour guide system with headsets from the audio specialists. The company developed special headsets for pilots.

The vertical range of manufacture at Beyerdynamic is high, with machine and special machine construction taking place in-house. However, the proportion of manual work is relatively high. "We are successful on the market. In order to manage our growth, we need to become more efficient and take our production to the next level with more automation," says Raphael Soccol, Process Engineer at Beyerdynamic. In order to improve the final assembly of headphones, the Heilbronn-based company was looking for a suitable transfer system. The requirements: It had to be easy to program as well as clear and intuitive to operate. In addition, low noise emissions were required and delicate parts had to be transported safely.

Complete package for transfer

As a workpiece carrier transport system from Stein had already proven itself in another production area, the decision was quickly made: "Stein was the best partner," says Raphael Soccol. "We proposed our Stein 300. It offers a complete package of system, support and control software," explains Martin Magrian, Sales Manager at Stein Automation.

The first Stein 300 has been working on the final assembly of headphones since 2017, followed by a second line in 2018. The parts come out of the machine semi-finished and are then assembled. They pass through up to seven stations. A drying and painting system is integrated. Acoustic testing can also be carried out on the workpiece carrier transport system. The SoftMove system from Stein plays a special role. This transports sensitive parts particularly gently. "We process coil wire that is thinner than a human hair. SoftMove ensures that the wire gets from A to B undamaged," explains Raphael Soccol. Once assembly is complete, robots remove the parts and stack them in containers.

Beyerdynamic achieves a whole range of advantages with the stone transfer system. In the past, components used to spend a whole day drying in the warehouse. Today, this is done much faster directly on the transfer system. "We have reduced throughput times from days to just a few minutes," says Raphael Soccol. The company saves on personnel and storage space. "In addition, the risk of damage during manual transportation is eliminated because the parts are transferred automatically and safely from process to process," he explains. Output has increased significantly. Assembly usually takes two minutes. "This allows us to handle the large quantities that are produced." The Stein 300 has also improved repeat accuracy and precision in final assembly. "The combination of the transfer system and our innovative machines has optimized the assembly process," summarizes Soccol.

Support arrives immediately

The process engineer also has words of praise for the collaboration with Stein, which he describes as consistently positive and very cooperative. "If we need anything, we receive immediate support. Change requests are implemented quickly, even via remote maintenance." Stein employees were regularly on site during the project phase, and several training sessions were held in Villingen-Schwenningen. Commissioning of the ten-meter-long workpiece carrier transport system went smoothly. Stein will remain Beyerdynamic's first choice when it comes to efficient transfer systems in the future. Raphael Soccol: "A third system is currently being planned and a fourth is being considered."