Re: The Behringer Model D
Quote of Uli Behringer from this excellent article [Good find t]:
The next batch will hopefully leave the factory by end of coming week with some units being air-shipped to the US. The production is still relatively slow due to the fact that each unit takes over 30 minutes to warm up followed by a meticulous one-hour calibration and quality assurance procedure.”
So this is a manufacturing problem, and not one that happens every time the user turns the box on cold. (Or it better be.)
Perhaps this is something like, which trimmer pot of the twenty do you set first and how, so you’re not changing this one that changes the setting of another one you already did. Coming up with a detailed manufacturing calibration procedure can take time. (Trimmer pots, or trimpots are the little components on the board that you can only get at inside the box. There can be capacitors and inductors like this too.)
There is no way they meet their internal cost goals if they need to do this much hand tweaking on every unit.
Put simply the engineering of a product for production, especially with the extreme constraint of low cost, is complicated. It takes time.
My own wild guess to what might have happened: Skip this.
Sounds to me that there is too loose a relationship between the engineering and/or quality assurance team with those in manufacturing. This sort of problem should get caught long before a large manufacturing run and shipment. This is something that companies can face when they are large and are spread geographically, and fail at close communication.
It also could come from trying to work too fast, feeling pressure, committing to a large manufacturing run too soon. Personal experience here – perhaps they’ve been delayed with something else already and are looking to hit a home-run to catch up to schedule.
It also could be incompetence in the engineering design that didn’t account for the calibration process in manufacturing and basically engineered something that is almost impossible to mass produce, as every unit is hand tuned. I doubt this but it sure is possible, it’s been done.