Series production boatbuilding

[VIKING]

HI,

I HAVE A SMALL BOATBUILDING BUSINESS PRODUCING ONE 33 FT POWERBOAT A MONTH. I WOULD LIKE TO INCREASE PRODUCTION TO 3 PER MONTH AND THEN LATER TO 5 PER MONTH. MY FLOOR SPACE IS 660 SQUARE METERS. (STORES ARE EXCLUDED- NEXT DOOR)
I HAVE VERY BASIC FACILITIES AND WOULD LIKE TO KEEP IT THAT WAY AS THE BOATS ARE SIMPLE SOLID GRP (CSM) CONSTRUCTION.

I AM PRESENTLY BUILDING ONE A MONTH WITH 2 SKILLED LAMINATORS (ONE IS ALSO A SKILLED CARPENTER). I ALSO HAVE ANOTHER 2 SEMI SKILLED LAMINATORS WHO HELP.

I WOULD APPRECIATE ADVICE ON HOW TRIPLING MY PRODUCTION WILL EFFECT WHAT RESOURCES I WILL NEED . ALSO ANY RELEVANT TIPS WOULD BE MUCH APPRECIATED.

I ASSUME I WILL NEED TO GET A PRODUCTION LINE GOING WITH TEAMS AT EACH STATION? (SOUNDS LIKE A LOT MORE LABOUR IS NEEDED!

I ALSO ASSUME IT WILL NOW BE NECESSARY TO DOCUMENT ALL PROCESSES TO ENSURE PROPER QUALITY. (I PREVIOUSLY COME FROM A CUSTOM BOAT BUILDING YARD SO DO NOT HAVE EXPERIENCE OF PRODUCTION LINE WORK).

[Timm]

One of the most important things you can do is come up with an accurate Bill of Materials. Find out how much of each and every part on the boat you use. Make sure this is accessible and easy to update as prices and part numbers change. Try to also get a good handle on the consumables, ie... rags, sandpaper, acetone, etc.. You will be amazed at how much of that stuff you go through.

I am not familiar with your environmental laws or worker safety laws, but I'd also check to make sure increasing your production doesn't reclassify you as far as the guvmint is concerned. Here we have to file more forms and meet higher safety requirements as the company grows.

Also take a hard look at your finances. As you put more boats in production, you will find your inventory needs increase substantially due to having more boats in process. I think a number of growing builders have failed to grasp just how much money is sitting in their palnt at one time.

Lastly, try to make sure your tooling and design is up to the increased production. Try to design any extra labor out of the process. If a mold has a flaw that you repair on every part, it may not be a big deal at one a month, but at 4 or 5 month it could be very costly. I have worked for companies that devoted one stop on their production lines to patch and repair parts. I never agreed with this philosophy as it tends to "create" repairs as the lamination crew knows there is someone to cover their buts when they screw up. Not a whole lot of incentive to get it right the first time.

I hope this helps! I have worked for companies building up to 50 boats a week and things could get very complicated, very fast.

[JORGE LANG]

Out of curiosity, what type of engines are going into these boats?

[VIKING]

Hi Jorge,

These boats all have outboard motors (Generally 115Hp - 150 Hp Yamaha as the company is also a Yamaha agent).

[VIKING]

Hi Tim,

Our moulds are shocking so this is a major issue. We will have to work on all of them. Some are very 'crinkly' too so not sure how to sort that out!

Re Govt regs here, they're very slack so not an issue- although workers and environ must be adressed of course.

Some good pointers thanks - I'm glad you confirm what I was thinking.

[War Whoop]

The easiest way to ramp up is just to add another line complete with Molds. And personal.

[Leego]

Hi there Viking

My husband and myself is interested in building our own boat for personal use. No commercial etc. involved. We, however, want to obtain the plans etc. for a Waverunner 65B [Steel]. Do you possibly know where we can purchase this plans in South Africa?

Thank you

Kind regards

[CDBarry]

Start out by looking at standard manufacturing texts to get some ideas:

"Reinventing the Factory", anything by Deming, Juran, etc., tuff on "Toyota Production System", "Lean", "5S", "Just In Time", and so on.

[Leego]

Thank you CDBarry, I will look into it.