garygid
07-18-2008, 11:46 AM
Please remember, these are just guesses for the sake of discussion:
Assuming that there are about 14 people employed on each "production"
line, and that they can turn out 2 vehicles per shift (doing a 4-hour cycle
on each mold, and jig ... which seems like it might be possible), then each
vehicle would take 56 "direct" man-hours to build.
For skilled people, one might pay ... what, $50 per hour?
So, there might be $2800 in direct labor costs on the 4-hour cycle?
Actually, in my production estimates, I assumed one vehicle per shift to get
started, but then 2 per shift as reasonable, and finally that a maximum of
4 per shift (a 2-hour cycle) might be achievable.
A typical mold-use cycle probably includes:
After taking one part out of the mold, one has to clean up the mold,
lubricate, gel coat, wait for the gel coat to get firm, lay up the included
materials, "bag" it, vacuum down, infuse the resin, and wait for it to set up
sufficiently to remove the part.
While waiting, one can be preparing the next included materials and finishing
a previously-removed part (perhaps after it cured for an additional "N" hours).
This part of the process might use two persons.
Two people joining the parts using a "body jig", making holes as needed,
finishing edges, laying in the wiring harness (made by a third person),
and adding other major internal fiberglass pieces, like the floor and trunk.
One person assembling the electrical motor, rear suspension, and
fitting it to the vehicle, with wheel and tire. (Now, that is 6 people.)
Another two people assembling and installing the pre-fabricated front end
frame and and the two front wheel assemblies, with wheels and tires,
and install the steering column.
Now, that would be 8 people, and the vehicle can sit on its own wheels.
Another two people to install batteries and electronics, and test them.
The rear wheel would sit on some torque-test rollers.
Finally two people to install lights, trim, seats, skirts, doors, etc.
Add one more person for pre-fab of the metal work and another
for getting receiving and getting parts available for others to assemble.
Total, 14 people.
The work cycle:
I guess that 8 hours is relatively "easy" (but you need to have
personnel dedicated to production), 4 hours is probably "doable", but
2 hours would take getting the process very well optimized.
If the resin takes too long to cure, then a duplicate set of molds would be
necessary to achieve the faster times. Maybe the "Composite Technician"
will be creating a set of production molds for the first production line.
Anybody have good insight or experience in these areas that
they would care to share?
Assuming that there are about 14 people employed on each "production"
line, and that they can turn out 2 vehicles per shift (doing a 4-hour cycle
on each mold, and jig ... which seems like it might be possible), then each
vehicle would take 56 "direct" man-hours to build.
For skilled people, one might pay ... what, $50 per hour?
So, there might be $2800 in direct labor costs on the 4-hour cycle?
Actually, in my production estimates, I assumed one vehicle per shift to get
started, but then 2 per shift as reasonable, and finally that a maximum of
4 per shift (a 2-hour cycle) might be achievable.
A typical mold-use cycle probably includes:
After taking one part out of the mold, one has to clean up the mold,
lubricate, gel coat, wait for the gel coat to get firm, lay up the included
materials, "bag" it, vacuum down, infuse the resin, and wait for it to set up
sufficiently to remove the part.
While waiting, one can be preparing the next included materials and finishing
a previously-removed part (perhaps after it cured for an additional "N" hours).
This part of the process might use two persons.
Two people joining the parts using a "body jig", making holes as needed,
finishing edges, laying in the wiring harness (made by a third person),
and adding other major internal fiberglass pieces, like the floor and trunk.
One person assembling the electrical motor, rear suspension, and
fitting it to the vehicle, with wheel and tire. (Now, that is 6 people.)
Another two people assembling and installing the pre-fabricated front end
frame and and the two front wheel assemblies, with wheels and tires,
and install the steering column.
Now, that would be 8 people, and the vehicle can sit on its own wheels.
Another two people to install batteries and electronics, and test them.
The rear wheel would sit on some torque-test rollers.
Finally two people to install lights, trim, seats, skirts, doors, etc.
Add one more person for pre-fab of the metal work and another
for getting receiving and getting parts available for others to assemble.
Total, 14 people.
The work cycle:
I guess that 8 hours is relatively "easy" (but you need to have
personnel dedicated to production), 4 hours is probably "doable", but
2 hours would take getting the process very well optimized.
If the resin takes too long to cure, then a duplicate set of molds would be
necessary to achieve the faster times. Maybe the "Composite Technician"
will be creating a set of production molds for the first production line.
Anybody have good insight or experience in these areas that
they would care to share?