We manufacture campers in batches on a weekly cycle with a two-week completion time. That means that when your camper is scheduled to begin, a process starts that takes two weeks to complete. Here's a breakdown of what that process looks like.
Sometime before the scheduled build week, we gather the build details from the customer. Things like color options, window preferences, delivery method, etc. These get entered into a fancy spreadsheet that our employees on the shop floor use to coordinate the build.
With the customer details locked in, Metal Town kicks off the build process by making space frames and aluminum panel sets. Right now we're building five campers per week, so for each new build week Metal Town will cut and weld up five space frames, cut, bend, and rivet five side panel sets, and cut five sets worth of tent frame extrusion. This process takes one week, at the end of which the new parts are dropped off at powder coating and the parts from the previous week's build are picked up and moved into Assembly Town.
Once parts are back from powder a whole lot of steps have to happen. We start by assembling the tent frames. Then we rivet hinges onto the side panels, install the struts, latches, and gaskets, and bolt the panels and tent frames onto the space frame. It's starting to look like a camper now. Next the floors get installed, the tent fabric gets snapped in, the graphics are applied, and the mattress cushions put in. The assembly process takes about a week as well.
Meanwhile, In Fabric Town
While all this is going on, Fabric Town is busy cranking out tents and mattresses. Parts get cut on the cnc fabric cutter, then they get welded, sewn, or glued depending on the part. We built a giant heat press to accommodate the size of the tent panels.
So that's a basic overview of the build process and timeline. Right now we're producing five per week and it takes two weeks for a camper to move through the process start to finish.