I saw this in another thread and thought I could add some input.
Originally Posted by Floating Cloud
I find it amazing that they have so many models, a new one at least every two years. I don't know how they do it. 13', 15', 17', 19', 21', 5.0, new 5.0. So many in a very short time. As someone said, the mind boggles.
Just to clarify, the 13' and 5.0 have been discontinued. We now offer 15' (2 plans), 17' (2 plans), 19', 21' and 5.0 TA.
Why so many sizes?
For those of you who have not toured our fibreglass facility...the Escape body assembly is different than most, if not all fibreglass trailers, campers and boats. Most put the body together after the shell in halves have been removed from the molds. With our system, once the two halves have cured, we bolt the top mold on top of the bottom mold and seam the two halves together while everything is still tight in the mold. The shell is then demolded as a full unibody shell.
This method ensures consistency with every unit, however the shell is in the mold for a much longer period. To speed up production, we alternate mold sizes. In our fibreglass facility, there is a large spray booth where the parts are made. Once the two halves are built and cured, they are moved out to be joined together. At this point another set of molds is set up in the spray booth.
The fibreglass shop operates about a month ahead of the main production. If you have noticed our production schedule, we usually run a balance between two different sizes back to back. For example, the fibreglass shop will build 17,19,17,19,17,19,17,19, but for consistency, the production shop will build 17,17,17,17,19,19,19,19. Adding new sizes helps the fibreglass shop to squeeze in different sizes in their runs to keep up as the assembly is steadily increasing in speed.
We still want to be able to work with the customer in customizing their Escape, however we have had to streamline assembly a bit more and can't offer quite as many changes as we were once able to. For example we have to stay tighter to the floor plan designs offered. Small alterations, no problem. Moving a bathroom, major alteration...not possible.
More sizes coming? I don't anticipate anything larger. ( I know I have said that before!
We are trying to maintain a nice flow that keeps us busy, but at a pace that will allow us to continue to work one on one with each customers' needs and wants.