Cost-effective manufacturing

[tgmcg]

Hi,

We've developed a new recreational product and are seeking comments/suggestions as to how we might manufacture it in the most economically sensible manner. Some Solidworks images of the product can be viewed at "

http://www.tailboats.com".

We're currently planning to build the product in small batches of, say, 10 units, and cannot justify (afford) investing too much in expensive tooling. My background is in heavy industry, not consumer products, so am waaaay down the learning curve on what the most cost-effective manufacturing options may be for this type of product. We're at a point where a few ideas from experienced professionals like yourselves could prove extremely helpful.

The title of a good reference book would be helpful.

Many thanks for your help.

Best regards,

Tom

 

[automatic2]

Don't expect to profit on batches of 10. You have a proto type that you can work out the basic requirements. Metal joints with Kevlar sparring?. CNC your metal, outsource your spars, mould your plastic finning. You need to find a marketing resource that will get excited and who can sell a hundred, and sell a couple of investors. Then pay youself well, and negotiate a reasonable percentage when some profit roles in.

 

[tgmcg]

Many thanks for your insights.

Not sure what you mean by "metal joints with kevlar sparring".

We're CNC'ing the metal and may mold the fins. The prototype fins are hot wire cut foam cores with vacuum-bagged carbon fibre epoxy..which can be done in reasonable quantities in a pinch. The carbon fibre tubes are outsourced. We've redesigned the metal parts 3 times to minimize machining costs and use standard sections. We've been toying with the idea of casting some of the larger aluminum parts....but haven't explored the options.

We plan to make a small profit on every boat sold and bootstrap our way up. I agree that we need to focus on marketing outlets, and that is exactly what we plan to do. Since we have a proprietary product, we should have some pricing power. We won't base our business plan on finding a major marketing resource or outside investor, but we'll certainly be on the lookout for such assistance.

Best regards,

Tom

 

[griffengm]

Tom,
Interesting product!
I think there are several manufacturing actions you can do to position this product. Do you want to market to innovators who are willing to pay any price for their toys or do you want to get some of these out and visible and then work on improvements?
The machined design of the metal parts seems like overkill. If my impression of the functions is correct, they could be done in SS tube for less and maybe less weight.
It seems that you might also be able to either vaccuum form/bond or rotomold the fins for small capital outlay.
I realize weight is a consideration but do you really need such high tech push tubes? Ultralight planes have been making use of plastics in landing gear for some time and those really take some beating (especially mine!).
Are you marketing to high performance techies or outdoors folks who want to try something different?

Griffy

 

[tgmcg]

Griffy,

Thanks

When building the prototype, most parts were milled as my only precision machine tool is a CNC mill.

The prototype shown on the video clips is 2 design iterations old. The 3D color images represent the current desgn for the commercial product. As far as possible, the metal parts are machined from standard aluminum rectangular section tubing or bar stock with a single set-up. The pedal cranks, main pylon and clevis are milled from solid billets....perhaps casting is a better/cheaper way to go. I know zip about low cost casting methods.....perhaps that's an oxymoron. It's not clear to me where you see the application for ss tube....can you be more specific?

We might possibly be able to use aluminum tubing for the steering shaft..instead of carbon fiber.

The propulsion fin has to be strong, stiff, light and fatigue-resistant. Composites seem to be the way to go. The prototype uses a couple of plys of s-glass/carbon weave over foam which has held up perfectly well. I've been quoted between $9-22k for tooling/molds depending on fabrication method. I may need to use 2 different size fins....therefore twice the tooling cost. That's a chunk o' change.

Regarding target market, we're aiming to make it as affordable as possible. Until we can gauge market response, we don't want to invest "too much" in tooling. Being a new product, there's a high liklihood of design modifications which could impact tooling design/cost. However, once a revenue stream is established, the whole picture changes.

I've been demonstrating the boat up and down the West Coast for the past 18 months and the response from onlookers has been very enthusiastic....hopefully this will translate into sales. The hull we're using is selected for versatility and stability, not speed...but I'd imagine that the boat will appeal to those folks wanting to be on the cutting edge of a new sport as well as to those looking to cruise around the local lake/river/bay with comfort, speed and style. I also want to build a scaled down model for smaller children 5-12 years old.

We sometimes refer to it as my "5-legged dog"...it's a surefire means to strike up a friendly conversation with hundreds of perfect strangers. (g)

Tom