Tooling up the SPDR Production Line
Continuing with our behind-the-scenes posts, once we have a viable prototype we need to work out any production kinks. So, here's how we're setting up the production line for the SPDR Net.
Setting up Our Production Line
Once the design for the prototype SPDR has been sufficiently tested and the last additions and fixes are done it's time to ramp up to full production. This involves bulk orders of materials, assembly of the frames, checking the nets, and getting the whole package ready for delivery. This is, obviously, the most expensive part of the production process and takes the most time.
Once the raw material costs are calculated, bulk orders are placed to take advantage of any discounts available. The materials come from outside suppliers which must begin production ahead of schedule so the materials will arrive in time for the assembly of the product. Since leaving an unassembled product sitting on the production floor is a headache both in terms of labor costs and missed deadlines we have a system for placing orders and then following up with our outside suppliers to ensure this doesn't happen. In addition, Ryan will be at the factory where he is empowered to make snap decisions and review materials instead of having to go back and forth with suppliers via email.
In order to make parts for the frame various pieces, like the rubber bases and connectors for the fiberglass arms, have to be molded. This is done by making an injection mold. Injection molds are built using CAD and look like big clocks of steel with a hollow core in the shape of whatever piece we're making. The mold is placed in an injection molder that injects the rubber or plastic in a molten state into the mold. The mold has cooling liquid pumped through it and, once solidified, out comes the finished piece. The mold can usually turn out two or three pieces per minute. Each metal part for the frame has to be cut using either lasers or formed in a stamping press. Every press has its own die, which is simply a fitting that is attached to a large pneumatic press that can exert massive pressure on it. The stamped pieces are placed in a jig (which has to be built as well) and a computer controlled welder trims and makes any precise attachments needed. Here an engineer is needed to program the welders to work properly and optimize the speed for maximum output. The individual pieces are then cleaned to remove any oil or dirt and hung on hooks that pass through a powder coating machine. Again, we make careful measurements of how long it will take to produce enough of each part to fulfill our order and, based on past experience with the assembly, we can cut production time by starting assembly while parts are still being molded and pressed.
The netting has a bit more of a human element to it and requires the most quality control. The raw netting is woven on large looms and put onto “bolts”. The bolts are moved to a cutting room. Cutting the netting is a bit different than cutting normal material. It is hung on hooks and the worker must count the “squares” of netting to get the right shape. For accuracy our nets are either cut using an electric knife or by using a pneumatic press. The pieces of material are marked using chalk and logos screen printed directly on the nylon. Then the netting and nylon edges are sewn together using industrial sewing machines. Whenever netting is attached to netting an interlocking stitch is used because it's the most durable method for attaching netting and prevents it from coming apart under the forces exerted by a near supersonic golf ball.
Once the netting is finished it is hung and checked for production flaws and any excess stitching is cut off. The netting is folded and packed in a clear polyester bag and then shipped off for packing. Pro tip: Always ship the lightest part of the product to the heavier part as shipping is calculated by weight.
Back at the frame production line the product pieces are removed from the powder coating machine for final assembly. All the parts are checked for quality and the final frame is set up. The netting and SPDR frame are packed into a box with poly bags and styrofoam for protection during shipping. Finally the boxes are taped and stacked for final count and loading into our shipping containers. The next stop is our distribution facility and your front doorstep.
If you have any questions or comments please let us know here or through info@rukket.com.
-The Rukket Team
