We went to Newmar for the past two days to see our 2013 Dutch Star 4018 in production. What a fabulous time. A few pictures are attached.
We were really lucky. We showed up at the time for the daily tour at 10:00 a.m. on Thursday and we were the only ones to be on the tour. Our tour guide, Michelle Howard, allowed us to spend all the time we wanted checking out our coach on the line and talking to the guys working on it. Michelle is very knowledgeable and was able to answer all of our questions about the production and the workers.
We must have talked to at least seven or eight of the workers and they were all very happy to talk to us. Most of the workers building our coach appeared to be Amish. Every one of them were really, really nice -- no pressure not to talk to us and answer all of our questions. The more questions we had, the more they rose to the occasion. They definitely took pride in their knowledge and experience and were very proud of their work (justifiably so). We were careful not to take pictures of the Amish and Mennonite workers.
What was most amazing to us, again and again, is how quickly and how efficiently they work as a team. Our coach started out in Building 7 on Tuesday and by the time we rolled in on Thursday, it was completely down the front line, the superstructure was completely built, the roof was installed, the front and rear caps done and it was on the back line getting the slides installed, the AC/heat pump units put on, the exterior mirrors installed. In just the time we had to spend on Thursday, from 10:00 a.m. till 12:30 p.m., then back again from 3:00 p.m. till about 3:45, we got to see a lot of work done.
While we were there on Thursday, we saw them finish and install the full wall slide, install the two curb side slides, install all cabinets, all furniture and all windows. It was just amazing to watch these guys work. Each guy knows his job to a "T" and to see how these guys work together is nothing less than impressive. You watch as the group leader calls out a simple command and four or five guys converge to do a team task -- such as installing the full wall slide or putting the fiberglass skin on it.
One minute we were watching the guy finish screwing the cabinets into to the full wall slide, gluing and taping the carpet and moving it on its wheels to the installation crew -- the next minute the group leader calls out his command to convene the crew to put the full wall slide into the coach -- the hydraulic lifts are brought in, the five crew members converge, the slide is lifted up to the opening in the coach, lined up, secured, hooked up and made operational. The fiberglass siding is put into placed, four guys glue and screw it to the side. Six windows are positioned into the openings, glued and screwed in place.
How much time did all of this take? You are not going to believe it. No more than 15 minutes, start to finish! Unbelievable. Cause these guys work so closely and so quickly. And when you watch these guys work, you have real confidence that they not only have the knowledge and experience to do it right but that you got a perfect installation.
We then took PDR John's recommendation and asked Michelle if we could see the paint shop in operation and, because of no other tour guests, she gave us a great tour there.
Just a fascinating process, from complete painting prep and sanding to application of base coat, all stripe painting, clear coating, baking, repair and final inspection. These guys are just wizards. Fun to see the guys on stilts doing the prep and paint work on the top parts of the coaches!
We finished up for lunch by checking out some of the coaches in the final inspection area, getting ready for release and transport to dealers (or factory delivery). To see what they catch for adjustment or repair on the final punch list is itself a fascination process. These are very fussy tailors!
We came back in the afternoon after lunch and running a few errands and we got to see the coach with all stuff completed before going into wheel alignment and then painting prep. By that point, we had witnessed a chassis with superstructure but no slides grow into a real motorhome with all three slides installed and operational, all windows, cabinets, appliances, furniture installed and having the look of the colors, countertops and fabrics we selected. What a transformation.
Today, Friday, we again had the good luck to be the only ones to show for tour. Again, we had our wonderful friend Michelle Howard as our guide and we got to check out our Dutch Star again. Since the crew starts at 6:00 a.m., we got to see how much work gets done in four hours -- and it's a lot.
By the time we were ready to leave by noon, the coach was in alignment, off the air blocks by which it is moved throughout the plant before painting occurs, the engine was running (oh my, how incredibly sweet that sound!!!) and she was headed for paint. Michelle promised to get us pictures as we go through paint and other work is completed and we definitely look forward to those.
Our biggest hope at this point is that the good weather (50-55 degrees yesterday and today in Nappanee) will hold -- or at least not diminish too much -- by the time we get back to Newmar on February 11 for factory delivery.
Deek
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