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Phase I: Forming the Shells
In this step, a flat sheet of TPO is loaded into our thermoforming machine. The plastic (TPO) is then heated to a jelly-like state, and pressed over a mold. Once on the mold, the sheet is cooled and hardened into the shape of either a base or a lid for one of the trailer models.
From there, the operator removes the part, performs some trimming and drilling, and stacks it to be placed in our warehouse.
This process allows us to form around 3 trailers per hour (one lid and one base) compared with one or two per DAY when forming fiberglass.
Phase II: Secondary
At the beginning of the year, our secondary department builds a “batch” (usually 10 each) of completed lids and bases. Once enough trailer orders have been placed to use up most/all of these parts, another “batch” is scheduled.
The following actions are performed on the lids in this step…
While the following operations are performed on the bases…
Phase III: Final Assembly
In order to reduce inventory costs, Final Assembly is scheduled only after an order is received. When the scheduled time arrives, a base is placed on our assembly line, and the lights are installed (and tested). Any options that go on the base itself (bumper, bezels, etc.) are also added here.
From there, we rivet a lid to the hinge. Any options that go on the lid or inside the trailer (lug. rack, carpet kit, etc.) are then installed.
Lastly, we add the tongue, coupler, and wheels. The wheels and tongue are left detached if the trailer is being crated for truck shipment. All Rovers and Quests are locked for shipment, and the keys are delivered separately.