PowerUp 3.0 turns your self-made paper airplane into a smartphone-controlled flying machine Read more
This project was successfully funded on January 25, 2014.
PowerUp 3.0 mass production
What an exciting (and exhausting) couple of weeks it has been! I am returning home today from a long factory visit in China, all to ensure that our production is running on course. Soon Kickstarter shipments will be flying overseas to more than 70 different countries!
Check out our Facebook page for updates from my trip to China.
Pre-production took us 3 days, and we started at 300 units per day. As with any mass production, there is a learning curve, and these first few days are integral to spotting areas where we can tweak the process to improve production efficiency. With 20 unique assembly stations – ranging from soldering of parts, to quality checking the pieces, to assessing the Bluetooth functionality with our test app – we looked for any bottle capping in the production process. One example of this that we found was in the soldering of the thin wire pieces, which requires considerable attention to detail. By adding an additional person to this station, we are able to expedite the process and minimize the time it takes to pass the module along to the next station.
After three days, we ramped up to 500 units per day, and we aim to increase this to 600, then 800, and then 1000 units per day by the end of the month. As the schedule stands today, we expect to have 10,000 units ready for shipment by June 20th. We will then continue to produce 10,000 units every two weeks, completing our final two Kickstarter orders on July 5th and July 20th. Once each container is completed, it will be shipped right off to our fulfillment center, at which point rewards will arrive at your doorstep within 10 days.
We know that everyone is eagerly anticipating the arrival of their PowerUp 3.0 kits, so we want to start shipping as soon as each of these containers is completed (i.e. 10,000 at a time). This leads us to the burning question: who receives the first batch?
For streamlining purposes, assembly must be done one package type at a time, meaning it would greatly complicate the process to assemble Barebone packages simultaneously with Perfect packages. With over 7,000 Basic-only orders, nearly 3,500 Perfect-only orders, and roughly 2,500 Barebone-only orders, we are going to start with single item rewards so that we can fulfill the most orders in the shortest amount of time. Bundled orders will ship out in July as part of the second and third containers.
I hope that this has shed some light on the challenges that come along with producing large quantities of a brand new commercial product. We want to “wow” each and every one of you with the PowerUp 3.0 – that is our priority – and to ensure you get the best possible product, I can only ask that you work with us as we scale our production speed for the sake of quality. I know it’s like sitting on your hands, and I cannot thank you enough for your ongoing patience and support!
All the best,