GM Is Building The New Chevy Bolt 30 Cars At A Time. Here Is The Brilliant Reason Why.

"Usually, cars go on the manufacturing line in VIN order, which means multiple trims, colors, and options have to be fitted by workers in a short amount of time. This increases the risk of something going wrongand if the line has to stop, the money stops flowing. To get around this issue, the 2027 Bolt is assembled in batches of 30 identical cars at the Fairfax plant in Kansas City."

"According to General Motors, this Winning with Simplicity approach has so far managed to reduce complexity and costs, and, at the same time, boost productivity and quality. Workers know they no longer have to reach for different parts trays from one car to another, ensuring that vehicles don't have to be pulled off the line to repair mistakes."

"Even if that happens, though, the automaker has another ace up its sleevethe clone process. For every configuration, the plant holds back two bodies, so that if a vehicle is removed from the assembly line for a quality issue, its matching clone can take its place on the line, and manufacturing can keep moving forward."

"In the Chevy Bolt's case, we're talking about 21 clones, seeing how the EV is available with three roof configurati"

The 2027 Chevrolet Bolt EV uses a manufacturing approach that lowers costs by simplifying assembly. Instead of routing different trims and configurations together on the line, identical cars are produced in batches of 30 at the Fairfax plant in Kansas City. This “Winning with Simplicity” method reduces complexity and costs while improving productivity and quality. Workers handle the same parts repeatedly, which lowers the chance of mistakes that would require pulling vehicles off the line. For quality issues, the plant keeps matching clone bodies on standby for each configuration. If a car is removed, its clone can immediately replace it so production continues. The process involves multiple clones to cover roof configurations.

Read at insideevs.com