Corvette Product Manager Harlan Charles shared Friday during the National Corvette Museum’s Corvette Team Seminar that previously built 2020 Corvettes plus already accepted dealer orders for 2020 Corvettes total 20,181 possible 2020 Corvettes.
Assuming that the report of a November 2nd model year change proves accurate, here is how we get to 20,000 Corvettes produced during the 2020 model year:
- Normal build rate is 11.5 cars per hour. (NOTE: This figure already accounts for downtime. Additional explanation below.)
- For each 8-hour shift, 92 cars can be built.
- Each shift can build 460 cars per week.
- There are 22 weeks between now and November 2.
- In 22 weeks, one shift can build 10,120 cars.
- That leaves 7,000 cars for a second shift to complete, which would require the second shift running for 15 weeks.
- The second shift only needs to start by July 20 in order for the 17,000 number to be achieved.
Assuming there are no further COVID-19 related disruptions, including supplier-related disruptions, 20,000 Corvettes built for the 2020 model year definitely seems attainable.
Additional Production Volume Information
During the National Corvette Museum’s Ambassador Convention on November 1, 2017, Plant Director, Kai Spande, provided the following production information after the 2017 plant retooling:
- C7 daily production volume prior to retooling: 17.2 units per hour/137 per 8 hour shift
- C7 takt time was approximately 3.5 minutes per station prior to retooling
- C7 daily production volume after retooling: 11.6 units per hour/93 per 8 hour shift
Data source: https://youtu.be/R_dSECWDuDk
Daily production information was also provided during the National Corvette Museum’s Birthday Bash on April 26, 2018.
- C7 daily production volume averaged 116 cars during each 10-hour shift (the plant was on a 4 day/10 hours per day work week at the time)
- It was noted that the pre-retooling production rate used to be roughly 17.5 cars per hour and was now 11.5 cars per hour. (11.5 cars per hour referenced at 20:38 in the video)
Data source: https://youtu.be/v8ZmFF-oaQo
During the NCM’s 25th Anniversary Celebration, the following production information was provided on August 29, 2019.
- The desired takt time is about 4.5 minutes per station.
- 2020 production should start at around 6 minutes takt time.
- The benchmark rate for getting to full speed production is 6 to 7 weeks.
Data source: (starts with my question and Kai Spande’s response at 35:21 in the video) https://youtu.be/TbpdAmCsKkU
Finally, Kai Spande provided a plant update seminar during the NCM’s Virtual Bash on May 28, 2020 and once again stated that takt time is 4.5 minutes per station.
While a target takt time of 4.5 minutes would result in an hourly production volume of 13.33 cars per hour (60/4.5=13.33), the 4.5 minute figure is the target so that the desired net production volume can be 11.5 or 11.6 cars per hour. The 11.5 or 11.6 figure accounts for down time and other interruptions. This goal translates to a net takt time of 5.2 minutes per car, providing the desired volume of 11.54 cars per hour.
Based on the information presented Friday, here’s how we can anticipate 2020 Corvette production breaking down:
Coupes – 16,750
1LT – 2,680
2LT – 6,700
3LT – 7,370
Convertibles – 3,431
1LT – 275
2LT – 1,235
3LT – 1,921
FE1 Non-Z51 – 4,843
FE3 Z51 – 4,440
FE3 Z51+MR – 10,898
(note: numbers on the chart equal 101%, so the following numbers add up to 20,383)
Torch Red – 5,045
Arctic White – 3,027
Black – 2,422
Sebring Orange – 1,413
Elkhart Lake Blue – 1,413
Rapid Blue – 1,211
Ceramic Matrix Gray – 1,211
Blade Silver – 1,211
Shadow Gray – 1,211
Long Beach Red – 1,009
Accelerate Yellow – 605
Zeus Bronze – 605
Jet Black – 5,651
Jet Black w/Red – 2,422
Jet Black w/Yellow – 605
Adrenaline Red – 5,045
Sky Cool Gray – 1,816
Natural – 2,422
Natural Dipped – 1,211
Two-Tone Blue – 807
Morello Red – 202
Editor’s Note This post was updated with additional information about the production process based on previously discussed information from representatives of the Bowling Green Assembly Plant.
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