Roll Wrapped Composite Tube Production System

Ratio Made Inc.

Challenge:

Develop a cost-efficient production system for high-performance composite sporting goods fabrication.

Maximize in-house processes to align with brand mission and reduce external dependencies.

Operate within 1,700 sq ft with no ventilation or climate control.

Methods:

• Conducted in-depth research of analogous production systems in fishing pole and golf shaft manufacturing to inform primary equipment specifications and drive the design of custom jigs and fixtures.

• Built a Python throughput model incorporating product mix, technician shifts, passive task times, task dependencies, and equipment exclusivity constraints to pinpoint bottlenecks and drive productivity improvements.

• Applied 5S and continuous improvement methodologies to identify inefficiencies and systematically enhance production workflow.

Results:

Achieved 200+ units/month throughput with consumer-quality surface finishes and aerospace-grade void content from an out-of-autoclave process, all within 1,700 sq ft facility.