Winnebago Plant

We did tour a Winnebago Plant yesterday also.  It was absolutely amazing to see the work that goes into constructing an RV like all of the different ones we see on the road.  We saw several versions on the "line" in several states of completion.  We were not allowed to take photos inside the plant as we traveled through several buildings on their property.

We saw computer controlled machines that cut the fabric and leather for chairs, trim and interior cabinet lining.  The process uses computer designed patterns to minimize the wasted portions.  Then we saw the cushions sewn together and the most amazing vacuum system to shrink foam to fit perfectly into the cushion where it then expands back to its original size to fill the cushion.  The foam is purchased locally in pre-trimmed sizes for everything they make.  In fact Winnebago uses local providers for many of their components, in not most!  This creates a delivery system to them called "just in time" meeting their needs as they arise and avoiding the need to keep huge amounts of parts and material inventory on hand at their factory.

The chassis for smaller campers are built by Ford or Mercedes while large RVs like ours are Cummins.  These are delivered by truck to the Winnebago factory which keeps a three week supply or about 600 on hand in various sizes.  The chassis are ordered and used to fulfill orders from dealers so each RV is already pre-sold before they start making it.  Upon delivery to the dealer, Winnebago is paid with a middleman transport company across the street from the factory working between the dealers and Winnebago to coordinate the deliveries.

We saw welders working on attaching the RV frame to the chassis, then the floors and side panels being constructed and finally the roof put into place.  Then wiring and plumbing and interior cabinetry is installed.  The exterior is painted on-site by a separate business.  They even have a "test track" and a "shower stall" where the RV is test driven and checked for leaks.

So it was a great experience to see all of this I highly recommend to anyone.  I took away a feeling of confidence in the quality emphasis (not quantity) the company is focused on.  I also am so pleased to see so many Americans making a product "from scratch" with American parts.  Hurray for Winnebago!  By the way, the average age of workers there is 47 years with lots of evidence of ages both younger and older as we walked the factory floor.  There were as many women employed as men.  The company requires a high school diploma to start there and they have on-site training.  Another pat on the back for Winnebago and the little town of Forest City, in the middle of Iowa that makes all of this possible.  You have my utmost admiration!