World Cat Boat Design

Building a "Lean" Kitty

noreply@blogger.com (Chris Brockway) — Fri, 04 Jul 2008 02:54:00 +0000

Lean manufacturing is a strategy. Essentially, it's about reducing waste wherever it occurs in the organization. Lean wastes include excess inventory, excessive movement, over-production, and the list goes on... The goal of "Lean" is ridding the system of these wastes, along with the costs associated with those wastes.

During these tough economic times, and skyrocketing commodities costs it's essential to begin the journey of being lean, especially in the boat industry. It's what allows us to hold price increases to a minimum while operating profitably, and most importantly stay in business while others are not.

At World Cat we are committed to running a lean organization, and that includes our product development process too! The goals of eliminating waste are especially important in PD and is what has made companies such as Toyota not good but great!

The results of a lean PD process are getting the product right the first time, less rework and engineering changes, shorter lead times and most importantly designing and building with the customer in mind up front. Customer value drives the PD process from start to finish... if we don't build what the customer wants, then why are we building it at all?

I receive many questions on how we take products from concept to production from readers of this blog. I've tried to detail the steps of what we do in this blog and will continue to do so in the future. Additionally, I'm going to widen the scope of this blog to talk about our manufacturing and lean initiatives as well.

The next 6-18 months will be an exciting journey for us as a company, hopefully you'll come meets us for a factory tour and learn firsthand about the journey we're taking to be not just good, but great!

Project Updates - Happy 4th!

noreply@blogger.com (Chris Brockway) — Wed, 02 Jul 2008 02:45:00 +0000

I hope this post finds everyone happy and healthy, it's been a while since I posted an update on the projects that we're working on. It's been a busy couple months with finalizing one boat and getting another design off the ground... we should have lots of updates over the next couple months.

We're finalizing the 3rd prototype 290 Express Cabin, it will soon be handed off to manufacturing for full production status. In order to get vendor parts approved, work instructions written, and associates up to speed we build three prototypes using resources from product development, manufacturing support, and manufacturing. The 4th boat is built by manufacturing with assistance from manufacturing support (including quality assurance), and is the milestone for product development that the project is complete. We're almost there! We'll have a video review done by Dean Travis Clarke of Sportfishing Magazine soon...

The 290 Center Console is moving along nicely, the deck plug arrived Monday during our annual factory shutdown and looks good. I'll post a photo once we return to give everyone an idea of the layout better than the renderings provided. We are finalizing our systems layout and vendor parts, and will start building mock-ups and tooling once we return from break.

We're also starting to work on concepts for our first cruising-oriented 290 model that is intended for customers who wish to cruise 1st, and fish 2nd. We're really excited about this project and we think it will be a great product that introduces the benefits of catamaran ownership to a new segment of the market.

Have a great 4th of July celebrating the greatest country in the world! The flag I attached is a photo I took while at Chimney Rock Park in North Carolina, schedule a visit and be sure to drop by and see us for a factory tour. Now vacation starts for me!

290CC Design Finalized!

noreply@blogger.com (Chris Brockway) — Fri, 09 May 2008 19:30:00 +0000

We have finalized our 290 Center Console design and have begun constructing the necessary tooling to build the next boat in our 290 Series. We intend to have our initial prototype complete in time for the Fort Lauderdale International Boat Show in October.

Many of our customers have been looking to upgrade from their 250SF, 270SF, and 270TE center console fishing boats. Many have stepped up to our 330 Tournament Edition, but others have been waiting for a product in the 29-30' range.

With forward wrap-around seating and a flip-down forward facing seat for two on the front of the console passengers will be able to relax comfortably or convert the area for hard-core fishing. And the wrap-around windshield with wiper and washdown ensure that the crew will be protected from the elements.

Some of the highlights of this model will include:

Expansive wrap-around bow seating for (4) adults
(2) insulated 225-quart storage tubs w/ overboard drains
(1) insulated 105-quart cooler w/ overboard drain
Flip-up forward console seat for two
Wrap-around windshield w/ integrated hardtop
Dual helm seating w/ flip-up bolster seats
Marine head w/ 15-gallon holding tank
Fiberglass leaning post w/ 42-gallon livewell
(2) insulated 300-quart macerated floor fishboxes
Option fold-down transom seating
Euro transom w/ walk-through and transom shower
Extensive tackle and bulk storage compartments
Easy access to service areas

Visit our website to view complete specs on the 290CC

290EC Running Video - Exclusive!

noreply@blogger.com (Chris Brockway) — Wed, 07 May 2008 18:38:00 +0000

Just a quick follow-up to my post about the 290EC Trial Run, here's some of the video that I shot while we performed our initial float and performance testing on the soon to be released 290 Express Cabin.

I shot this video from one of our 330 Tournament Edition boats; keep in mind that I'm no professional photographer or videographer, so please don't pick on the amateur. From the video you should be able to see the quality of the ride, and especially the maneuverability (don't let anyone fool you that a World Cat can't lean into a turn). Oh, and the boat looks great! Enjoy...

290EC First Splash!

noreply@blogger.com (Chris Brockway) — Mon, 05 May 2008 01:00:00 +0000

We ran the 290EC Friday at Town Creek Marina in beautiful Beaufort, NC with great success! The boat performed flawlessly, and the ergonomics at the helm where fantastic while operating her. The performance numbers were consistent with the 290DC prop tests, cruise speed was 33MPH and WOT was 48MPH @ 5900RPM.

With our initial float and performance testing complete, we've taken her back home to our factory and will complete the cabin and details of this first prototype in preparation for full production starting in July.

I'll post more photos of the finished prototype once we're complete in the next couple weeks. We're excited to get this boat completed, feedback from customers has been phenomenal. This offshore sportfishing boat is sure to be a big hit!

290 Express Cabin Update

noreply@blogger.com (Chris Brockway) — Mon, 28 Apr 2008 19:10:00 +0000

The 290 hull, liners and deck have been poly-bonded together, so we officially have a boat now that is in one piece. It has now taken it's place on our production line, which means we're getting very close to being completed.

We're working hard to finalize this prototype in time for the first water test this Friday... engines are hanging today and the dash and baitprep station will be added tomorrow in time for the first splash. This boat really comes together when we installed the hardtop and windshield, now we've got our cabin builders concentrating on finishing out the berth so that it looks "World Class".

Stay tuned for an update of our initial water test this weekend!

Friday Night Updates!

noreply@blogger.com (Chris Brockway) — Fri, 18 Apr 2008 18:11:00 +0000

Here's a couple photos from late in the day on Friday, I couldn't wait until Monday to share. The deck fits great! The lines look good, and cabin is very spacious similar to the 320EC.

We also checked the bait prep station and the dash, which fit perfect as well. Next week will be a big week wiring the boat (hopefully the harnesses show up!) and starting to install cabinetry, doors, and doing final fit to check all the details...

This is going to be a great boat for fisherman... did I mention the two 300-quart fishboxes? How about the completely re-designed baitwell? You can read all the specs at our website for this offshore fishing catamaran...

As always, stay tuned for the next update on this boat and others in development... yes, we have other models we're working on currently too. Soon I'll reveal the final renderings on the next center console that we're working on, the 290CC... it's headed to mill today to get started!

We're also working on 270's and 290's designed more around cruising than fishing. You might remember that we originally pitched the idea of World Cat Cruisers a couple months ago on this blog, and have received enough positive feedback to get started!

Support Green Boating

noreply@blogger.com (Shelby Brown) — Fri, 18 Apr 2008 16:15:00 +0000

Earth Day and boating. It sounds like a marriage headed straight for divorce court. A day set aside for honoring, protecting and replenishing Mother Earth, trying to get along with something as seemingly environmentally unfriendly as boating. Never going to happen you say.

At World Cat we’re working to change that perception. “Going Green” is something we take very seriously here. Heck, “World” is our first name. In honor of Earth Day on April 22nd I’d like to share with you how World Cat is embracing “Green Boating.”

World Cat’s product development and engineering team are working to integrate solar panels into future designs to charge battery banks and power electronics on our boats. We’re also investigating diesel electric power to propel our boats, similar to how hybrid vehicles work. Think that’s cool? How about recycling our old boat molds to use in fishing reefs? Gives a whole new meaning to fishing on a World Cat.

We feel like as a company we have only begun to scratch the surface of how Mother Nature and boating can peacefully co-exist.

The EPA estimates the average American produces 4.5lbs of solid waste each day. Think about it. That adds up quickly! Any materials that can be recycled will reduce the amount of waste that is incinerated or sent to landfills, therefore conserving natural resources and raw materials. Recycling prevents the emission of many greenhouse gases and water pollutants, saves energy, conserves resources and reduces the need for new landfills. Did you know that the following marine-related products can be recycled?

· Oil
· Used oil filters
· Shrink wrap
· Flares
· Lead batteries
· Monofilament fishing line
· Antifreeze

*Source: Earth911.org

29 Express Cabin

noreply@blogger.com (Chris Brockway) — Fri, 18 Apr 2008 02:30:00 +0000

The hull liner for the 290EC was completed on schedule, looks great, and fits perfectly in the hull! Most importantly it holds the toilet quite nicely as you can see in one of the photos... seriously, everything seems really well spaced and comfortable.

We hit our first snag... waiting for wiring harnesses in order to set the liner into the hull. Oh well... we worked it out and they'll be here next week, we just hate losing time upfront but better they are done right than done quickly.

The headliner was pulled today too! We're setting the headliner into the deck tomorrow, and will be doing a preliminary dry set on Monday... at which point it'll look like a real boat. Just a couple more weeks until the maiden voyage and extensive testing!

Rigging the 290EC Hull

noreply@blogger.com (Chris Brockway) — Fri, 11 Apr 2008 01:30:00 +0000

We have begun installing tanks, pumps, plumbing and soon electrical this week... this process of building the prototype, approving the vendor parts, and documenting the build to ensure manufacturing will be able to replicate consistently starting on boat #4 will continue throughout next week.

The hull liner was built today, it will be pulled and set in the boat next week and then the cabin build will begin.

Once we complete the under the deck work, and the initial cabin build, we're scheduled to set the deck onto the hull and bond together on April 21st. Right on schedule to have the first prototype to the water for testing and propping.

Next week it will start to look like a boat! Stay tuned for updates...

290EC Hardtop Preview

noreply@blogger.com (Chris Brockway) — Thu, 03 Apr 2008 21:14:00 +0000

The 290EC is moving along on schedule and major components are starting to come together. We visited Ashley Welding to see the progress of a couple of the most important components, the aluminum hardtop frame and the stainless steel bow rail... both are coming along great, and fit the boat quite well.

You can see the deck lines in the photo, the final prototype version of the hardtop frame will be awesome. Sturdily built, looks great, and plenty of room to rig electronics.

I will post updates of the rigging and assembly process, we've been very busy trying to get all the vendor parts in house. The hull liner mold was completed today, as well as the bait prep station and various lids. Won't be long until this begins to look like a boat... stay tuned for updates, April will be a busy month.

290DC Offshore Dive Boat Video

noreply@blogger.com (Chris Brockway) — Sat, 22 Mar 2008 17:55:00 +0000

Here's the newest video of the World Cat 290 Dual Console, The Ultimate Offshore Family Fun and Dive Boat... This video was a review done by Dean Travis Clarke of Sportfishing Magazine.

Cat vs Mono - Check Out This Video

noreply@blogger.com (Chris Brockway) — Fri, 21 Mar 2008 15:09:00 +0000

Evinrude created a video to explain the differences between the catamaran hull and the mono hull designs, and what to look for while purchasing a catamaran... whether it be a World Cat, Glacier Bay, Twin Vee, ProKat or other... or even a mono-hull! There's a boat for everyone! Take a look if you haven't seen, it's quite informative.

290 Express Cabin Moving Along

noreply@blogger.com (Chris Brockway) — Fri, 21 Mar 2008 03:32:00 +0000

The 290EC continues to move forward, we now have the stringers and bulkheads installed in the hull and are starting to fit the hull with tanks and rigging... I'll get some photos to update the stiffening and rigging processes. Everything is fitting together nicely so far, we're working hard on the head/cabin liner plug, which is the most difficult part of the project. I've included a photo of that process here, it's tedious and not too exciting... but extremely important to designing and bringing to life a high end boat.

Once we're done with the head/cabin liner, we'll build the mold and pull the first part to be included in our first prototype. A few more weeks until that is done, but we're building the hull liner, the dash, and lids mold next week... so stay tuned for updates on those processes. Next week will be a busy one!

Be sure to email us at pde@worldcat.com if there are any items you have questions on how we go through the boat design and boat construction process, hopefully everyone is finding this blog informative and interesting.

Happy Easter to All!

290EC Deck #1 Built

noreply@blogger.com (Chris Brockway) — Thu, 06 Mar 2008 17:30:00 +0000

We finished building the first 290EC deck part today, it looks great! This will be the deck used on prototype #1 which is scheduled to be completed May 2nd for dealer and customer feedback as well as extensive water testing.

Next week we'll start rigging this deck, and fitting vendor parts. The 290 hull for proto #1 will be completed next week, so we'll be able to start on that as well. Once we verify rigging and fit, we begin setting up jigs and fixtures to ensure that we build each and every 290 Express Cabin to the tight tolerances we expect.

This boat is going to be a great addition to our sportfishing cabin boats!

Additional 290 Hull Mold

noreply@blogger.com (Chris Brockway) — Thu, 06 Mar 2008 14:45:00 +0000

We've completed our second 290 series hull mold... this will be a welcome addition to our plant and quickly become a necessity with the addition of the Express Cabin and Center Console models in order to meet retail demand.

If we continued with only one hull mold this would mean that we could only build a 290 series boat every other start. This is because we build our hulls over a two-day period in order to maximize the benefits of a properly cured skin coat.

Day one consists of spraying gelcoat, and skinning the hull to approx 70 mils. We allow this to cure overnight in order to ensure that the proper hardness is reached in the skin coat which protects the finished surface.

Day two consists of adding the bulk laminate which consists of layers of bi-axial and tri-axial materials, and foam coring above the waterline. Once they are done with bulk laminate, they finish day two by installing the transom, stringers, and the bulkheads.

Adding this second mold we mean that we can start a 290 series boat every single day, and considering we build one boat per day, that's a lot of capacity! Once we get the metal framework glassed onto the hull mold for rigidity, mold care will then properly bring it up for the first two production parts by buffing, sealing, and applying release agent. After building the first two parts we'll perform final tooling to take the mold to 1000-grit finish, and it'll be ready for years of high-quality production parts.

290EC Deck Mold Framed

noreply@blogger.com (Chris Brockway) — Wed, 27 Feb 2008 04:07:00 +0000

The metal framework was added to the World Cat 290EC deck mold and it was pulled Monday... we've templated our patterns for coring and glass kits, and the mold has now entered mold care.

In mold care they will tape off all non-skid to protect, buff the mold using three separate buffing compounds to bring out the shine in the mold for production, and then add two coats of sealer, and five coats of release agent.

Once we complete mold care, we will mount the mold to it's spindle to allow for easy lamination. We will then build the first two parts! Part #1 will be for the first prototype 290EC, and part #2 will remain in the mold to build the fiberglass cabin headliner. Building the headliner in the mold takes much more time than simply milling a plug and building a mold, however, yields a part that is perfectly mated to the deck. Details like this will show show up in the final product.

Both deck parts will be built next week, and then we can simultaneously start the prototyping process on the 290EC deck and begin building the 290EC cabin headliner.

Once we complete the headliner mold, the deck mold will be sent back to mold care to perform final tooling on the mold and take it to 1000 grit in order to ensure the highest quality parts will be built using the deck tooling.

We're also working on splashes for use as cutting templates on the deck plug before we send it off to Ashley Welding to build the hardtop frame and bow rail...

All in all this is the busiest couple weeks of the project... did I mention that we're building 290 hull mold #2? More on that later... stay tuned.

290EC Deck Mold Complete

noreply@blogger.com (Chris Brockway) — Mon, 18 Feb 2008 22:45:00 +0000

We finished building our 290EC deck mold last Friday while I was at the Miami Boat Show. The flange has been trimmed and the mold (sitting atop of the plug) has been sent over to maintenance to add the steel framework. The steel framework will give the mold rigidity to ensure that each part comes out per our design specification and also that the mold is structurally sound enough to last many years.

This mold looks great! At World Cat, we have a dedicated in-house team that builds our molds and takes their job very seriously as leaders in charge of our future. Many manufacturers outsource the mold making process, we believe that we're best suited to build our most valuable assets!

When building our molds we use a 100% vinyl-ester tooling resin that is specifically designed to build tooling and to withstand heat and shrinkage. After the plug is completed, we wax and prep the mold and spray one layer of black tooling gelcoat (the outside layer), and one layer of green tooling gelcoat (the inner layer). We do this so that we can see problem areas that need fixed on the mold before they become real problems in production. On hulls and decks, once the gelcoat has become tacky, we buildup the mold by hand-laying 12 layers of chopped strand mat which results in a 21-ounce buildup. This is allowed to cure completely, and that's where we are at now... time to add metal!

Hope you found this interesting, stay tuned for future updates to the 290EC and our other projects, we'll finish building the metal framework this week and pull the mold next week to begin prepping it for the first deck!

Miami Boat Show Recap

noreply@blogger.com (Chris Brockway) — Mon, 18 Feb 2008 21:45:00 +0000

I just got back from the Miami Boat Show, it truly is the show that kicks off the boating year! You could feel the electricity in the air in Miami, this was a big show for the boating industry, lots of new and interesting products and technologies as always.

This was the first in-water show for our 290DC Dual Console, which was a great success. The 290DC sea trial schedule was filled for each and every sea trial from 10AM to 5PM from Thurs day until today with over 120 trials taken! Although we applied for an NMMA Innovation Award for the 290DC, we weren't able to win. We're not going to let that get us down, based on customer feedback and feature comparison, we believe the 290DC to be the best in class offshore dual console boat available... styling, features, seating, safety, and of course... ride. Lots of excitement around the World Cat docks and booth. Our preliminary sales results show an increase in retail units over last year of 50%! This gives us the confidence that we're listening to our customers and designing products with them in mind. We're looking forward to releasing the new products we currently have in development (290EC, 290CC), and especially the ones we've been dreaming up over the past week!

We'll keep trying on those awards!

Atlantic City Boat Show

noreply@blogger.com (Chris Brockway) — Mon, 11 Feb 2008 19:20:00 +0000

The Atlantic City Boat Show ended yesterday, a successful event for World Cat and our area dealers... lots of interest in our products and we're holding up strong during these uncertain economic times. World Cat's new and used boats continue to be in high demand in the marketplace.

Great feedback on the 290DC, lots of interest and excitement on the 290EC! Lots of talk about bigger World Cats (hmmm...) with and without diesels, and World Cat Cruisers or cruising-type boats. It's Always great to get to take some time out of our busy schedules and get an opportunity to speak with our owners. After all, that's what it's all about...

Off to the Miami International Boat Show this week, and then back to the drawing boards to continue working on new models! Just wanted to say thanks to all the owners who were able to make it to the event!

World Cat Cruisers?

noreply@blogger.com (Chris Brockway) — Thu, 07 Feb 2008 03:00:00 +0000

I'm extremely excited to announce that we are working on concept designs in anticipation of adding a catamaran cruiser to our product offerings! Currently we build three types of boats, all with an emphasis on fishing:

Center Console Catamarans
Dual Console Catamarans
Cabin Catamarans (Express & Walkaround)

On our new 290 series hull design, we've entered full production on the Dual Console model (290DC), we're building our first prototype Express Cabin model (290EC), and we're finalizing the design of the Center Console model (290CC).

But wait... if that wasn't enough, we're working on a cruising type layout that you can fish... we haven't decided on the model designator yet, but we're gathering customer feedback on the features and specifications that would make this new addition a real winner for our customers.

We are extremely excited to make this jump into the cruising market and growing the World Cat family to include all boat owners, not just our fishing customers. We think that the catamaran hull benefits all boaters in safety and comfort.

If you'd like to provide feedback to help us design these models and be included in future market surveys, please send an email with your comments to pde@worldcat.com.

Stay tuned for future updates!

290DC @ Miami Boat Show

noreply@blogger.com (Chris Brockway) — Wed, 23 Jan 2008 06:08:00 +0000

The 290DC will be In-Water at the Miami International Boat Show (Feb 14th-18th) for sea trialing at the Marriot docks... The test boat will have 225 Honda's on it, we'll be releasing performance data on our website next week on the DC w/ 225 Honda 4-strokes.

The Crouch's coefficient of the 290 series hull is second to only the 330 series hull... what is the Crouch's coefficient you ask? It's a standard method Naval Architect's use to analyze the efficiency of planing hulls. That said, the 330 is a boat that really turns heads, and this 290 will do the same!

Don't miss the opportunity to take the Ultimate Ride and experience this power catamaran for yourself! You must sign up before hand for a sea trial and show up at the World Cat booth in the convention center beforehand... You can request a sea trial via info@worldcat.com.

We'll post the performance data with the Honda 225's on the boat soon, you can view the current prop testing that was completed with Yamaha 250's in the Prop Tests section of the 290DC.

290EC Design Complete

noreply@blogger.com (Chris Brockway) — Mon, 21 Jan 2008 03:12:00 +0000

We have completed the design phase of the 290EC and have begun creating the tooling necessary for this model. Built upon the 290 series hull, this boat is sure to be a big hit.

Here's some of the notable features for the model:

Full cabin with master berth, and integrated storage
Galley package w/ refrigerator, microwave, and sink
Enclosed, lockable head w/ 15-gallon holding tank, freshwater shower, and vanity
Molded-in bow seating with cushion
Stainless-steel grabrail and toe kick
Centerline helm including dual helm seat
Centerline bait prep station w/ 40-gallon livewell
Frigid Rigid 81-quart ice chest
Euro-style transom
Freshwater transom shower
Shorepower w/ 30A service and battery charger
35-gallon freshwater system w/ water heater
(2) 250-quart insulated floor fishboxes

First Prototype expected to complete in April... more info to follow!

290DC Finalized

noreply@blogger.com (Chris Brockway) — Mon, 07 Jan 2008 03:10:00 +0000

The 290DC has been finalized and has been released to full production status! Final performance testing shows the 290 series hull to be one of the best World Cat hulls to date (view the sea trial w/ 250's Yamaha's).

Don't miss seeing this boat at the 2008 Atlantic City Boat Show, or seeing and sea trialing the boat at the 2008 Miami International Boat Show in February.