Factory Visit

<body topmargin=0 leftmargin=0 marginheight=0 marginwidth=0> <table cellpadding=0 cellspacing=0 border=0><tr> <td valign="top" rowspan="2" width=210 BGCOLOR="#9999FF" TEXT="#080000" bgproperties="fixed" background="11e924263.jpg"> <div> <IMG SRC="6d4c1890.png" border=0 width="193" height="137" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></div> <div> This article is based on Malcolm & Eileen Perrins' visit to the factory in February 2001. The majority of the production photographs show the Sun Odyssey 34.2 production line.</div> <bR> <bR> </td> <td valign="top" colspan=2 height=70 BGCOLOR="#99CCFF" TEXT="#080000"> <div> <B> </B><FONT SIZE="2" COLOR="#0000CC" FACE="Times New Roman" ><B>   |   </B></FONT><FONT SIZE="2" COLOR="#0000CC" FACE="Arial" ><A HREF="index.htm" TARGET="_top" TITLE=" "><U>home</U></A></FONT></div> <div> <A HREF="reviews___info.htm" TARGET="_top" TITLE="Reviews Info"><U><B><IMG SRC="0430e0e0.png" border=0 width="14" height="14" ALT="up" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></U></A><B>  </B><IMG BORDER="0" SRC="1x1.gif" HEIGHT="14" ALIGN="BOTTOM" HSPACE="0" VSPACE="0" WIDTH="14"><B>     </B><A HREF="id170.htm" TARGET="_top" TITLE="Rigiflex"><U><B><IMG SRC="0440e0e0.png" border=0 width="14" height="14" ALT="previous" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></U></A><B>  </B><A HREF="id332.htm" TARGET="_top" TITLE="Sun Kiss Maintenance Manual Spare Parts"><U><B><IMG SRC="0450e0e0.png" border=0 width="14" height="14" ALT="next" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></U></A></div> <div> </div> </td> </tr><tr> <td valign="top" height=410 colspan=2 BGCOLOR="#99CCFF" TEXT="#080000" bgproperties="fixed" background="91940403.png"> <div> Factory Visit</div> <div> <TABLE BORDER="0" CELLPADDING="2" CELLSPACING="1" WIDTH="660" BORDERCOLORLIGHT="#C0C0C0" BORDERCOLORDARK="#808080" FRAME="BOX" RULES="ALL" HSPACE="0" VSPACE="0" > <tR> <tD VALIGN=TOP HEIGHT= 294 WIDTH="238"><div> The Jeanneau factory is located inland some 50 miles from the Biscay coastline in the town of Les Herbiers. The factory has incrementally grown over the years, but still occupies a single site with numerous buildings spreading out behind the main office building, there are currently around 1200 employees on the site.  A vast new building is presently under construction, at the rear of the existing buildings, which when complete will be used for production of the larger models.</div> <bR> <bR> </tD> <tD VALIGN=TOP><NOBR><div> <IMG SRC="22e96200.png" border=0 width="406" height="288" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></div> </NOBR></tD> </tR> <tR> <tD VALIGN=TOP HEIGHT= 411 WIDTH="238"><div> Our guide for the visit was the helpful and knowledgeable Erwan de Vuillefroy from the newly formed customer support section. Erwan first took us to the Joinery shop that had recently been equipped with a fully automated varnishing line. Like a huge car-wash perhaps 150 feet in length, the huge sheets of teak faced plywood receives, in a fully automated process, three coats of varnish between sanding and drying phases. The treated sheets are then cut into intricate shapes using massive computer controlled cutting machines. For the precise alignment needed the sheets are held to the cutting table under vacuum pressure. The resulting jig-saw of pieces are then marked and transferred for the next stage. The exclusive use of teak for all joinery in Jeanneau yachts has become a unique hallmark of the brand, and a considerable amount of hand finishing still occurs, particularly for the smaller pieces of solid wood trim. The joinery shop is also equipped with a huge "clean room" area that is dust free where the final varnishing is completed. The workshop, as everywhere else in the factory was extremely tidy and well organised.</div> <bR> </tD> <tD VALIGN=TOP><NOBR><div> <IMG SRC="230933a0.png" border=0 width="403" height="314" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></div> </NOBR></tD> </tR> <tR> <tD VALIGN=TOP HEIGHT= 361 WIDTH="238"><div> Next stop was the laminating areas, here the huge hull and deck moulds are prepared for the lay-up stage. Vinyl ester layers are incorporated to provide osmosis protection and Jeanneau uses considerable amounts of woven rovings during the build to provide strength, whilst the hulls of yachts from 37 feet and above also use Kevlar rovings in the below waterline areas. Erwan informed us this was to ensure strength in the hull to keel area, although this is not required in the smaller yachts, as they do not have the same potential to flex. Jeanneau continues to use a traditional hull strengthening system of bonding in wooden stringers to provide rigidity, unlike many production builders who insert a moulded fibreglass grid system.</div> <bR> </tD> <tD VALIGN=TOP><NOBR><div> <IMG SRC="232f4630.png" border=0 width="500" height="355" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></div> </NOBR></tD> </tR> <tR> <tD VALIGN=TOP HEIGHT= 360 WIDTH="238"><div> The lay-up is completed by hand using a team of four or five laminators. The hull moulds incorporate platforms for the laminators to gain easy access to the hull interior. The deck moulding is of a two piece construction, with a moulded headliner married up to upper deck surface. This construction method enables wiring conduits and cabling to be preinstalled. Reinforcement for winches, cleats and other deck hardware, is provided by bonding in pieces of end-grain balsa. Thorough quality control checks are regularly made with any moulding flaws identified being marked with red tape, prior to being rectified.</div> <bR> </tD> <tD VALIGN=TOP><NOBR><div> <IMG SRC="234f4620.png" border=0 width="500" height="354" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></div> </NOBR></tD> </tR> <tR> <tD VALIGN=TOP HEIGHT= 361 WIDTH="238"><div> Erwan then conducted us to the outside storage and testing area, which includes a "swimming pool" Every boat is launched here and all underwater fittings tested. Engines are started and thoroughly checked for satisfactory operation and alignment. As the factory currently only has one pool it is acts as quite a bottleneck, but the new factory building will be complete with its own tank testing facility - and this one will be larger to enable larger boats to be constructed in future.  </div> <bR> </tD> <tD VALIGN=TOP><NOBR><div> <IMG SRC="236f4630.png" border=0 width="500" height="355" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></div> </NOBR></tD> </tR> <tR> <tD VALIGN=TOP HEIGHT= 361 WIDTH="238"><div> In various corners of the factory site it was amusing to see was the rather surreal sight of numerous shells of Jeanneau's other product, the Lyra microcar, which is available both in diesel and electric powered versions. These tiny cars have a strong export market and a few are even used around the factory for movement of materials, there is even a micro pick-up version. The factory also makes a wide range of "Rigiflex" dinghies using a vacuum blow-moulding process. Quite sizeable boats can be made in a single moulding operation that simply transforms the raw material of plastic granules into a robust weatherproof hull. A similar technology is now being employed for the GRP production of the new Sun 2000, where a double mould is first lined with glass fibre, then sealed prior to the injection of resin. This method provides a consistently strong and reproducible moulding.</div> <bR> </tD> <tD VALIGN=TOP><NOBR><div> <IMG SRC="238f4630.png" border=0 width="500" height="355" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></div> </NOBR></tD> </tR> <tR> <tD VALIGN=TOP HEIGHT= 361 WIDTH="238"><div> As we have ordered a Sun Odyssey 34.2 the next part of the tour was of particular interest as this was close inspection of the 34.2 production line. Five yachts, ranging from a bare hull through to an almost complete boat were on the construction line. A raised floor area makes working on the boats particularly easy. Much of the interior is completed prior to the deck and cockpit module being lowered onto the hull. Various pre-assembled modules are installed as complete units, including the heads compartment and the galley, which is fitted complete with cooker and fridge. Erwan said the line can now assemble a 34.2 in around 2 weeks!! The deck is bonded to the hull using a special Sikaflex adhesive with self-tapping screws fitted both before and through the toe rail assembly. The transom joint is resinated and then from the inside addition woven rovings are laminated into place.</div> <bR> </tD> <tD VALIGN=TOP><NOBR><div> <IMG SRC="23af4630.png" border=0 width="500" height="355" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></div> </NOBR></tD> </tR> <tR> <tD VALIGN=TOP HEIGHT= 361 WIDTH="238"><div> Erwan explained that new customer support section would be developing a range of addition services for Jeanneau Owners that would include regular newsletters, boutique clothing and arrangements for Boat show and events. He said that they would also provide a telephone helpline for owners wanting information about any aspect of their Jeanneau craft.</div> <bR> </tD> <tD VALIGN=TOP><NOBR><div> <IMG SRC="23cf4630.png" border=0 width="500" height="355" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></div> </NOBR></tD> </tR> <tR> <tD VALIGN=TOP HEIGHT= 359 WIDTH="238"><div> Overall the tour was really enlightening, although a vast factory it was rewarding to see the level of detail, care and attention being made on each craft. The precision and reproducibility that the automation brings to the routine elements of the building  is married to the evident high level of craftsmanship and overall pride in making a first class product.</div> <bR> </tD> <tD VALIGN=TOP><NOBR><div> <IMG SRC="23ef4610.png" border=0 width="500" height="353" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></div> </NOBR></tD> </tR> <tR> <tD VALIGN=TOP HEIGHT= 16 WIDTH="238"><IMG BORDER="0" SRC="1x1.gif" HEIGHT="16" ALIGN="bottom" WIDTH="238" HSPACE="0" VSPACE="0"></tD> <tD VALIGN=TOP WIDTH="411"><IMG BORDER="0" SRC="1x1.gif" HEIGHT="16" ALIGN="bottom" WIDTH="411" HSPACE="0" VSPACE="0"></tD> </tR> </TABLE></div> <bR> </td> </tr></table></body>