John Butler, a KGP Associate Partner (pictured below) worked with the  Modec team from inception to start of production. John describes some key issues for those considering venturing into a production project.

Today, you cannot open a newspaper or technical magazine without seeing something on low emissions or electric vehicles.  However, when the Modec zero emissions vehicle was conceived some seven years ago, there was much less mention of the emerging technology.

Electric vehicles have been around since cars were first made but the only one that has survived the test of time has been the classic milk float.  It was not until a small team originally from the taxi company LTI Carbodies, designed a new vehicle that the concept of the electric vehicle developed to one which had driving characteristics of a conventional vehicle and a range between charges which would meet the needs of customers.

For those who are not familiar with the Modec vehicle, it is a purpose designed and built urban 5.5 tonne delivery vehicle having a limited top speed of 80 kph, a payload capacity up to 2 tonnes and a range in excess of 160km. The fact that it has been designed from first principles, without the backing a large multi-national automotive company, makes the success of this programme remarkable.  The initial team of six dedicated people managed to secure the backing of industrialist Jamie Borwick (now Lord Borwick) who had the foresight and confidence to support the programme through to production.
 
Not based on any conventional concept, the Modec has a novel power pack and drivetrain, a cab with single rear door access to allow safe delivery of goods, a keyless system  plus a host of other features. 

To manufacture this novel vehicle required innovative production. The primary track is an 8-station facility. Component parts are added at each station.  The track remains stationary for the planned TAKT time and indexes at the end of this period thus allowing the build of several components at each station.

At the eighth station a virtually complete vehicle has been built.   All the parts had been fitted, including wheels, but with the exception of the main battery assembly.  At this stage the vehicle was still lying on its chassis and had come to the end of the track. 
At this point overhead cranes lift the vehicles off the track and turn them through 90 degrees and place them, on their wheels, onto a second raised track.  The first station of this second track is for the fitment of the battery cassette.
 
Having become a drivable vehicle, it is then driven from the battery fit station, along the second track, through a brake dynamometer station, wheel alignment facility and other end of line test areas before proceeding down a slope to ground level.

Modec, invested in a significant test and validation programme to gain EU Whole Vehicle Type Approval – the highest level of vehicle certification available. Modec is very proud to have completed this process recently, making it the first electric commercial vehicle to gain the certification. The N2 Type Approval allows Modec to be sold in all EU member states, enabling rapid European expansion in 2009 and 2010.

Support from the suppliers for all the equipment, tooling and fixturing was excellent and their patience and understanding through the periods of change was well appreciated.
At the time there were companies such as MG Rover and Peugeot who were closing plants within the locality. Modec therefore had a good choice of skilled automotive people from whom to select operatives.  The company also employed some very good people from Toyota who were vastly experienced in the lean operations to which the company was working.

Starting up a new company from scratch and developing a new vehicle through to production at the same time produces an enormous drain on financial resources for any company and Modec was no exception.  Details on the range of Modec vehicles can be found on their web site- www.modeczev.com - A full copy of John’s article can be obtained from Jane Woodward. If you have any clients who might be interested please make contact.