by Brad Anderson
- Chevy builds 30 identical examples of the Bolt EV at the same time.
- Building the EV in batches ensures suppliers deliver parts at the right time.
- Company delivered just 791 examples of the Bolt in the first quarter.
Reviving a discontinued nameplate is one thing. Building it profitably is another. In an effort to improve efficiency, reduce complexity, and boost quality for the 2027 Bolt, Chevrolet is employing a new batch production process for the affordable EV at its Fairfax Assembly plant.
The new-and-improved Bolt, unveiled late last year, is currently being built in relatively low numbers of between 2,000 and 3,000 vehicles a month. It is produced in batches of 30 identical copies at a time, all painted the same color, and it allows the carmaker to provide suppliers with a fixed seven-day schedule of exactly which models it’s building and when, ensuring parts arrive on site at the perfect time.
Read: Chevy Promised 255 Miles, The New Bolt Beats It Anyway
The logic is mostly about paint. By building 30 identically specced Bolts at a time, the paint shop equipment doesn’t need to be changed or cleaned as often, since all 30 get the same treatment. Seven exterior colors are on offer, so there might be 30 blue examples moving down the line together, followed by 30 red ones, and so on.
Speaking with Auto News, Michael Youngs, director of GM’s Kansas City plant, noted that the factory also keeps clones of each Bolt configuration to easily identify any issues with the models it’s building. If it finds one, the car will be pulled from the batch and replaced by another.
A New Production Process
“It was an idea that we had to look across the enterprise, not just in the plant but to suppliers, to say, ‘How do we make sure we can be as efficient as possible as we launch the Bolt?’ And the concept of batch was born,” Youngs said.
GM will continue building the Bolt in batches like this when the Fairfax also starts manufacturing the Chevrolet Equinox in 2027 and a new Buick crossover the following year. Indeed, the Equinox and this Buick will also be produced in similar batches.
For now, the Chevrolet Bolt remains a small seller for the brand, particularly when compared to the first-generation model, which posted several years of 20,000-plus sales. Through the first three months of this year, Chevy delivered just 791 examples of the 2027 Bolt, meaning it barely outsold the BrightDrop 400 and 600 electric delivery vans.
