TL;DR Skip to the line to read the tech aspect of my visit rather than the person experience.
Last week I decided to plan out a trip to visit Butterfly Labs as I had a week off this week. Sunday night I drove 12 hours, stopped to visit family, then Tuesday 6/11/2013 headed out ~5AM and made the 6 hour drive to KC getting there just after 11AM. Josh seems to always be working later in the day had not gotten there yet, so I met some of the other BFL employees including the hard working CS team. I had asked if I would be able to take pictures with an answer of "Wait til Josh gets here, we don't know."
They showed me around the place and I saw the pick and place machine which was in the room they had racks for burning in units. They had 3 racks in that room which appeared to be able to handle a few hundred no problem with 8 hour burn in shifts allowing over 1k units a day to be burned in. I was walking back to the assembly and testing room which just after I walked in there, Josh came in. I spoke to him for a few and got to see a few Singles up and running. He then confirmed that "nothing is a secret anymore, it's all fair game" for pictures.
I only got a couple pictures before lunch, which was shortly after Josh got in. Josh and Sonny had an argument about what real BBQ is, so they decided to take me to a place where I could get brown sugar based and vinegar based sauces and decide for myself. To avoid any BBQ arguments in this thread I wont say what I chose.
When we got back it was all about the Bitcoin, I not only got pics of everything from every angle, but also met Gigavps and a few other people who are heavily invested in BFL. I had an interesting conversation with Giga about Litecoin FPGAs and a few projects he has going on to better the Bitcoin community and enhance miners experience.
I hung out at BFL until ~7:30 PM with Sonny and Josh and then proceeded to make the 6 hour drive back to where I was staying. Overall it was a very rewarding experience and an extremely long day. So now for the good stuff... All the technical and important information everyone has been craving as well as some clarifications and confirmations.
I think the best place to start is on their parts in stock... They have everything they need in stock, the only holdup is them telling the assembly plant to go all out, which will start very soon (notice I didn't say should), I can not promise a date, because that depends on the date they get their final "test" longboards in which is supposed to be this week (I personally don't know and Josh is out of town today and tomorrow so I wouldn't expect an answer until at least Friday 6/14/13.
The only part that "could" be considered a hold-up but most people could do without would be the power brick for Singles and Little Singles. Yes I said power brick. It is a relatively large brick being custom made with a Y-cable ending with 2x6pin plugs. The reason I said it is not really a hold-up is that the first Single went out without this brick... Most people that mine have at least one PSU around and almost all of those people have some 6 pin cables lying around. They said if it came to it and the bricks were delayed, they would give people the option to receive their units without a brick or wait until they get them in.
Next topic to cover should definitely be assembly. They only had a couple people working while I was there, and they have confirmed they have a lot of people lined up to come in and work, but even with such a small crew assembling, they assembled and tested a couple hundred Jalapenos with ease. Those units probably shipped out today after being burned in or will be shipping out tomorrow. I don't see assembly being any sort of issue or bottleneck. A 3 year old with a torx set could put together these devices. They literally made them as efficient to put together as possible without making them snap together. The assembly on the Singles did take a little longer, but still nowhere near being a time issue. I probably could have put together over 50 Jalapenos in my spare time there.