A PROPOSED

MOTORCYCLE
ASSEMBLY PLANT
(RESEARCH PAPER)

DELOS SANTOS, LIGAYA A.

ARCHITECTURAL DESIGN 6

ARCH’T. WILFREDO FERNANDO

MECHANICAL MANUFACTURING: PRECISE BACKBONE.

Motor housing, cylinder heads, crankshafts and

connecting rods as well as frames, tanks and chassis
components: In the mechanical manufacturing the core
components of the engine occur.

The computer-controlled machining centers guarantee a

highly flexible and thereby precise mechanical
manufacturing the components. The use of experienced
and qualified staff and modern machine tools and
measuring machines ensures best quality.

MOTOR MOUNTING: MARRIAGE TO THE HEART.

Three highly flexible assembly systems and technologically sophisticated,

integrated testing technology are the key features of the BMW engine assembly.
From over 600 different small parts and components high-performance engines
with two (Boxer), four or six cylinders are assembled. This support 21 automatic
stations employees. The installation of a boxer engine takes about 90 to 130
minutes that the straight-six about 150 minutes to complete.

PAINT: RANGE OF POSSIBILITIES.

Computerized robots paint the motorcycle parts in up to 160 different

shapes with water-based paints in more than 40 shades. The paint shop is
designed so that the robot can paint parts of different size and geometry in no
particular order. But often the fate experienced refinisher is needed, especially
when applying the traditional trim lines and when the tape applications to the
tanks and side panels.
ASSEMBLY: THE CUSTOM-MADE PERFECTION.
To assemble the bikes are hung in a flexible conveyor system to swivel
hook. Because they undergo apparently floating the assembly line in 150
stations and introduce themselves to each individual automatically on an
ergonomically ideal for employees working height. All job-related data and
tightening torques and settings are automatically transferred to the respective
assembly station. Until the 2,000 parts and components to a running order BMW
Motorrad completes elapse depending on model 220-360 minutes.

SHIPPING: SAFE AND SUSTAINABLE.

Even in the finish area is carried out to prepare the BMW motorcycles for
the journey to the customer. For the transport in the main European markets
recyclable, foldable steel packaging is used. After the overseas transport takes
place in stable transport containers made of wood and cardboard.
Sustainability and logistical efficiency decide if the motorcycle is transported the
way from our Berlin plant to the customer by truck, train or cargo ship.
Find out more about our further production processes here.
Background
The motorcycle is "a form of entertainment that can appeal only, one would
think, to the most enthusiastic of mechanical eccentrics," Engineering magazine
stated in 1901. "We think it doubtful whether the motorcycle will, when the
novelty has worn off, take a firm hold of public favour."
Last year, four million motorcycles were in use in the United States alone.
Whether relied upon as a primary means of transportation, used to provide
weekend recreation, souped up and sped along for racing, or displayed as
antique, millions of people across the world have shown that the novelty most
definitely has not worn off.

History
As might be imagined, the motorcycle evolved from a vehicle powered by
sheer human energy—the bicycle. French bicycle maker Pierre Michaux and his
sons Ernest and Henri first fitted a bicycle with cranks and pedals—precursors to
the modern-day motor—in 1861. The Michauxes' velocipede was an instant hit
and the family became the largest velo producer in Europe with a large factory
at Bar-le-Duc in France. Working with Michaux, L.G. Perreaux devised a steam-
powered motorcycle engine, called a velo-a-vapeur, which was patented in
1868. Sylvester Howard Roper of Roxbury, Massachusetts pioneered a similar
invention in the United States around that time as well.
In 1879, Giuseppe Munigotti of Italy patented the first gas-burning internal
combustion four-stroke engine for the new motorcycles, although his invention
existed only on paper. Meanwhile, two Germans, Dr. Nicolaus Otto and Eugen
Langen were developing four-stroke stationary engines, which ran on coal gas
supplied from mains. Gottlieb Daimler took the invention further by developing
an engine that ran on benzine. Since benzine could carry a vehicle
approximately 25 miles on one gallon, only a small tank would need to be
attached to the machine. Daimler later abandoned the motorcycle business to
concentrate on another invention—the first automobile that became the basis
for his company, Daimler Benz, maker of the luxury Mercedes Benz automobile.
Several innovators improved upon these inventions over the next 30 years, and
in 1901 the machine that is still regarded as Carl Hedstrom, a Swedish immigrant
to the United States, developed the first modern motorcycle. Hedstrom fitted an
Indian bicycle with a 1.75-horsepower single-cylinder engine, and the legendary
Indian motorcycle was born. Several other U.S. makers came out with similar
models, including the company whose name is synonymous with the
motorcycle—Harley-Davidson—in 1903. William Harley and Arthur Davidson were
students in Milwaukee when they built their first motorcycle on a
borrowed lathe from patterns they had made. Davidson's older brothers, both
toolmakers, assisted, as did Ole Evinrude, who later became famous as a
designer and producer of outboard motor boat engines.
Other makers included Royal, Merkel, Yale, Reading-Standard, Rambler, Tribune
and Curtiss. By 1904, motorcycle manufacturers had begun to construct bulkier,
sturdier frames, stronger wheels, bigger engines and reinforced forks for their
bikes and a clear distinction between motorcycles and bicycles emerged.
Around this time, the sidecar, affixed to a light, tubular frame extending from the
main motorcycle frame, began to be popularized. Based on a similar accessory
for the bicycle, his device allowed the driver of a motorcycle to carry a
passenger.
By 1905, the focus was on power, and manufacturers begin to beef up their
engines. That year, Hedstrom produced a machine boasting a 500 cc twin
engine that featured twist-grip control for the throttle and ignition. That same
year saw the development of "free engine" devices, which eased the starting
and launching of a machine, and variable gears, which eased use on hills and
at slow speeds. Chain drive followed, and the stage was set for production of
the motorcycle that is currently in use.
Motorcycles continued to grow in popularity for decades, although production
for civilians tapered off during World War II. During World War II, however, a
need arose for lightweight, collapsible models to be used by parachutists once
they had landed. Royal Enfield produced a Flying Flea model for this purpose,
while Excelsior came up with its Welbike, which could fit into a small air-drop
container. The Welbike was later marketed to civilians as the Corgi, spawning
the post-war popularity of the motor scooter, especially in Europe.
The 1950s were regarded as a "golden age" for the motorcycle, with its use
being popularized by such prominent figures in popular culture as James Dean
in his movie "Rebel Without a Cause." The United States and Europe dominated
the motorcycle industry through 1960, at which time Japanese manufacturers,
including Honda, Yamaha, Suzuki and Kawasaki, rose to a prominence they
maintain to this day.

An Indian motor-cycle made by Hendee Manufacturing Co. of Springfield, Massachusetts, circa 1911.
 (From the collections of Henry Ford Museum & Greenfield Village, Dearborn, Michigan.)

The Europeans took the lead in developing the motorcycle in the early twentieth
century. One Englishman proclaimed his countrymen loved the cycle because
they enjoyed mechanical things. However, Americans enjoyed their
motorcycles as well. An American gentleman could have purchased this home-
grown motorcycle manufactured in 1911 by the Hendee Manufacturing Co. of
Springfield, Massachusetts. Hendee made early American motorcycles, which
featured Native American names indicating a proud ruggedness. Red with gold
striping, this one cylinder 3.5 horesepower loop-framed cycle weighs 140 lb (63.6
kg), has a wheel diameter of 23.5 in (59.7 cm) and cost a whopping $225.00
back in 1911. Founded in 1901, the company ceased operation in 1953.
However, Indian motorcycles are still beloved—enthusiasts claim that there are
still 50,000 Indian motorcycles on the road.
Indian bikes might reach 60 m.p.h., but handbooks cautioned riders to not
exceed 10 m.p.h. through town. These early handbooks are full of advice and
etiquette for the motorcyclist. Some period gems include: don't ride with the
muffler open as "the noise scares restive horses, and worries invalids and nervous
people," don't run away in case of accident but "stand by like a man … don't
get rattled," and don't ride by a motorcyclist who is stalled by the side of the
rode as "you may be in the same fix yourself some day."
Nancy EV Bryk

Raw Materials
The primary raw materials used in the manufacture of the body of motorcycle
are metal, plastic and rubber. The motorcycle frame is composed almost
completely of metal, as are the wheels. The frame may be overlaid with plastic.
The tires are composed of rubber. The seat is made from a synthetic substance,
such as polyurethane. The power system consists of a four-stroke engine,
a carburetor to transform incoming fuel into vapor, a choke to control the air-
fuel ratio, transmission, and drum brakes. The transmission system contains a
clutch, consisting of steel ball flyweights and metal plates, a crankshaft, gears,
pulleys, rubber belts or metal chains, and a sprocket. The
electrical system contains a battery, ignition wires and coils, diodes, spark plugs, head-
lamps and taillights, turn signals and a horn.

A cylindrical piston, made of aluminum alloy (preferred because it is lightweight

and conducts heat well), is an essential component of the engine. It is fitted with
piston rings made of cast iron. The crankshaft and crankcase are made of
aluminum. The engine also contains a cylinder barrel, typically made of cast iron
or light alloy.

The Manufacturing
Process
1. Raw materials as well as parts and components arrive at the manufacturing
plant by truck or rail, typically on a daily basis. As part of the just-in-time delivery
system on which many plants are scheduled, the materials and parts are
delivered at the place where they are used or installed.
2. Manufacturing begins in the weld department with computer-controlled
fabrication of the frame from high strength frame materials. Components are
formed out of tubular metal and/or hollow metal shells fashioned from sheet
metal. The various sections are welded together. This process involves manual,
automatic, and robotic equipment.
3. In the plastics department, small plastic resin pellets are melted and injected into
molds under high pressure to form various plastic body trim parts. This process is
known as injection molding.
4. Plastic and metal parts and components are painted in booths in the paint
department using a process known as powder-coating (this is the same process
by which automobiles are painted). A powder-coating apparatus works like a
 large spray-painter, dispersing paint through a pressurized system evenly across
the metal frame.
5. Painted parts are sent via overhead conveyors or tow motor (similar to a ski lift
tow rope) to the assembly department where they are installed on the frame of
the motorcycle.

A motorcycle engine.

6. The engine is mounted in the painted frame, and various other components are
fitted as the motorcycle is sent down the assembly line.
7. Wheels, brakes, wiring cables, foot pegs, exhaust pipes, seats, saddlebags, lights,
radios, and hundreds of other parts are installed on the motorcycle frame. A
Honda Gold Wing motorcycle, for example, needs almost as many parts to
complete it as a Honda Civic automobile.

Quality Control
At the end of the assembly line, quality control inspectors undertake a visual
inspection of the motorcycle's painted finish and fit of parts. The quality control
inspectors also feel the motorcycles with gloved hands to detect any bumps or
defects in the finish. Each motorcycle is tested on a dynamometer. Inspectors
accelerate the motorcycle from 0-60 mph. During the acceleration, the "dyno"
tests for acceleration and braking, shifting, wheel alignment, headlight and
taillight alignment and function, horn function, and exhaust emissions. The
finished product must meet international standards for performance and safety.
After the dyno test, a final inspection is made of the completed motorcycle. The
motorcycles are boxed in crates and shipped to customers across North
America and around the world.

The Future
Motorcycles remain popular and the collecting and riding of antique models is
just as popular as riding the new versions. While sleek, new versions will continue
to be produces,

A motorcycle transmission and disc brake system.

it is anticipated that the value of older models will continue to rise.