The “Everything” mentioned in the title is from owner’s point of view and “Nothing” is from manufacturer’s point of view. I would like to add few lines wrote by our Editor-in-Chief, Mr.Deepak Raj as a reason of why bike becomes everything in a life of a biker. He says “We should really work hard and achieve what we desire. Only when we are faced with obstacles to acquire something, we know how much we really need it and we work to achieve it. When we get something easily we would never know how much we wanted it and the thing we have got does not have as much perceived value as it would have deserved.”
So let us now discuss some facts about bike manufacturing hierarchy. How companies decide to launch a bike? Which procedures work behind the designing? Which are the processes adopted for bike designing and testing?
1. Market Research
The safest way to launch any product in today’s competitive market is to have research: Research about who will be the customer, what customer likes, and what customer needs. These researches are carried out by marketing department of the companies or given to other surveying companies.
This market research also depends on type of vehicle that a company wants to introduce i.e. new segment, facelift version of previously launched vehicle, or DNA type vehicle. Market research becomes more vital when any company plans to launch a new segment. Customers are openly or circuitously got involved in this type of survey. New segment may be decided with respect to fuel economy, price tag, top speed, type of engine or type of vehicle.
Generally, market survey becomes worthless at the time of facelift launch. DNA type vehicles also don’t required detailed survey as they are small scale versions of already successful vehicles. Company develops few concepts after studying market research and finally one concept got selected by the authorities either mandatorily or by voting.
2. Sketching
Drawing or Sketching was the first language used by Homo sapiens and still used in all industries either on paper or on computer screens. It is the most productive and economical method to develop and predict any concept. Same is also applicable with automobile industry. Each and every vehicle running on the road today was a conceptualized sketch on the paper before few years.
Numbers of sketches are prepared by the designers on final concept which got selected by the authorities. Designers also have to include benchmarks of the company along with engineering aspects. Engineering aspects like dimensions, space, and feasibility of manufacturing of exterior components are considered in conjunction with aesthetics. First of all, one sketch is selected as a final product which contains overall look. After that, overall dimensions are selected according to vehicle’s segment and engineering terms. After deciding vehicle as a whole, designers start sketching each details of the vehicle like head lights, side indicators, ORVMs, tail lights, tank, seats, fairings, wheels, axles, muffler, foot rests, locking nuts etc. One more time vehicle is assembled on paper and final sketch is prepared for modelling.
3. Software Modelling
Modelling is done before starting any designing for vehicle. This provides idea about space available with engineers to design any component. It already has become very easy to prepare a model for any product with the help of softwares and robots. In the case of automobile, this process is very important and required precision. Modelling gives three dimensional judgement about vehicle.
Today’s computer technologies help engineers to prepare full model of vehicle in just few mouse clicks because modelling of individual components itself is easy with the help of extraordinary softwares along with readymade libraries. Special libraries are available for each and every component commonly used in the automobiles. Parametric facilities also help engineers to develop models very quickly. Individual teams work simultaneously to generate models of each and every component because number of parts used in vehicle is very large. Finally all the components are assembled to have complete model of vehicle.
4. Clay/ Wax Modelling
Besides soft modelling, many companies also prepare clay or wax models of vehicle. These models are used to judge the bulk and to predict aerodynamic characteristics of vehicle. Generally, clay models are prepared for expensive rides. It is just like a hard copy or printout of any softcopy from the computer.
Robots are used to create these types of model. Robots help to get precision and reduce process time. Before technical revolution in computers, this was only method used for modelling of any vehicle.
5. Designing
Designing is a complex synthesis and analysing process of forces and stresses on any component. Each and every component of vehicle is analysed with the help of softwares. Designing software works with that model which is generated in modelling software. This is done with the help of Interface facilities. Engineer has to import the ready model of component from modelling software to designing/ analysing software.
Earlier, trial and error method was used to analyse components or systems. It got disappeared quickly with technological revolution because of cost and time consumption. Manufacture had to spent lots of money at the time of failures. Analysis softwares have made this designing system very prolific and errorless. Engineer can check any component under static, dynamic, thermal, or cyclic loads and can predict component’s life.
6. Simulations
Particularly for automobiles, simulation softwares are computer logics for vehicle’s dynamic conditions. Simulation softwares can generate identical road and wind conditions which an original vehicle is going to face.
This helps engineers and designers to predict and modify any of the dynamic characteristic of vehicle before actual production. Just like analysis softwares, simulation software also reduces cost and time for testing a vehicle. Different road profiles like smooth road, bumps, pit holes etc. can be generated and vehicle model can be tested without original vehicle.
7. Testing
No one can remain dependable on softwares when safety comes into picture. Software can generate wrong results if input data differs slightly. That’s why each and every company tests it’s each vehicle before starting its production.
Generally 5 to 10 vehicles are manufactured after completing all design, analysis and simulation processes. These vehicles are used for different road tests, rollover tests and crash tests. Experience test drivers are allowed to drive these vehicles up to extreme conditions on the testing tracks. This testing period is kept long enough to get exact idea about any failures. Many a times new failure arises which is not exposed by the analysis or simulation softwares.
8. Pilot Vehicles
Spy photos which we all are watching on our website frequently, in which bike mostly remains covered with black cloths, are called pilot vehicles. Pilot vehicles are limited edition type original vehicles produced for testing purpose only. Testing of manufacturing facilities within the plant, testing of machining ease, testing of interchangeable parts, testing of material handling etc. takes place with the help of pilot vehicle.
After satisfactory modifications in plant operations, these pilot vehicles are allowed to run on road. Whole bunch of pilot vehicles is distributed between company’s local test drivers. The company collects feedbacks for different driving conditions. All the necessary modifications in vehicle get completed before final starting of production.
9. Production
Finally production starts after completing all the required modifications in manufacturing facilities. These modifications includes testing rigs, testing tracks, material handling methods, material handling racks, manpower, production of subassemblies, assembly lines, quality testing, paint shop, vendor management etc. Company announces official launch of vehicle and starts distributing fix numbers of produced vehicle amongst each dealers.
Then sales department studies the market demand through dealers. New production schedule is introduced according to demand and supply chain. Each vehicle is tested according to minimum standards decided by country’s governing body (As ARAI in India). Vehicles are distributed in different numbers to different dealers according to their regional demand.
10. Sales
At last, day comes when we are called by dealer for vehicle delivery. It is I think the most precisions moment of any biker’s life when he holds his vehicle very first time. From that instant, vehicle becomes everything in his life for which he has waited for a long time, has crossed many obstacles and has worked hard.
I hope this post will stay interesting for you all. Please share your experiences and ideas on these processes.
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