The document defines the manufacturing and industrialization system for ESPSEVG Racing Team's motorcycle. It includes: 1) Defining the company structure and marketing plan. 2) Describing the assembly flow and 14 work stations for assembling subgroups and the full motorcycle. 3) Developing a production and distribution plan considering suppliers, storage, logistics and distribution. 4) Implementing quality controls integrated into the manufacturing process.

1. Definition of the manufacture and industrialization
system of ESPSEVG Racing Team's motorcycle
TFG105468_Júlia Llanas
1
Definition of the manufacture
and industrialization system
of ESPSEVG Racing Team's
motorcycle
1. Objective
In this project we will elaborate an
effective manufacture and industrialization
system for our motorcycle. For its
development we will treat the following
points:
 Definition of the structure the
producer company should have and
describe the marketing plan and help
service the product will have.
 Describe the assembly flow with
different stations in which different
worker take part. For its best
efficiency, we will detail each work
station, the elements that are needed
for them and for the assembly.
 Make a production and distribution
plan of the product considering all the
elements that are part of it, as the
supplier, storage, logistics and
distribution.
 Decide and define the quality controls
that will take part of the manufacture
process which must be integrated in
the process.
 Analyze the legal framework on which
we are working on.
2. Development of
industrialization plan.
To star work, we define 3 main phases that
have to be in this project. After defined, we
development this phases and design 8
basic points for work. Following, the
diagrams that show this phases:
Now, we can start to work whit this
phases.
Design and marketing
plan
Supply of materials and
manufacturing their own
parts
Subgroups assembly
Motorcycle assembly
Final quality control
Storage
Distribution
After sales service
Analyze the
viability of
the product
Manufacturing
process
Sales and
after sales
service

2. Definition of the manufacture and industrialization
system of ESPSEVG Racing Team's motorcycle
TFG105468_Júlia Llanas
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1. Design, marketing plan and
definition of the company
and the elements that
comprise it:
Regarding the design of the product, we
work with the prototype designed by the
team EPSEVG Racing Team for
Motostudent competition.
When we have the design of the product,
start to work with marketing plan to
analyze if our products may be exit in the
market. It is based on a market study based
in two analysis (PESTE and DAFO), which
confirms that our product can occupy a
niche market and therefore will sell
successfully.
Known that our product could sold, define
the pillars of the marketing strategy to
achieve business objectives.
From there, begin to build our company. It
defines the location and location of our
headquarters, as well as their impact. It
describes an organization which identifies
the different types of workers and do a
health and safety analysis of respective
jobs.
2. Supply of material and
manufacturing of own parts:
Having defined our company begins to
design the structure of supply and
manufacture their own pieces. It defines
two main subgroups of suppliers, materials
and services. In the first group are three
differences, parts suppliers own
manufacturing, the parts that stay on the
market and standardized parts.
We aim to be fixed between two and three
suppliers for each item or service. This
guarantee will not be ever without supplies
of material, and therefore to avoid the
delays in assembling motorcycle.
The most difficult part involved logistics
manufacturing, is the manufacturing of
own parts. This phase requires
coordinating different suppliers looking for
the maximum savings of money and time.
3 and 4. Assembling the
subgroups and the whole
motorcycle:
When everything is done, proceed to the
assembly of the motorcycle. The assembly
subgroups and the whole were
intertwined. To organize for us and for
workers, the process has been divided into
14 phases. These 14 phases are:
•Full frameSite 1
•Swingarm and motorSite 2
•Rear suspensionSite 3
•Brakes and wheelsSite 4
•TransmissionSite 5
•SubchassisSite 6
•Electrical systemSite 7
•Cooling systemSite 8
•Power suppliSite 9
•ClutchSite 10
•EscapeSite 11
•AirboxSite 12
•DepositSite 13
•FairingSite 14

3. Definition of the manufacture and industrialization
system of ESPSEVG Racing Team's motorcycle
TFG105468_Júlia Llanas
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After defined the 14 stages, we
development the sheets for each one.
These files define the steps to do the
operator and the material required. From
these cards and their respective
descriptions are performed calculations of
time.
Calculations
We calculated the approximate time
needed to complete the assembly of the
motorcycle. Was made with the MTM
method. This method is based on the
definition of basic movements performed
and attributed a specific time based on
MTM tables.
We had to analyze each phase and each
step. From the analysis were prepared
tables with UMT time units and then
converting in seconds and minutes. Please
find attached table with the final results of
each phase:
SITE TIME
1 15.85 min
2 11.39 min
3 9.98 min
4 20.51 min
5 11.30 min
6 14.97 min
7 4 min
8 5.70 min
9 3.18 min
10 4.83 min
11 7.04 min
12 2.86 min
13 4.8 min
14 18.58 min
TOTAL 134.99 min = 2h and 15 min
In conclusion, we can say that: if it needs 2
hours and 15 minutes to make the
assembly of a motorcycle, a single operator
could make the required daily production
(3 motorcycles) to achieve the annual
target set (600 units).
5. Quality control:
Has been defined a quality system
integrated between the different tasks of
the company. To achieve integral quality
we have to work in 3 ways: quality
concerted with suppliers; self-governed
with Poka-yoke system; and stock control
based on Kanban system.
In quality concerted states that each
supplier must sign an agreement on quality
concerted agrees that any material you
provide will comply with quality standards
and if they do not, will replace the product.
The self-control to avoid errors during
assembly. So Poka-yoke system is used in
for search the error 0. We are looking for
from a design that he detects errors or
avoid directly.
Finally, an efficient stock control will help
the production never affected by the lack
of material and financial losses while
avoiding excess material. The Kanban
system helps to regulate this aspect.

4. Definition of the manufacture and industrialization
system of ESPSEVG Racing Team's motorcycle
TFG105468_Júlia Llanas
4
6. Storage:
Store our bikes in their own factory.
However, we will through a window, so
that the store will also serve as an
exhibitor. We have factory and shop at the
same place, reducing resources.
7. Distribution:
Regarding the distribution, use the van
business which can store 3 motorcycles.
This will be done in the case that we have
to carry in a radius of less than 4 hours in
drive. If the distance is too large, we can
offer a transport service whit extra charge
or allow the client to provide it.
For transport that we do, we use reusable
boxes. However, for the transport external
boxes will be provided more resistant and
reusable.
8. After sales service:
Provide a full after sales service is
necessary to retain our customers and get
new ones. So work on three services: Grant
1 year, specialized workshop and spare
parts store.
During the first year, free of charge repair
the damages caused by defects in factory.
After this first year, provides specialized
workshop for all customers who have
purchased a motorcycle with us. Finally, we
offer our customers the option to buy their
genuine parts. Our company will function
as an intermediary.
Although the main objective of the service
after the sale is customer satisfaction, the
last two services can mean extra income
for the company.
3. Conclusions
Once defined the manufacture system and
industrialization of the motorcycle of the
EPSEVG Racing Team, we can extract the
following conclusions:
 To reach up to our commercial
objectives we must develop and
execute our marketing strategy.
 We must work in the constant
development of our product. This will
lent us find new ways of optimizing our
production in what assembly refers
(saving time and mistakes) as to the
own manufactured pieces (economic
savings).
 We must have always a minimum of 3
suppliers for each product. A good
channel of suppliers makes easier that
the surprises don’t affect the
production.
 Control the quality following the 3
applied systems will help us reduce
mistakes, time and stocks. In
consequence we will reduce costs. We
must work to improve this systems,
specially we must develop the Poko-
Yokes.
 A distribution service made by our own
factory will facilitate the treat with the
costumers. Completing with a
complete after sales service,
contributes to promote loyalty with
the costumers and that new ones want
to work with us.
 The cost of the series production of the
motorcycle could be still reduced more

5. Definition of the manufacture and industrialization
system of ESPSEVG Racing Team's motorcycle
TFG105468_Júlia Llanas
5
if we decided increment the annual
production. The fix costs (services) will
reduce in portion to the increment of
product and also the material costs
could be reduced, because if the
buying to our suppliers increments,
probably they increase the discount
they apply us (rappels)
 The Labor Risk Prevention should be
realized for each work place,
evaluating the possible risks,
subtracting the ones that are feasible
or adopting the suitable preventive
measures which contribute to
minimize incidents as loosing material,
or a worse thing, accidents with
personal damages. The cost of the
incidents and accidents have a great
economic repercussion.
 A good environmental management is
also indispensable: energetic save,
remains segmentation, evaluation and
use of rests of material...
 A correct planning and program of
work is basic for not increasing costs of
workers.(assembly, distribution..) In
this way any digression must be
contemplated and analyzed strictly to
see its repercussion in the global
analysis.
The actual commercial competitiveness
doesn’t regulate exclusively by the relation
of cost and benefit (market price). Facts as
the working climate, the analysis of the
accidents/incidents, the environment
management, the social corporative
responsibility, the quality... can be
determinate to make that a costumer opt
for a supplier or another. Therefore a good
image in all areas will decisively contribute
in the success of our product.
4. Bibliography
Webs:
mtmingenieros.com
http://www.galfer.eu/index.php/es/galfer-
moto
http://soldatal.com/
http://www.yamaha-
motor.eu/es/index.aspx
http://motostudent.com/
AUTOR: Júlia Llanas Batista
TITULACIÓ: Grau en Enginyeria Mecànica
DIRECTOR: Juan Jose Aliau Pons
DEPARTAMENT: Departament d’Expressió
gràfica a l’enginyeria
DATA: 29/1/15