TY - THES

T1 - Planning and preparing the implementation of new models to the production process at the GASGAS factory in Terrassa

AU - Brandner, Andreas

N1 - embargoed until 14-11-2029

PY - 2024

Y1 - 2024

N2 - In 2022 the Pierer Mobility Group opened a new factory in Terrassa, Spain, with an area of approximately 2.000 m2 and 50 employees. The production site was initially planned to produce the whole range of Trial motorcycles, but in 2023 a new project, the E2-project, an electric minibike, was started. The goal for the E2-project is to ensure a high customer loyalty from a young age, as it will be the first of multiple bikes from the brand that a customer can ride from the age of three years. The bike has three riding modes, which combine easy handling, sustainability and high-quality standards. As the E2-project increases the yearly production from approximately 2.500 to 6.500 bikes, changes in the processes of production and logistics are required. An improved and stabilized production process is aimed, to implement additional models in the future, like an electric Trial bike in the following year. Therefore, the implementation of the E2 bike is intended to enable economical production, while keeping the modular design in the production facility. As for the much smaller E2 bike production rises from 15 to 96 motorcycles per day, the new packaging concept must be adapted to provide a low takt time, to keep up with the production takt times. Since the E2 bikes are only built for about three months a year, no extra workforce should be added to the production area. This means, the new packaging concept should be handled by two operators, while their task is also to load the truck for shipping finished bikes. Therefore, the takt time in the packaging area must be much lower than the production takt time. The new packaging process may be usable for the Trial bike production as well without major changes to be made, to secure a fast change between the assembly of both models, leading to less down time. After implementing the new concept for the new E2 bike, the concept is also tested for fitting Trial production, as the new electric Trial, which is built from 2024, may offer lower takt times in production, due to less preassembly necessary. This should help to improve the Trial packaging process as well, while necessary improvements are discussed.

AB - In 2022 the Pierer Mobility Group opened a new factory in Terrassa, Spain, with an area of approximately 2.000 m2 and 50 employees. The production site was initially planned to produce the whole range of Trial motorcycles, but in 2023 a new project, the E2-project, an electric minibike, was started. The goal for the E2-project is to ensure a high customer loyalty from a young age, as it will be the first of multiple bikes from the brand that a customer can ride from the age of three years. The bike has three riding modes, which combine easy handling, sustainability and high-quality standards. As the E2-project increases the yearly production from approximately 2.500 to 6.500 bikes, changes in the processes of production and logistics are required. An improved and stabilized production process is aimed, to implement additional models in the future, like an electric Trial bike in the following year. Therefore, the implementation of the E2 bike is intended to enable economical production, while keeping the modular design in the production facility. As for the much smaller E2 bike production rises from 15 to 96 motorcycles per day, the new packaging concept must be adapted to provide a low takt time, to keep up with the production takt times. Since the E2 bikes are only built for about three months a year, no extra workforce should be added to the production area. This means, the new packaging concept should be handled by two operators, while their task is also to load the truck for shipping finished bikes. Therefore, the takt time in the packaging area must be much lower than the production takt time. The new packaging process may be usable for the Trial bike production as well without major changes to be made, to secure a fast change between the assembly of both models, leading to less down time. After implementing the new concept for the new E2 bike, the concept is also tested for fitting Trial production, as the new electric Trial, which is built from 2024, may offer lower takt times in production, due to less preassembly necessary. This should help to improve the Trial packaging process as well, while necessary improvements are discussed.

KW - Production

KW - Motorcycles

KW - GASGAS

KW - KTM

KW - Implementation

KW - New

KW - Models

KW - Increase

KW - Increasing

KW - Quanitity

KW - Adding

KW - Bikes

KW - Packaging

KW - Concept

KW - Optimise

KW - Optimization

KW - Planung

KW - Einführung

KW - Produktion

KW - Produktionsprozess

KW - Motorräder

KW - Motorrad

KW - Trial

KW - GASGAS

KW - KTM

KW - Terrassa

KW - Spanien

KW - Barcelona

KW - Produktionssteigerung

KW - Effizienzsteigerung

KW - Effizienz

KW - effizient

KW - Verpackung

KW - Strategie

KW - Verpackungsstrategie

KW - Rollenbahnen

KW - Umrfeifungsbandmaschine

KW - Umreifung

KW - verpacken

M3 - Master's Thesis

ER -