Case:
Bohemia
Improved Production of Bicycles and E-bikes
Leader Fox is an established Czech bicycle manufacturer operating in České Budějovice. The company is part of the Bohemia Bike Group and designs and manufactures various types of bicycles and e-bikes for both adults and children. To meet diverse customer needs and changes in demand, production must be able to handle multiple models efficiently and flexibly.
Need
Bohemia Bike Group chose to invest in a new assembly line to improve the production process for various types of bicycles. The goal was to create an efficient flow through assembly, optimize the use of production space, and provide operators with good ergonomic working conditions.
A key prerequisite was that the same assembly line could be used for multiple types of bicycle frames. The solution therefore needed to be flexible and adaptable to changes in model range, production volumes, and demand.
Solution
In close cooperation with the customer, OCS developed a Heavy Duty system tailored to Leader Fox’s production process. The overhead conveyor system is installed three meters above the floor and automatically transports bicycle frames between workstations.
The assembly line includes several steps in production: assembly of individual components, pre-assembly of various parts, final assembly, quality control, and packaging. By transporting the bicycle frames overhead, the space above production is utilized, while operators gain better access to the bicycle at the workstations.
A special product carrier was developed based on the size and design of the bicycle frames. The product carrier is adapted to handle as many different frame models as possible, which creates flexibility when the model range or production needs change.
After final assembly, the finished bicycle is packed in transport packaging. The empty product carrier is then automatically transported back to the starting point and is ready for the next bicycle frame. The system’s modular design makes it possible to adapt the assembly line to future changes in production.
Oil-Free, Clean, and Quiet System
Increased Production Rate
Improved Quality
Ergonomic and Space-Efficient
Solution Benefits
- Oil-Free, Clean, and Quiet System
- Increased Production Rate
- Improved Quality
- Ergonomic and space-efficient
- Adapted for multiple bicycle frames
- Automated transport between stations
Results after installation
Production capacity amounts to 50,000 bicycles per year, the majority of which are e-bikes. The assembly line enables Leader Fox to handle several different bicycle types in a continuous production flow, from the initial assembly steps to quality control and packaging.
The overhead transport frees up valuable floor space in the production hall and creates more room around the workstations. Operators have good access to the bicycle frames during assembly, which contributes to better ergonomics and improved working conditions.
Results
The result is a clean, quiet, and flexible assembly solution that is adapted to Leader Fox’s current production and can evolve with future needs.
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