650,000 square
foot factory.
The Harley-Davidson
Vehicle Operations in York, PA assembles the Touring, CVO and Trike models of
motorcycles (CVO - Custom Vehicle Order).
They also perform a variety
of manufacturing operations such as making parts like frames, fuel tanks, and
fenders.
Two different tours are offered. The Steel Toe Tour and the Classic Factory
Tour. The Steel Toe Tour is $38 and
offers everything the Classic Tour does plus goes into some of the employee
only areas in paint and polish. There is
also a group picture and a commemorative pin.
The Classic Factory Tour is free, has a
maximum of 9 people and takes you on the assembly line and fabrication
areas. It takes about an hour. This is the tour we took.
While waiting for our tour to begin we
walked around the show room. There were
wonderful exhibits and story boards.
Cameras are not allowed inside the factory but there were plenty of
exhibits and story boards showing us the
various assembly processes.
The tour started with
an introductory video before heading to the factory floor. We were given eye protection and a ear piece
in order to be able to hear the guide.
It was very loud in the factory.
I have never seen
giant robotic arms before and there were plenty of them on the tour. We started in the area where the fenders are
made.
The fenders are made
from sheet steel delivered in pieces pre-cut for each style of fender.
The giant robotic arm
would pick up a sheet of steel and put it in an area where it would be squared
up. Then the arm would lay the sheet on
a die press and the press would descend with 300 tons of pressure, stretching the steel to form the shape of the fender. This is called the deep-draw process. We watched several sheets of steel being
shaped by the die press before moving on to the next robot.
A robotic laser trims
excess steel from the edge and cuts mounting holes. We were told there are holes in the floor
where all the excess steel is dropped and every bit of it is picked up by a
recycling company.
Another press punches
additional holes and the fender is hemmed, or folded over to create a smooth,
rigid edge. Brackets are spot-welded or
riveted onto the fender.
The fenders are sent
to painting.
Next up were the fuel
tanks.
Steel for the fuel
tank arrives in coils weighing 5,000 to 10,000 pounds.
The coil dereeler and
leveler removes any bend in the steel and feeds it into the deep-draw
press. A die descends over the steel to
form a tank half-shell. The left and
right halves are created simultaneously on two different presses.
A shimmy trim press
cuts off excess steel from the edge of the tank shell.
The tunnel is the
third component of the fuel tank and is made from a coil of steel. A press forms the
tunnel.
The fuel tank goes
through a washer and then is moved to the weld assembly area.
The appropriate gauge
cup or filler cup is brazed to the tank half shells, if required for that
model. The shells are then robotically
welded together. The manifold and
castings are welded by a second robot.
In a final welding
step, the tunnel and mounting brackets are added to complete the tank. Every fuel tank is filled with compressed
air, immersed in water and inspected for leaks.
Finished, painted fuel
tanks.
Next up was the frame
area. The frame is loaded into the
weld-cell fixture with more than a dozen other parts. The tail section is welded on the other side
of the cell.
Six robots work
simultaneously inside the weld cell to handle the materials and weld the
frame. This process takes less than five
minutes. A completed frame and tail
section arrive at an inspection station where a welder verifies every weld,
scrapes off weld spatter and touches up welds by hand.
This was one of the
few places we saw a person on the line.
The frame and tail section are then sent to the paint area.
After seeing the areas
where components were made in this factory we went to the assembly area. In this area we saw most of the
employees. This factory employees 800
permanent employees with an additional 200-400 temporary employees added when
needed.
It was fun to see the
various parts hanging on hooks and moving through the factory. In addition there were computer operated
carts moving along the floor.
There were signal
lights (red, yellow, and green - just like a street signal light) to let us
know when we could cross certain areas and when we had to wait for a cart to go
through. There were copper strips in the
floor that the carts followed.
At one point while we
were watching the assembly line one of the AGC’s (Automatic Guided Cart) ran off the rails a little bit
and stopped the whole line! It didn’t
take long for a technician to arrive to find out what the problem was. We did notice several screws on the floor
under the cart. I don’t know if that was
normal - they were picked up quickly!
The assembly line was
very slow moving and it looked like each employee had plenty of time to do
his/her job. We were told there is a
lever they could pull to stop the movement of parts for 30 seconds in case they
needed additional time but, if pulled, a supervisor would be at your station
quickly!
The motorcycle moves
through the assembly area on the AGC (Automatic Guided Cart), which follows a
strip of magnetic tape laid on the shop floor, moving at about six feet per
minute while the motorcycle is being assembled.
In the first assembly
leg, components installed include the electrical harness and inner and outer
primary drive housing and chain. The
form of the motorcycle begins to take shape with the installation of the rear
wheel.
The AGC self-adjusts
through a 24-inch range to best match the work level to the height of the
employee and process at each station.
The employee never has to bend over or stretch.
We saw the AGC
adjusting as the employees were assembling different parts. In Leg B the brake system is added. Next the vehicle receives the front fork
assembly which includes the front wheel.
Then the handlebars are attached.
Before moving on to Leg C, the vehicle passes through an area to receive
the rear fender subassembly.
The battery, horn and
mirrors are installed at the beginning of this leg. Next, most models receive the inner section
of the fairing, which holds instruments and audio electronics. The inner fairing is delivered to the line
ready to install on the motorcycle.
Finally on Leg C all vehicles receive exhaust systems, mufflers, and the
kickstand which is referred to as the Jiffy Leg.
Installation of the
front fender and outer fairing completes the front end, and the saddlebags are
hung on the tail section of all models except Trike. The fuel tank is secured in place, and
covered with a plastic “hard guard” to protect the paint as the motorcycle
proceeds down the line. Hard guards also
protect fenders and other bodywork. On
Leg E Trike models receive the rear axle, exhaust, wheels and Trike body. At the end of Leg E, the Tour-Pak rear
luggage and lower fairings are installed.
After going through
the final assessment station, every Harley-Davidson is “hot tested” in the roll
test cell. While still mounted to the
AGC, the motorcycle is raised and rotated onto a set of rubber rollers. A technician flashes the electronic control
system with required software, attaches fuel and electrical lines, and fires up
the engine. Following a standard
sequence, the technician “rides” the motorcycle on the rollers at highway
speeds and verifies that all systems are functioning correctly, including the
brakes, transmission, lights and electronics.
Any issues are resolved in repair areas, and the motorcycle is re-tested
before it is released for shipment.
We watched the “hot
test” for several minutes. There was a
large display where we could see how fast the driver was going and information
on different systems. No fuel is put
into the fuel tank during this test. We
were told that if the technician thought it was necessary he could take the
motorcycle outside and ride it. The fuel
tank would then be flushed and cleaned.
The AGC carries the
finished motorcycle to the Vehicle Delivery System where it is secured on a
special steel shipping pallet. The
unusual shape of this pallet is designed to allow more motorcycles to fit on a
standard-size semi trailer. The loaded
pallets are placed on a conveyor, which feeds an entire batch of 15 motorcycles
into a trailer equipped with a self-loading system. Trikes are rolled onto a designated Trike
trailer and strapped down. The motorcycles
are transported to a local shipping center, unloaded, and sorted into efficient
regional loads that are stacked two-high.
30 motorcycles are carried in a single trailer for the journey to an
authorized Harley-Davidson dealer. The
shipping pallets are returned to York after the motorcycle is delivered to the
dealer.
There were several
motorcycles on the floor to try out.
They were bolted to the floor so there wasn’t any problem with them
falling over.
Nope - riding is not
for me.
We were given this pin
to wear while we were on our tour. After
the tour we were told it was our souvenir and we could keep it. So, or course, I’ll pull the pin off and make
mine into a magnet.
This was a very
interesting tour even though we’re not interested in owning or riding a
motorcycle. It’s always fun to see how
things are made.
You did such a thorough write up on this one, and since I really disliked the Harleys that moved into our neighborhood since they were SOOO LOUD, I might skip this tour. The robotics sound really interesting though, we'll see.. As you said though, it is always interesting to see how things are made!
ReplyDeleteWe're right there with you on the love of Harleys. Nothing like some jackass blasting through a park to shatter the serenity! But we love to see how things are made and this was a great tour for that.
DeleteOn the other hand, I would love this tour, because of all the robotics. I could see self driving delivery trucks in the future for this company.
ReplyDeleteGreat detailed post. Thank you.
Or perhaps they will just teach the motorcycles how to drive to their new owners homes!!
DeleteNow that would be a sight to see.
Delete