PROCESS INVOVLED IN MAKING AN RACING BICYCLE

The Manufacturing Process Seamless frame tubes are constructed from solid blocks of steel that are pierced and "drawn" into tubes through several stages. These are usually superior to seamed tubes, which are made by drawing flat steel strip stock, wrapping it into a tube, and welding it together along the length of the tube. Seamless tubes may then be further manipulated to increase their strength and decrease their weight by butting, or altering the thickness of the tube walls. Butting involves increasing the thickness of the walls at the joints, or ends of the tube, where the most stress is delivered, and thinning the walls at the center of the tube, where there is relatively little stress. Butted tubing also improves the resiliency of the frame. Butted tubes may be single-butted, with one end thicker; double-butted, with both ends thicker than the center; triple-butted, with different thicknesses at either end; and quad-butted, similar to a triple, but with the center thinning towards the middle. Constant thickness tubes, however, are also appropriate for certain bikes. The tubes are assembled into a frame by hand-brazing or welding by machine, the former being a more labor-intensive process and therefore more expensive. Composites may be joined with strong glue or plastic binders. The components are generally manufactured by machine and may be attached to the frame by hand or machine. Final adjustments are made by skilled bicycle builders. Assembling the Frame Tailoring the tubes

1 The metal is annealed, or softened by heating, and hollowed out to form "hollows," or "blooms." These are heated again, pickled in acid to remove scale, and lubricated. 2 The hollows are measured, cut, and precision mitered to the appropriate dimensions. Frame sizes for adult bicycles generally run from 19-25 inches (48-63 cm) from the top of the seat post tube to the middle of the crank hanger. 3 Next, the hollows are fitted over a mandrel, or rod, attached to a draw bench. To achieve the right gauge, the hollows pass through dies which stretch them into thinner and longer tubes, a process called cold drawing. 4 The tubes may be shaped and tapered into a variety of designs and lengths. The tapergauge fork blades may have to pass through more than a dozen operations to achieve the correct strength, weight, and resilience.

Brazing, welding, and gluing

5 Tubes can be joined into a frame either by hand or machine. Frames may be brazed, welded, or glued, with or without lugs, which are the metal sleeves joining two or more tubes at a joint. Brazing is essentially welding at a temperature of about 1600F (871C) or lower. Gas burners are arranged evenly around the lugs which are heated, forming a white flux that melts and cleans the surface, preparing it for brazing. The brazing filler is generally brass (copper-zinc alloy) or silver, which melt at lower temperatures than the

tubes being joined. The filler is applied and as it melts, it flows around the joint, sealing it. Aligning and cleaning

6 The assembled frames are placed into jigs and checked for proper alignment. Adjustments are made while the frame is still hot and malleable. 7 The excess flux and brazing metals are cleaned off by pickling in acid solutions and by washing and grinding the brazing until it is smooth. 8 After the metals have cooled, further precision alignments are made.

Finishing

9 The frames are painted, not only to create a more finished appearance, but also to protect the frame. The frame is first primed with an undercoat and then painted with a colored enamel. Paint may be applied by hand-spraying or by passing the frames through automatic electrostatic spraying rooms. The negatively charged frames attract the positively charged paint spray as the frames rotate for full coverage. Finally, transfers and lacquer are applied to the frame. Chrome plating may also be used instead of paint on components such as the fork blades.

Assembling the Components Derailleurs and gear shift levers

10 Depending on the style of bicycle, the gear shift levers are mounted either on the down tubepopular on racing bikeson the stem, or on the handlebar ends. A cable is attached, which extends to the front and rear derailleurs. Front derailleurs, which move the chain from one drive sprocket to another, may be clamped or brazed onto the seat tube. Rear derailleurs may be mounted with bolt-on hangers or integral hangers.

Handlebars, stems, and headsets

11 Handlebars may be raised, flat, or I dropped. They are bolted to the bicycle stem which is then fitted into the head tube. The headset components, including bearings, cups, and locknuts, are attached to the head tube. The headset allows the fork to turn inside the head tube and thus makes steering easier.

Brakes

12 The brake levers are mounted to the handlebars. Cables extend to the brakes and are fastened to the calipers. Tape, made of plastic or cloth, can then be attached to the handlebars and the ends are plugged.

Saddles and seat posts

13 Seat posts are generally steel or aluminum alloy and are bolted or clamped into position. The saddle is generally made of molded padding and covered with nylon or plastic materials. Although leather was the norm for saddles for a long time, it is less commonly used today.

Crank sets

14 The crankset supports the pedals and transfers power from the pedals to the chain and rear wheel. Cranksets consist of steel or aluminum alloy crank arms, chain rings, and the bottom bracket assembly of axle, cups, and bearings. They are attached with bolts and caps into the bottom bracket of the bicycle frame. The pedals are then screwed to the ends of the crank arms.

Wheels, tires, and hubs

15 Wheel manufacturers conform to the A J International Standards Organization (ISO) system for wheel diameter and tire sizes. Wheels may be constructed by machines, which roll steel strips into hoops that are welded into rims. The rims are drilled to accept spokes, which are laced one round at a time between the rim and hub flange. 16 A wheel must be trued, or straightened, in radial and lateral directions to achieve uniform tension. Next, the rim liner, tire, and inner tube are attached. The chain may also be fitted onto the bicycle. 17 Rear wheels are fitted with a free-/ wheel, consisting of several cogs and spacers, which frees the rear wheel from the crank mechanism when the rider stops pedaling. 18 Wheels are attached to the bicycle frame by means of an axle which runs through the hub of the wheel. The axle may be tightened with bolts at the ends or with quick-release skewers.

END USER REQUIREMENT

Riding Comfort Forget all of the stories about small wheels and wobbly handling, hard work and unusable low gears. Bicycles are more maneuverable than traditional bicycles; they're lighter and offer a low step-thru frame (no high cross bar to negotiate when mounting and dismounting the bicycle). bicycles can be adjusted in variety of ways to provide a custom fit ride. Greater Adjustability = Greater Flexibility Flexibility is what bicycles is really about. Whether you need the portability for your commute by rail, bus, subway, or air OR a bicycle to conveniently fit into the trunk of your car, RV or boat, or where storage is a problem (condo/apartment dwellers) OR want a bike that adjusts to fit anyone in your family, then bicycles are right for you. Car and RV owners, say goodbye to roof racks and the associated hassles dirt, damage, theft, vandalism, time and effort. Adjustable Handlebars Different riders want different riding positions: some want their handlebars higher for easy cruising, while others want them low for a more aerodynamic position over long rides or even lower as in the case of children. All bicycles include adjustable handlebars that can be changed to the desired height in seconds with no tools required. Long, Adjustable Seat Post Just because a bicycle can be compressed into a small, portable size, doesnt mean that it cant handle riders over 6 feet tall. Our seat posts can be extended in seconds to accommodate even the tallest of riders, up to 6 4. And, just as easily, the seat post can be lowered to accommodate shorter riders. Durability Bicycles zinc plated steel frames provide the ideal combination of strength and durability but at a fraction of the cost of more expensive metals like titanium. Unique design allows for the bicycle to be lightweight too weighing only 27 lbs (for the 16 model). Affordability:-, Bicycles stretch to fit the size of the rider (one bike fits all). The frame length, seat height and handle bar height are all adjustable to ensure that the rider has a custom fit for the ultimate in riding comfort. The unique, adjustable frame combined with a low frame tube connecting the front & rear wheels allows one bike to be suitable for the whole family with a few, quick adjustments. Adults (both men and women), kids and older folks will find the bike equally easy to ride. Stretching also means that bicycles can grow along with your kids and its unique design also means that mounting and dismounting is effortless because there is no high horizontal bar to negotiate.

Convenient, Easy Storage Bicycles storage friendly too, bicycles can be easily stored in a closet, car trunk, corner of an apartment living room or balcony or just about anywhere. You can even leave it in the trunk of your car and use it when its convenient. It can even double as an emergency transportation too should your car break down or run out of gas. Sportability With its rugged good looks and comfortable ride, turns portability into sportability! The bicycles is a real head turner, especially when you collapse your in seconds and carry it away. The bicycle 6 speeds lets you get the maximum possible speed/distance for the minimum effort. It also affords the maximum flexibility for different types of riders and road conditions. Faster Acceleration The lower rotating mass of the small wheels, compared to conventional bikes, facilitates faster acceleration. The shorter spokes on the smaller wheels make them stiffer and stronger than larger wheels. Also the center of gravity is lowered, resulting in improved stability. Smaller wheels also reduce the overall length of the bicycle, making it more compact, lighter and easier to transport. Serviceability Most components of bicycles are standard and can be replaced with off the shelf items carried by your local bicycle dealer. V-brakes the latest in technology, V-brakes provide the ultimate in lightweight stopping power. All bicycles incorporate V-brakes for both the front and rear brakes. Saddle - Bicycles come with modern 2-tone waterproof saddles that are padded for comfort, light in weight and require no maintenance. Optional saddles are also available including a deluxe comfort saddle and a saddle with a built-in rear light for extra visibility during night rides.

SAMPLE EVALUATION FORM:FACTORS

Energy requirement Availability of raw materials Safety of processes Energy requirement Required development time & cost Facilities & other equipments Other applications of technology Change in quality of output Size of potential market for output Consumer acceptance Impact on consumer safety Impact on current product line Estimated life of output Spin off project possibilities Impact of cash flow Cash requirement Impact on seasonal & cyclical fluctuations Labor skill requirements Impact on working conditions Availibity of required labor skills Training requirement Change in size of labor force Communication skills Meet government safety standards Impact on image with competitors, customers ,suppliers Degree too which we understand new technology

PROJECT MANAGEMENT ASSIGNMENT: 1,2,3

CUSTOMERS NEED FOR RACING BICYCLE,& DIFFERENT ACTIVITIES INVOLVED IN DEVELOPMENT,PROCESS,& SAMPLE EVALUATION FORM

Submitted to: Mr.Syed Habeeb Ad-Hoc faculty , SOM

Submitted by: Manish Kumar Dash

ROLL:-118911 MBA (2ND YR)

SCHOOL OF MANGEMENT NIT Warangal,AP-506004