Faster to the customer: bicycle assembly in the packaging

The market for bicycles of all kinds has been booming since 2020, and the development of current fuel costs is contributing to the fact that two-wheelers are increasingly being used as a mobility alternative. The high demand presents bicycle manufacturers with enormous challenges in terms of their productivity and speed of delivery in order to serve the growth market. Against this background, we developed an efficient, time and material-saving and environmentally friendly assembly solution. This means that the employees in the bicycle assembly can concentrate more on their essential tasks if a new work organization is implemented. The unique "bicycle garage" made of corrugated board is at the heart of the solution found.

The experts at Coswiger Wellpappe developed and implemented this high-performance and sustainable packaging system. The multi-part packaging consistently accompanies the two-wheelers through all assembly stations. Between the various assembly steps, it serves as a warehouse-friendly logistics solution. After completion of the bicycles, they leave the production well protected and go on their way to the trade or to the end customer in the recycling-friendly packaging.

The bicycles are not produced in a linear manner, taking into account the customer's wishes; various individual configurations are possible. Therefore, the production and assembly is always different, the workstations vary and must be controlled flexibly. This way of working used to take a lot of time to store the partially assembled wheels, including packing and unpacking between work steps. At the end of the assembly process, the bicycles then need protective shipping packaging.

With the bicycle garage, the time and material required for production can now be significantly reduced. The packaging, designed for the maximum dimensions of the bicycles (format 1880 x 740 x 1293 mm), consists of robust, load-bearing corrugated cardboard. It remains open from above during internal transport and assembly work. With the help of a Velcro strip attached to the side, the front of the packaging can be opened and closed again as often as you like. The bicycles are thus created in the garage, which accompanies all internal transport routes. The garage stands either on a wooden Euro pallet or on a corrugated board pallet, made by Panther.

Each individually printable components of the corrugated board construction are put together by the bicycle manufacturer to form the packaging, which is designed for the optimal course of the specific assembly stations. This ensures that the wheels are always securely fixed and protected - both during production and on the shipping route. A slip-on lid that fits perfectly is then put on for transport to the end customer.