Runner Motorcycle Industry Renovation Design

PRESESNTED BY SUSMITA BISWAS SATHI 10.02.01.025 AHSANULLAH UNIVERSITY OF SCIENCE & TECHNOLOGY

CONTENTS PAGE

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PROJECT PROPOSAL PROJECT BRIEF SITE ANALYSIS PROGRAMME METHODOLOGY LITERATURE SURVEY STANDARDS STUDY CASE STUDY FINDINGS ISSUES TO BE ADDRESSED IN THE DESIGN PROPOSAL FINAL DESIGN CONCLUSION BIBLOGRAPHY

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By Susmita Biswas Sathi susmitabsathionline@yahoo.com

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PROJECT PROPOSAL

Title of the Project: RUNNER MOTORCYCLE INDUSTRY General information: Client Project type Location Area of site

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: Runner Automobiles Ltd. : Industrial. : Bhaluka, Mymensingh. : 35 acre.

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PROJECT BRIEF RUNNER MOTORCYCLE INDUSTRY Two major component of this project 1. Motorcycle.

2. Manufacturing plant.

Industry Any building structure used by the industry to store raw materials for manufacturing products of the industry is known as an industrial building.

• Manufacturing raw material.

New industries developed in th 20th century: • chemical industry, e.g. plastics • car manufacturing industry, i.e. motor vehicles • •

aircraft industry, i.e. planes and fighters electronics, e.g. computers, etc.

Motorcycle manufacturing plant is in the category of motor-vehicle industry.

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REASONS BEHIND CHOOSING THIS PROJECT AS B. ARCH THESIS BANGLADESH IS SOON BECOMING A MOTORCYCLE MANUFACTURING HUB. DUE TO ITS GEOGRAPHIC LOCATION, CHEAP LABOUR COST, INCREASING LOCAL DEMAND AND STEADY GROWTH OF THE MARKET, FAMOUS MANUFACTURERS LIKE HONDA,SUZUKI, YAMAHA HAVE ALREADY STARTED INVESTING ON JOINT VENTURE PLANTS WITH LOCAL DEALERS AND SHAREHOLDERS LIKE ATLAS GROUP,RANCON MOTORS,UTTARA MOTOS ETC BUT THEY ARE RECEIVING GREATER PROFIT USING OUR MANPOWER

TYPE OF THE PROJECT : • • •

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CONVERTED ASSEMBLING PLANT TO MANUFACTURING PLANT. MANUFACTURING PLANT IS THE COMPONENT OF AN INDUSTRY. ALSO WITH A MOTORCYCLE DISPLAY FOR SHOWCASING PRODUCTS.TEST TRCAK INCLUDED. SO IT IS AN INDUSTRIAL PROJECT.

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architectural project & Archetype Basic component and Working flow chart of a motorcycle manufacturing plant

Finished product wareho use

Admin

Entry

Loading/unloa ding

RND

•

Engine shop

Paint shop

Body shop

In any industrial project there were this basic working flow

material •

Raw material wareho use

Assembl y shop

Processing of raw material

product

This is the archetype of any industrial building

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Background of runner: 200 0

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Project brief 200 5

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RB L

RA PL

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RAL(Runner automobile ltd) Started its journey in the year 2000 in Bangladesh a name of dayang runner with Thai and Chinese companies.

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Assembling motorcycle in 2007.

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Established a assembling plant in valuca, mymenshing 35 acres(120 bigha) with a covered space of over 200,000 sft. In 2011 The organization over 700 employee.

Company produced 500 motorcycle per a day. capacity to produce 1.5 lakh motorcycles a year.

vision

Mission

strategy

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To become the leading manufacture in the country

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Manufacture motorcycle Maintain standard Prosperity for employee

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To built a strong production range Explore expansion opportunity globally

It will act as a landmark and innovation in the field of motorcycle industry in Bangladesh.

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summ ary

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Project brief

Significance of the project(in national and local context): Going to acting as a landmark and innovation in the field of motorcycle industry in Bangladesh.Explore history of motorcycle and Aware people about its significance in transportation & riding rules through museum.plans to manufacture motorbike engines locally in 2015 to create a manufacturing hub in Bangladesh.produced 1.5 lakh motorcycles a year and earn a huge foreign currency. In 2007 its earn 300$ million.Going to export motorcycle internationally in the end of 2015.Going to established a regional industrial policy.

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OBJECTIVES

• • • • •

To establish a public space into the industry through a historical museum of motorcycle.

To establish an eco-friendly industry & a great working environment .

To establish Bangladesh as a motorcycle manufacturing hub.

To earn a huge foreign currency by exporting local product.

To create a place of inspiration for other industries in Bangladesh.

Scope: • Going to established a manufacturing plant so there is a scope of innovation and research.

• Going to established a motorcycle hub nationally so there is a scope of exporting motorcycles in next year.

• Earn foreign currency & developed a job market.

• Amalgam of industry with motorcycle museum to develop a public space within motorcycle museum.

• Scope of Creating a eco-friendly environment .

Limitation: Have to maintain the functional consequence for the real purpose of this project.

Possibilities of environmental pollution

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SITE ANALYSIS

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Month

Rainfall (mm)

January

9

February

19

March

47

April

118

May

264

June

411

July

384

August

339

September

274

October

171

November

27

December

4

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Year

2066

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SITE: SEEDSTORE, VALUKA, MYMENSINGH, AREA 35 ACRE

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Bus route.

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Site location from seedstore road

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DAILY SUN PATH DIAGRAM

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ANNUAL SUN PATH DIAGRAM

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WEATHER DATA OF MYMENSINGH

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OPTIMUM ORIENTATION

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SUN POSITION WITH DAYLIGHT SAVINGS

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AVERAGE WIND TEMPERATURE

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Average wind temperature with monthly comparison

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Monthly durinal averages

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ADMIN OFFICE ENTRY

PLAY ZONE

INSIDE OF THE SITE

INTERNAL ROAD

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PROGRAMME

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architectural project & Archetype Basic component and Working flow chart of a motorcycle manufacturing plant

Finished product wareho use

Admin

Entry

Loading/unloa ding

RND

•

Engine shop

Paint shop

Body shop

In any industrial project there were this basic working flow

material •

Raw material wareho use

assembl y shop

Processing of raw material

product

This is the archetype of any industrial building

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By Susmita Biswas Sathisusmitabsathionline@yahoo.c om

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Research Center

Manufactur ing plant

BROAD PROGRAM ME PROPOSED PROGRAM

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Detail Programme Manufacturing plant Body shop

Engine shop

Paint shop

Assembly shop

Entry/ Check point

press shop

Weld shop

Leather upholst ery

Entry/ checkp oint

Entry/ checkp oint

Engine KD store

Entry/ checkp oint

Entry/ checkp oint

Entry/ checkp oint

Dedust .

KD STORE

Assemb ly line

HYDRO LIC PRESS

Weldin g cubicles

Scrap metal

Engine testing

Mechan ical PRESS

Stack .

Kiln .

Stack .

Lathe machin e

Enginee rs room

Mould process ing

Derust .

Dedust .

Degrac e .

Primer coating

Cadcam machin e

Paint chambe r

Heavy crane

heat paint cell

Plastic .

Metal

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Assemb ly line

Cable works Engine install Oil tank install

Shocks and forks

Handl ebars Fender Work cell Wheel Work cell Fuel tang install Air cleaner Testing And

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METHODOLOGY

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LITERATURE SURVEY

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HISTORY OF MOTOTRCYCLE AND ITS MANUFACTURINGThe motorcycle is "a form of entertainment that can appeal only, one would think, to the most enthusiastic of mechanical eccentrics,‖ Engineering magazine stated in 1901. "We think it doubtful whether the motorcycle will, when the novelty has worn off, take a firm hold of public favor."

Last year, four million motorcycles were in use in the United States alone. Whether relied upon as a primary means of transportation, used to provide weekend recreation, souped up and sped along for racing, or displayed as antique, millions of people across the world have shown that the novelty most definitely has not worn off.

As might be imagined, the motorcycle evolved from a vehicle powered by sheer human energy—the bicycle. French bicycle maker Pierre Michaux and his sons Ernest and Henri first fitted a bicycle with cranks and pedals—precursors to the modern-day motor—in 1861.

American, Sylvester Howard Roper (1823-1896) invented a two-cylinder, steam-engine motorcycle (powered by coal) in 1867. This can be considered the first motorcycle, if you allow your description of a motorcycle to include a steam engine. Howard Roper also invented a steam engine car.

The Michauxes' velocipede was an instant hit and the family became the largest velo producer in Europe with a large factory at Bar-le-Duc in France. Working with Michaux, L.G. Perreaux devised a steam-powered motorcycle engine, called a velo-a-vapeur, which was patented in 1868. Sylvester Howard Roper of Roxbury, Massachusetts pioneered a similar invention in the United States around that time as well.

a two-cylinder, steam-engine motorcycle 1867

Velopide 1861

velo-a-vapeur 1868

https://www.google.com.bd/

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In 1879, Giuseppe Munigotti of Italy patented the first gas-burning internal combustion four-stroke engine for the new motorcycles, although his invention existed only on paper.

Meanwhile, two Germans, Dr. Nicolaus Otto and Eugen Langen were developing four-stroke stationary engines, which ran on coal gas supplied from mains. Gottlieb Daimler took the invention further by developing an engine that ran on benzine. Since benzine could carry a vehicle approximately 25 miles on one gallon, only a small tank would need to be attached to the machine. Daimler later abandoned the motorcycle business to concentrate on another invention—the first automobile that became the basis for his company, Daimler Benz, maker of the luxury Mercedes Benz automobile.

Several innovators improved upon these inventions over the next 30 years, and in 1901 the machine that is still regarded as Carl Hedstrom, a Swedish immigrant to the United States, developed the first modern motorcycle. Hedstrom fitted an Indian bicycle with a 1.75horsepower single-cylinder engine, and the legendary Indian motorcycle was born. Several other U.S. makers came out with similar models, including the company whose name is synonymous with the motorcycle—Harley-Davidson—in 1903. William Harley and Arthur Davidson were students in Milwaukee when they built their first motorcycle on a borrowed lathe from patterns they had made. Davidson's older brothers, both toolmakers, assisted, as did Ole Evinrude, who later became famous as a designer and producer of outboard motor boat engines.

Other makers included Royal, Merkel, Yale, Reading-Standard, Rambler, Tribune and Curtiss. By 1904, motorcycle manufacturers had begun to construct bulkier, sturdier frames, stronger wheels, bigger engines and reinforced forks for their bikes and a clear distinction between motorcycles and bicycles emerged. Around this time, the sidecar, affixed to a light, tubular frame extending from the main motorcycle frame, began to be popularized. Based on a similar accessory for the bicycle, his device allowed the driver of a motorcycle to carry a passenger.

By 1905, the focus was on power, and manufacturers begin to beef up their engines. That year, Hedstrom produced a machine boasting a 500 cc twin engine that featured twist-grip control for the throttle and ignition. That same year saw the development of "free engine" devices, which eased the starting and launching of a machine, and variable gears, which eased use on hills and at slow speeds. Chain drive followed, and the stage was set for production of the motorcycle that is CURRENTLY IN USE .

Motorcycles continued to grow in popularity for decades, although production for civilians tapered off during World War II. During World War II, however, a need arose for lightweight, collapsible models to be used by parachutists once they had landed. Royal Enfield produced a Flying Flea model for this purpose, while Excelsior came up with its Welbike, which could fit into a small air-drop container. The Welbike was later marketed to civilians as the Corgi, spawning the post-war popularity of the motor scooter, especially in Europe.

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Several innovators improved upon these inventions over the next 30 years, and in 1901 the machine that is still regarded as Carl Hedstrom, a Swedish immigrant to the United States, developed the first modern motorcycle. Hedstrom fitted an Indian bicycle with a 1.75-horsepower single-cylinder engine, and the legendary Indian motorcycle was born.

Several other U.S. makers came out with similar models, including the company whose name is synonymous with the motorcycle—Harley-Davidson—in 1903. William Harley and Arthur Davidson were students in Milwaukee when they built their first motorcycle on a borrowed lathe from patterns they had made. Davidson's older brothers, both toolmakers, assisted, as did Ole Evinrude, who later became famous as a designer and producer of outboard motor boat engines.

first gas-burning internal combustion four-stroke engine 1879

four-stroke stationary engines

Carl Hedstrom,1901

motorcycle—Harley-Davidson—in 1903

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The 1950s were regarded as a "golden age" for the motorcycle, with its use being popularized by such prominent figures in popular culture as James Dean in his movie "Rebel Without a Cause." The United States and Europe dominated the motorcycle industry through 1960, at which time Japanese manufacturers, including Honda, Yamaha, Suzuki and Kawasaki, rose to a prominence they maintain to this day.

Motorcycles are one of the most affordable forms of motorized transport and, for most of the world's population; they are the most familiar type of motor vehicle. While North America, Europe, and Japan are car-centric cultures where motorcycles are uncommon, the non-car-centric cultures of India, China, and Southeast Asia account for more than half of the world's population, and in those places two-wheelers outnumber four wheeled vehicles. About 200 million motorcycles, including mopeds, motor scooters, motorized bicycles, and other powered two and three-wheelers, are in use worldwide, or about 33 motorcycles per 1000 people. By comparison, there is about 1 billion cars in the world, or about 141 per 1000 people, with about one third in service in Japan and the United States.

Most of the world's motorcycles, 58%, are in the developing countries of Southern and Eastern Asia, and the Asia Pacific, excluding Japan which is one of the world's major car users. As of 2002, India, with an estimated 37 million motorcycles/mopeds, was home to the largest number of motorized two wheelers in the world. China came a close second with 34 million motorcycles/mopeds in 2002. As the middle class in India, China, and other developing countries grows, they are repeating the transition from motorcycles to cars that took place in the US in the years after World War I, and in Europe following World War II, and the role of motorcycling is changing from a transport necessity to a leisure activity, and the motorcycle is changing from a family's primary motor vehicle to a second or third vehicle.

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The first commercial design for a self-propelled bicycle was a three-wheel design called the Butler Petrol Cycle, conceived of and built by Edward Butler in England in 1884. He exhibited his plans for the vehicle at the Stanley Cycle Show in London in 1884, two years earlier than Karl Benz invented his first automobile who is generally recognized as the inventor of the modern automobile. Butler's vehicle was also the first design to be shown at the 1885 International Inventions Exhibition in London.

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The vehicle was built by the Merry weather Fire Engine Company in Greenwich, in 1888.

The Butler Petrol Cycle (first recorded use of the term) was a three-wheeled vehicle, with the rear wheel directly driven by a 5/8hp (466W) 600 cc (40 in3; 2¼×5-inch {57×127-mm}) flat twin four stroke engine (with magneto ignition replaced by coil and battery), equipped with rotary valves and a float-fed carburetor (five years before May Bach), and Ackermann steering, all of which were state of the art at the time. Starting was by compressed air. The engine was liquid-cooled, with a radiator over the rear driving wheel. Speed was controlled by means of a throttle valve lever. No braking system was fitted; the vehicle was stopped by raising and lowering the rear driving wheel using a foot-operated lever; the weight of the machine was then borne by two small castor wheels. The driver was seated between the front wheels. It wasn't, however, a success, as Butler failed to find sufficient financial backing.

Another early internal combustion, petroleum fueled motorcycle was the Daimler Reitwagen. It was designed and built by the German inventors Gottlieb Daimler and Wilhelm Maybach in Bad Cannstatt, Germany in 1885. This vehicle was unlike either the safety bicycles or the boneshaker bicycles of the era in that it had zero degrees of steering axis angle and no fork offset, and thus did not use the principles of bicycle and motorcycle dynamics developed nearly 70 years earlier. Instead, it relied on two outrigger wheels to remain upright while turning. The inventors called their invention the Reitwagen ("riding car"). It was designed as an expedient testbed for their new engine, rather than a true prototype vehicle.

Butler Petrol Cycle 1888

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Daimler Reitwagen 1885

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Many authorities who exclude steam powered, electric or diesel two-wheelers from the definition of a motorcycle, credit the Daimler Reitwagen as the world's first motorcycle.

If a two-wheeled vehicle with steam propulsion is considered a motorcycle, then the first was the French Michaux-Perreaux steam velocipede of 1868. This was followed by the American Roper steam velocipede of 1869, built by Sylvester H. Roper Roxbury, Massachusetts. Roper demonstrated his machine at fairs and circuses in the eastern U.S. in 1867, and built a total of 10 examples.

http://britishbikersassociation.org/history-of-motorcycles/ 12/6/2017

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FIRST MOTORCYCLE COMPANIES In 1894, Hildebrand & WolfmĂźller became the first series production motorcycle and the first to be called a motorcycle (German: Motorrad). Excelsior Motor Company, originally a bicycle manufacturing company based in Coventry, England, began production of their first motorcycle model in 1896. The first production motorcycle in the US was the Orient-Aster, built by Charles Metz in 1898 at his factory in Waltham, Massachusetts.

In the early period of motorcycle history, many producers of bicycles adapted their designs to accommodate the new internal combustion engine. As the engines became more powerful and designs outgrew the bicycle origins, the number of motorcycle producers increased. Many of the nineteenth century inventors who worked on early motorcycles often moved on to other inventions. Daimler and Roper, for example, both went on to develop automobiles.

At the turn of the century the first major mass-production firms were set up. In 1898, Triumph Motorcycles in England began producing motorbikes, and by 1903 it was producing over 500 bikes. Other British firms were Royal Enfield, Norton and Birmingham Small Arms Company who began motorbike production in 1899, 1902 and 1910, respectively. Indian began production in 1901 and Harley Davidson was established two years later. By the outbreak of the First World War, the largest motorcycle manufacturer in the world was Indian, producing over 20,000 bikes per year.

German: Motorrad 1894

Orient-Aster, built by Charles Metz in 1898

http://todayinmotorcyclehistory.blogspot.com/2014/07/today-in-motorcycle-history-july-31-1900.html www.google.com 12/6/2017

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Diagram of 1894 Hildebrand & WolfmĂźller.

Triumph Motorcycles Model H, mass-produced for war effort and notable for its reliability.

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motor vehicles manufactured by japan and china

In the 21st century, the motorcycle industry is mainly dominated by Japanese companies.

In addition to the large capacity motorcycles, there is a large market in smaller capacity (less than 300 cc) motorcycles, mostly concentrated in Asian and African countries. An example is the 1958 Honda Super Cub, which went on to become the biggest selling vehicle of all time, with its 60 millionth unit produced in April 2008. Today, this area is dominated by mostly Indian companies with Hero MotoCorp emerging as the world's largest manufacturer of two wheelers. Its Splendor model has sold more than 8.5 million to date. Other major producers are Bajaj and TVS Motors.

In numerous cultures, motorcycles are the primary means of motorized transport.

According to the Taiwanese government, for example, "the number of automobiles per ten thousand populations is around 2,500, and the number of motorcycles is about 5,000."[n places such as Vietnam, motorized traffic consists of mostly motorbikes due to a lack of public transport and low income levels that put automobiles out of reach for many.

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Number of motorcycles vs number of cars by country.

Size of pie indicates population. 2002 estimates.

Millions of cars (light blue) and motorcycles (dark blue) in the top 20 countries with the most motorcycles. Population in red. 2002 estimates.

In numerous cultures, motorcycles are the primary means of motorized transport. According to the Taiwanese government, for example, "the number of automobiles per ten thousand populations is around 2,500, and the number of motorcycles is about 5,000."[41] In places such as Vietnam, motorized traffic consists of mostly motorbikes due to a lack of public transport and low income levels that put automobiles out of reach for many.

DEMOGRAPHICS

http://en.wikipedia.org/wiki/Motorcycling

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The four largest motorcycle markets in the world are all in Asia: China, India, Indonesia, and Vietnam. The motorcycle is also popular in Brazil's frontier towns. Amid the global economic downturn of 2008, the motorcycle market grew by 6.5%. In China, the number of motorcycles in use increased from 34 million in 2002 to 54 million in 2006, with annual production of 22 million units.

Recent years have seen an increase in the popularity of motorcycles elsewhere. In the USA, registrations increased by 51% between 2000 and 2005. This is mainly attributed to increasing fuel prices and urban congestion. A Consumer Reports subscribers' survey of mainly United States motorcycle and scooter owners reported that they rode an average of only 1,000 miles (1,600 km) per year, 82% for recreation and 38% for commuting.[48] Americans put 10,000–12,000 miles (16,000–19,000 km) per year on their cars and light trucks.

As motorcyclists age, there is a tendency for riders to choose touring bikes over sports bikes.

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HISTORY OF RUNNER (RAL)

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It has the production capacity of manufacturing 500 motorcycles per day. After manufacturing all motorcycles and their components are tested in the computerized testing line and checked by quality control personnel before making delivery. RAL obtained government approval as motorcycle manufacturer from Bangladesh Road Transport Authority (BRTA) after a thorough quality testing by Bangladesh University of Engineering and Technology (BUET).

Runner Automobiles Ltd, plans to manufacture motorbike engines locally in the next two years. The company has so far invested around Tk 200 crore in its 120-bigha plant at Bhaluka in Mymensingh, and will make further investment to set up the full-fledged manufacturing unit. Currently, they make chassis and bodyin their factory and plan to start manufacturing engines in 2015.At present, the company has the capacity to produce 1.5 lakh motorcycles a year, and once the new unit is up and running, the capacity will double. Producing engines locally will increase the value addition of the pro-duct by around 25 percent. Runner Group is extending technical support and incentives to some small and medium enterprises that make and supply the component parts, including seat, side cover, indicator light, head light, back light, cables and wiring harness, to Runner and other companies. For the local market, the company uses the brand names — Dayang-Runner and Freedom-Runner, while for the overseas markets the brand name will be Runner.

Locally made spare parts like motorcycle seat, different cables like: break cable, clutch cable etc., wiring harness, tyre, tube, battery, plastic components (side cover, indicator light, head light, fender) and many other parts and accessories are being utilized in runner motorcycles of different models. All these local entrepreneurs are financially benefitted and they also created employment opportunities for a large no of people.

By earning good reputation, RAL has captured the domestic market as an avant-garde in this horizon. At present RAL has more than 200 dealers and over 400 sales centers run by trained dealer staff. RAL is selling the highest quantity of motorcycles in the domestic market as a manufacturer. It is to be noted that RAL is also the market leader as regards to 80 CC motorcycle in Bangladesh.

Here is the list of product they have currently in their showroom all over Bangladesh.

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DAYANG RUNNER : Model Engine Capacity and Power PRICE (BDT) DY 50 50 ( 5.1 BHP) 74,000 AD- 80S 80 (6.0 BHP) 80,000 Deluxe 80 (6.1 BHP) 84,000 Galaxy 80 (6.1 BHP) 85,000 Apollo 100 (7.0 BHP) 90,000 Bullet 100 (7.0 BHP) 97,000 Bullet 135 (7.0 BHP) 1,25,000

FREEDOM RUNNER : Model Engine Capacity (CC) PRICE (BDT) Trover 100 (7.0 BHP) 90,000 Royal KS 100 (6.4 BHP) 90,000 Royal ES 100 (7.0 BHP) 95,000 Royal + 110 (8.0 BHP) 102,000 Turbo 150 (11.4 BHP) 1,35,000 (2013)1,42,000 (2014) Each Motorcycle comes with 3 years Engine warranty while you get to have Free Servicing for 1 year. Runner automobiles always give out motorcycles in installments Runner has 12 motorcycles lined up on their grid to choose from. They too are giving bikes in installments.

http://www.runnerbd.com/ral/

12/6/2017

By Susmita Biswas Sathi susmitabsathionline@yahoo.com

76

Motorcycle business is booming in Bangladesh over the last 6-7 years.it is not becoming a trend for many young people to own a motorcycle, and we the Bangladeshi manufacturer are not that far off the grid. Hopefully Runner in the future will become a powerhouse in the motorcycle industry in Bangladesh.

Demand in world wide : Runner Automobiles Ltd, a concern of the local Runner Group, intends to export motorcycles from the middle of next year.

Its potential markets include the north-eastern states of India, Nepal and some African countries.

The company signed an agreement with China's Dayang Motorcycles Ltd for technical support for the next 10 years.

Runner, which started assembling motorcycles at its plant at Bhaluka in 2007, will start designing its own motorcycles in 2014, said Hafizur Rahman Khan, the chairman of Runner Automobiles Ltd, at the agreement signing ceremony.

For the local market the company will use the brand name of Dayang-Runner, while for overseas markets it will be the brand name of Runner, Khan said, Annually, Bangladesh imports motorcycles and spare parts worth $300 million, and according to Khan, the demand is on a steady rise. ―If our plant can start designing and manufacturing of motorcycles, the country will be able to save the dollars, he said.

At present, the company produces 200 motorcycles a day, with plans to hit the three lakhmark motorcycles annually from 2015.

The company currently manufactures headlights, backlights and other parts of a motorcycle, and has plans in place to manufacture motorcycle seats and chains as well.

In 2011 the company sold a total of 48,000 pieces of motorcycles in Bangladesh, Mamunur Rashid, Runner's head of sales, revealed.

Annually, a total of 3.5 lakh pieces of motorcycles are sold in the country, according to Rashid, with the growth of motorcycles business year-on-year in Bangladesh being 25 percent.

Runner has a 15 percent market share of the motorcycle market in Bangladesh, while the market leader Uttara Motorcycle which sells the Indian Bajaj-branded motorcycles has a 35 percent market share.

Rashid predicts the sales of motorcycles will be low in 2012, with the sales figure to be around the region of 2.5 lakh cycles. ―We need a long-term policy support from the government for the growth of motorcycle industry in the country,‖ said Khan.

The newly-appointed State Minister for Industries Omor Faruk Chowdhury said the country needs more than one industrial policy. http://www.runnerbd.com/ral/ 12/6/2017

By Susmita Biswas Sathi susmitabsathionline@yahoo.com

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I went to witness this making process of motorcycles in Bangladesh in Runner Automobiles Ltd’s motorcycle factory in Mymensingh. We saw many in depth process of how they make a motorcycle and their technician and staff explained to us every single step on the way.

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STANDARD STUDY

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Motorcycles basic component Front wheel

Fork

Head

Chassis

Back wheel

Engine

Exhaust

Back Seat

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Motorcycles basic component

Engine

Clutch cover Lower fairing Exhaust Master cylinder Break paddle Foot peg

Muffler 12/6/2017

By Susmita Biswas Sathisusmitabsathionline@yahoo.c om

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Motorcycle’s basic component

Chassis

Body case Bar end Fairing Sub frame Back seat

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Motorcycle’s basic component

Back wheel

Wheel Calliper (P) Rotor

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Motorcycle’s basic component

Head

Windscr een (P) Front fairing (P) Head light Intake duct Mirror Handler (P)

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By Susmita Biswas Sathisusmitabsathionline@yahoo.c om

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Motorcycle’s basic component

Fork

Breaker level (P)

Fork tube

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Motorcycle’s basic component

Front wheel Fender Rotor Calliper (P) Brake line (P)

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Motorcycle’s basic component

Head

Chassis

Back Seat Fork

Back wheel

Front wheel

Exhaust

Engine

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INDUSTRIAL SHED CONSTRUCTION

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MAXIMUM HEIGHT NEEDED 25’ FOR MACHINERIES

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OTHER MACHINERIES MEASUREMENTS

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TWO STRAIGHT SIDE MECHANICAL PRESS MACHINE OF 400TONS HEIGHT 25’ THREE FRAME MECHANICAL PRESS OF 100 TONS HEIGHT 15’

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Dock positioning involves the physical layout of the dock doors and levelers. The most common dock arrangement is a flush wall with doors spaced on at least 12' centers .If special trailers frequent the facility, door spacing may need to be increased. Twelve-foot centers allow for an overall truck width of 10' including side mirrors. Narrower spacing is possible when room is limited. When incorporating narrower centers, give consideration to common member dock seals and shelters.

Enclosed docks are generally used when climate control, product protection, security, and overhead lift capabilities are required. They are not a common choice due to high construction costs and vehicle exhaust pollution considerations.

Dimension of height of dock from ground level Trailers can range in height from flatbed units (approximately 48") to closed vans (162" from ground level).

The highest internal height for product loading is approximately 114" high.

Depending on the application, there are three basic door heights that are typically specified. Keep in mind that the common dock height is48" - 52". Eight foot (96") high doors can accommodate many loading/unloading operations, but do not facilitate full floor to ceiling loading of product.

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Dimension of height of trailer

Ground to trailer ceilling height

5’-6’

8’

Vertical dock levelers 12/6/2017

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MUSEUM STANDARDS

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CASE STUDY (LOCAL)

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RUNNER AUTOMOBILES LIMITED

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Flow-diagram of RAL:

Existing Runner motorcycle manufacturing plant

PRESS SECTION stamping operation (blanking, piercing drawing etc.) to get the required shape from a sheet metal

WELDING SECTION Attaching the metallic parts and joints through Welding operation

PAINTING SECTION Painting of the metal and the plastic parts

ENGINE ASSEMBLY SECTION Assembling of the engine Sent back to corresponding section

ASSEMBLY SECTION PRE-ASSEMBLY SECTION

Assembling of the Motorcycle

POSTPRODUCTION INSPECTION

CENTRAL QUALITY CONTROL

If No Quality Assured

If Yes DELIVERY SECTION

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List of motor-cycle components (IN-HOUSE PRODUCTION): Component

1.Fram e Body

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Parts 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

1.Fue l Tan k

Front right body Fuel tank front support Right reinforcing plate Left reinforcing plate Main pipe, rear Fixing rod, rear brake pedal Right hanging plate components Front left body Holder Left hanging plate components Steering stem components Stand assembly components Front support, L. seat Rear fork pivot support Rear pivot support Safe guard support Shield holder Fuel Tank rear support Rear support, seat Nut M6 Nut M8 Clip 3*60 Linking plate High tension coil holder Fixing hook Clip 3*80 Under support, RR fender Special nut M6 Support plate Support seat, L&R Square pipe (support) Right support, seat hook Left support, seat hook Seat hook Left cover plate Right cover plate Front support, R. seat Wire clip Frame mark Ball bearing holder Screw 2*6

By Susmita Biswas Sathi

1. Rear fork

1.Mai n sta nd

1.

2.

3.

4.

5.

6.

7.

8.

9.

Cover, Fuel Tank Upper Cover, Fuel Tank Under Shield Circle Connect Seat, Left Plate Connect Seat, Right Plate Reinforcing Plate Rear Plate Rear Plate Washer Outlet Bush

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

Rear fork pivot bushing Screw, rear shock absorber Front support plate Support plate Left tube Support plate, rear Left hook, Rear fork Right hook, Rear fork Right tube Strength plate Connection tube Limited pole Limited pole, Rear brake Screw axis A Rubber washer Washer Screw axis B Nut M8 Spring washer Ф8 Washer Ф10 Pin 2*6

1.

Limited block, Main stand Stand tube Stand bushing plate Stand linking plate Main stand left plate Strength plate Main stand right plate Main stand spring hook Main stand tube Fixing plate Main stand support 100pipe

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

1.Foo t peg And

1.Sid e stand

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Fixing position plate Foot pedal bar Side stand support Side stand bar Strengthen pipe Bush Foot peg Side stand pivot bolt Side stand spring Nut M10*1.25 Screw 8*32 Foot peg rubber

List of motor-cycle components (LOCAL SOURCING):

Components 1.

Rubber items

1.

Winkers

1.

Fairing

1.

Side-covers

1.

Battery

1.

Tire

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List of motor-cycle components (IMPORTED):

Components 1.

1.

1.

1.

1.

1.

Engine (in knocked-down condition) Nut, bolts and other hardware Fender Wheel Muffler Headlight & Taillight

1.

1.

Speedometer Wiring Harness and other electrical components (to be produced in-house in 2013) Lock set Seat Handle set Shock absorber (to be produced inhouse in 2014) Mirror assembly etc.

1.

1.

1.

1.

1.

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Measurement of the Buildings with structural description Runner Automobiles Ltd Engine Assembly Shed : Pre-fabricated : 180 ft x 100 ft x 20 ft ( Length X Wide x Height); Area: 18,000 sq.ft Press Shed : Pre-fabricated : 241 ft x 119 ft x 45 ft ; Area : 28,679 sq. ft Welding Shed : Pre- fabricated : 366 ft x 50 ft x 20 ft; Area : 18,300 sq. ft Old Painting Shed: Pre- fabricated : 160 ft x 100 ft x 20 ft; Area : 16,000 sq. ft I) New Painting Shed: Pre- fabricated: 200 ft x 280 ft x 24 ft; Area : 56,000 sq.ft Ii) General Store (half part of New Painting) : Pre – fabricated: 200 ft x 280 ft x 24 ft; Area : 56,000 sq.ft Assembly Shed : Pre-fabricated : 266 ft x 160 ft x 20 ft; Area : 42,560 sq.ft I) Ware House (Finished Goods Store): Pre- fabricated Two Storied Building (Gr. Flr.) : 195 ft x 150 ft x 16 ft: Area : 29,250 Sq. ft ii) Office : Pre- fabricated Two Storied Building (1st. Flr.) : 195 ft x 150 ft x 16 ft: Area : 29,250 Sq. ft Guest House : Two-storied R.C.C Building : 30 ft x 50 ft ; Area : 1,500 Sq.ft Generator/ Sub station : Two-storied R.C.C Building : 93 ft x 21 ft; Area: 1,953 Sq. ft Residential Building: Six storied R. C. C Building : 96 ft x 50 ft; Area : 4, 800 Sq. ft

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mosqu e

New painting shop

Engine assembly

CKD store proposed

Press shop

Painting shop

Assem bly shop

Residential building

Guest house

Wel ding sho p

Warehouse/ admin

SCHEMATIC DIAGRAM 12/6/2017

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PRESS SHOP

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PRESS SHOP

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The press shop

Mechanical press machine Lathe machine

An inside view of the Press Shop

Hydraulic press machine

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The weld shop

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PAINT SHOP Painting flowchart for plastic parts Pretreatment

Paint booth-2 (Final coat)

Flash off time

Phosphat e compone nts

Flash off time

Drying

Load compone nts and check

Paint booth-1 (Primer coat)

Unload compon ents & Pre-Q.C.

Final Q.C.

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Painting is known to be the heart of Automobile Industry, and it has to take place with utmost accuracy and specification. RAL has left no measures undone to ensure proper quality and accuracy of painting. At present RAL has two paint shops (Old and new paint shop). The new paint shop has been constructed recently to cope up with the increasing production load. Mainly 9 parts of a motorcycle are being painted in this section. Besides there are order from other companies to paint their products.

Fuel tank Chassis Rear fork Double stand Side stand Foot peg Foot rest Faring Side covers

Load compo nents in basket

Degre asing

Water rinse

Derustin g

Water rinse

Water rinse

Phosp hating

Water rinse

e compo nents from weldin g

Passiv ation

Drying

Read y for painti ng

Pre-treatment flowchart

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Load compo nents and check

Pretreatme nt

Phosph ate compo nents

Putting

Q.C.

Primer Coat

Rough Cutting

Primer Coat

Silver Coat

Clear Coat

Paste Sticker

Final Coat

Oven

Final Q.C.

Fuel tank painting flowchart Ready For Delivery

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Ready for Quality Control

Assembly 12/6/2017

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Delivery section (Outside view)

12/6/2017

Delivery section (Inside view)

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Dealer pays to the corporate office account

Corporate office sends a delivery order to RAL

Delivery section of RAL checks for availability of ordered products

If not available

If available

Ask production unit to manufacture new motorcycles

Simplified flowchart of delivery section Arranges the motorcycles for delivery

Check engine and chassis numbers and make a gate pass

Load motorcycles into delivery trucks

Number keys and motorcycles so that they do not get mixed up

00

Cover the products properly and pack gift items (If any)

Make receipts for government taxes

Delivery trucks leave from RAL to the delivery address

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ATLAS BANGLADESH LIMITED

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VIEW INSIDE THE SITE

ENTRY

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STORAGE

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WELD SHOP

ENGINE AEMBLY

By Susmita Biswas 12/6/2017

Sathisusmitabsathionline@yahoo.c om

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ENGINE ASSEMBLY AND ASSEMBLY

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ASSEMBLY LINE

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CASE STUDIES (INTERNATIONAL)

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Hyundai Motors Plant , Chennai, India.

Plot No. H-1, Sipcot Industrial Park, Sriperumbudur, Tamil Nadu 602105, India

COMPARED TO RUNNER Welding section

Welding section

Assembling section Assembling section

Tata Nano Plant , Gujrat , India.

Assembly Plant

Nano car

Industry view

National motorcycle museum, UK http://www.nationalmotorcyclemuseum.co.uk/

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perspectives Model of 1980

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GREEN COURT 12/6/2017

CONFERENCE HALL

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FINDINGS : • • • • • •

•

•

12/6/2017

A CLEAR PROCESS FLOW MAINTAINS INDUSTRIAL CHAIN NO PARKING FACILITIES FOR RAL EXISTING FACTORY PLAN HAS BEEN MADE BY MAINTAINING THE PROCESS FLOW. THEY HAVE VISION FOR MOTORCYCLE MUSEUM AND TEST TRACK BUT THEY DO NOT HAVE ANY. ATLAS BANGLADESH LIMITED HAS NO SUCH PROCESS FLOW IN PLANNING, LACK OF PRESS SHOP, PAINT SHOP AND THE FUNCTIONAL BUFFER. BANGLADESH HAS NO MOTORCYCLE MUSEUM RIGHT NOW NOT EVEN IN ASIA NO SUCH MOTORCYCLE MANUFACTURING PLANT WITH MUSEUM. THE SITE HAS ENOUGH SPACE FOR DESIGING THE MOTORCYCLE MUSEUM AND MANUFACTURING PLANT.

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ISSUES TO BE ADDRESSED IN THE DESIGN PROPOSAL

• • • • •

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A CLEAR PROCESS FLOW MERGING WITH SITE AND SURROUNDINGS NOISE CONTROL AND TRANSPERENCY IN THE CHAIN LINE WHILE DESIGING THE MAXIMUM HEIGHT AND SPAN LIMIT SHOULD BE KEPT IN MIND.

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concept

SUSTAINABLE DESIGN

GROWTH GREEN

CUSTOMER SATISFACTION

STRATEGY BUILDING

ECOLOGICAL FOOTPRINT

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FINAL DESIGN ( PLANS,ELEVATIONS,SECTIONS)

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ADMIN BUILDING

RACING TRACK

INDUSTRY BUILDING

STRUCTURAL EXPRESSION

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PRESS SECTION

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ENTRANCE

MOSQUE

BEAUTY OF GREEN

TEST TRACK 12/6/2017

By Susmita Biswas Sathisusmitabsathionline@yahoo.c om

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COMMUNITY BUILDING FOR LABOURS

PAINT SHADE VIEW

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STRUCTURAL EXPRESSSION

SAND AND WATER TESTING

BANGLOW

GUEST APARTMENT

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ELEVATION VIEW

By Susmita Biswas Sathisusmitabsathionline@yahoo.c om

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CONCLUSION RUNNER AUTOMOBILES LIMITED HAVE VISION TO MAKE A FURTHER DEVELOPED AND LARGER MANUFACTURING PLANT WITH TEST TRUCK AND MOTORCYCLE DISPLAY ,WHERE THEY WILL SHOW THEIR PREVIOUS MODELSAND HOW THEY HAVE DEVELOPED THE WHOLE SYSTEM GRADUALLY.THE SITE HAS ENOUGH SPACE TO DO. SUCH A DESIGN.AS A THESIS PROJECT I THINK THIS PROJECT HAS POSSIBLITIES IN DEVELOPING THE INDUSTRIAL IMAGE OF THE COUNTRY IN EVERY ASECTS OF ECONOMIC INDUSTRY DESIGN. THE MAIN POINT IS IT IS A COST EFFECTIVE SOLUTION WHICH RESULTS INTO 33% LESS IN TOTAL ECONOMIC COST.THE TESTING TRACK IS IN PROGRESS ON THE REAL SITE.I HAVE BEEN WORKING ON IT SINCE 2014.A CIRCULAR TESTING TRACK IS IN PROPOSAL.

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BIBLOGRAPHY http://www.nationalmotorcyclemuseum.co.uk/ http://en.wikipedia.org/wiki/Motorcycle_history http://www.totalmotorcycle.com/future.htm http://www.runnerbd.com/ral/ http://www.bikebd.com/runner-automobiles-manufacturing-motorcycles-in-bangladesh/ http://www.archdaily.com/66446/automobile-museum-in-nanjing-3gatti-architecture-studio/ http://www.designbuild-network.com/projects/bmw/ http://www.totalmotorcycle.com/future.htm http://inventors.about.com/od/mstartinventions/a/motorcycle.htm https://www.google.com.bd/search

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THANK YOU

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