Buzz
Shaping the pipes for ATV production takes six hours. Take a look at more images from the ATV factory.If you've ever ridden an ATV, you're likely familiar with how it works. It's essentially a smaller, simpler version of a car, with an engine, wheels, shock absorbers, and a steering system. But how do these parts come together to form an ATV? We visited the Suzuki Manufacturing of America Corporation's ATV factory in Rome, Georgia, to learn about the process.
An ATV's frame starts as straight pipes. Hydraulic presses bend these pipes into the correct shapes, while robotic plasma cutters trim them to the appropriate length. Each piece takes about six hours to become part of the final ATV.
Pipes of various shapes and sizes eventually form the left, right, top, and bottom of the ATV frame. The smaller components, known as 'kiddie parts,' combine to create the 'mother part.'
Since robot arms can't reach into extremely tight spaces, human welders are still needed for some tasks. A specialized mask shields the welder's eyes from both flying sparks and the intense light generated during the welding process. The mask's window is equipped with a light-sensitive feature that darkens automatically when welding begins.
Once the frames are completely put together and all welding is finished, an automated system steps in to clean, paint, and bake the frames.
After the painting process is done, the components are ready to be pre-assembled. Workers attach handlebars and other necessary parts before sending them off to the assembly line.
At the Rome facility, in addition to producing frames, they manufacture red and black fenders using an injection-molding machine. Some of the black fenders then receive a camouflage coating at a different location.
The machine works by drawing small resin granules through a hose, melting them, and then molding them into the required shape. It applies an impressive 3,300 tons of pressure to form the molten resin.
After the fenders leave the conveyor belt, workers trim them and apply a plastic coating to protect them as they cure. Stickers and logos are applied at another station before the fenders are sent to the assembly line. Different fender designs require specific molds, and these molds are incredibly heavy—moving them requires a 25-ton crane.
Once both the frame and fenders are ready, they are moved to the assembly line. Here, workers use pneumatic and battery-powered tools to install the engine, shock absorbers, fenders, and tires. During our visit to the plant, an ATV took 102 seconds to pass through each station, meaning one ATV was completed every 102 seconds. As of July 2006, the time per station was reduced to 89 seconds. With this speed, the Rome plant is able to produce around 310 ATVs daily, or roughly 80,000 per year.
The final two stations on the assembly line are for inspection and packaging. A seesaw-like mechanism lifts each ATV off the assembly pedestal and sets it on its wheels. Workers fill the gas tank and test the ATV's performance on a drum tester to ensure it operates correctly. The drums rotate beneath the wheels, allowing the vehicle to reach high speeds without moving forward. After the test, employees drain the gasoline. The factory uses between 200 and 300 gallons of gasoline each week for these tests.
Each completed ATV is placed on a wooden pallet. A box is lowered over the vehicle, and workers use industrial staple guns to secure and seal it. A forklift then transports the packaged ATV directly to a shipping truck, as the Rome plant does not store completed vehicles.
Over 250 people work at the Rome factory, but the entire process, including engine and part production at other facilities, involves more than 300 individuals. When you add in the staff who design the ATVs, plan the manufacturing process, and provide other support, it takes over 350 people to produce a single ATV.
We would like to extend our sincere thanks to Alan Horne and the team at Suzuki Manufacturing of America Corporation for their invaluable support in creating this article.
