Inside a Motorcycle Factory: Exceptional Engineering & Super-fast Processes | FD Engineering
Inside a Motorcycle Factory: Exceptional Engineering & Super-fast Processes | FD Engineering
Human Ingenuity at Work - Mega Airport, Extreme Flights & Hospital Secrets: • Human Ingenuity at Wor...
The BMW plant in Berlin-Spandau has been one of the most important international locations in motorcycle construction for 47 years. Two-wheelers made here are traded worldwide. The product range of the Bavarian automobile manufacturer includes a variety of models, including agile cross-bikes, sporty cruisers, and eco-friendly electric motorcycles. Special wishes? No problem. Bikes that go beyond the usual standard version can also be made to measure in Spandau.
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“Engineering: the branch of science and technology concerned with the design, building and use of engines, machines and structures.” So says the Webster definition. Our newest Free Documentary family member Free Documentary - Engineering is all about engineering - and bringing our community the best documentaries on engineering.
At the age of 17 I had the opportunity to have a personalized tour of that plant for an entire day the year was 1978! The material comes in one end and motorcycles come out the other! Several things blew me away, one was at break time, a person with a kart selling food items and beer, yes beer was sold I’m not kidding (only in Germany) the other was the engine assembly area. It was a large U shaped table/ area that started at one end with empty cases and at the other the nines would go through a door and put on one of three test cells the timing was amazing. The last one was the pinstriping, they three women hand pinstriping the tanks and if any type of mistake was made (very rare) they would throw out the tank, but that was true of any part of a bike! They never tried to repair anything in those days, if it wasn’t perfect it did not go on the bike! It’s a memory I will never forget!
I spent a semester abroad in Munich (1970), and at break time we were offered beer and white sausage, at 10am! We were amazed -- the Germans took it very casually. Only one beer per student, but it was a big 32 ounce glass. German engineering set the standard for the rest of the world. If you take a look at movies made here in the U.S. in the 1930's and compare them to movies made in the 40's, you will see a dramatic improvement in sharpness of the screen image. This was due to our appropriation of German technology in the making of camera lenses. Germany has always led the way in manufacturing genius. The quality of their products set the standard for the rest of the world.
@@garygruber1452 There is much your country could learn from Germany, or most other countries. But you won't.
I was stationed in England in '75 & '76, purchased a 1976 BMW R60/6, picked it up in London, road all over England & Scotland. Rode through France, Monte Carlo, Italy, Switzerland, Germany (Munich, but had I know where the MC factory was, could have visited there) on to Nederlands to ferry back to England... That was an Amazing time....and that same BMW motorcycle is in my garage today!
@@Katchi_Like what for example?
The U shape is a lean manufacturing idea. Lean manufacturing is particularly related to the operational model implemented in the post-war 1950s and 1960s by the Japanese automobile company Toyota called the Toyota Production System (TPS), known in the US as "The Toyota Way"
I love how the sealant machine at 6:42 makes a mess right as the narrator says a human couldn't do it as precisely.
😂 I liked that too😅
Yet a human does it perfectly precisely at the Japanese Yamaha factory... Lmfao.
The machine does it perfectly. Right up to the point where it shoves some sealant into the engine😂
Whaaaaat? There was no mess, only a tail of sealant behind the applicator, but that did not get into any unwanted areas.
It's a twist on the Heisenberg principle - works perfectly accurately and predictably, until someone wants to look at it.
Been a qualified bike mechanic and spent many years working in different dealerships, nothing beats the quality and performance of a Japanese bike, Europe’s bikes and even UK bikes have many issues and the price of parts! Not for me! I spend my money on Japanese bikes.
Good for you, but to each his own.
My experiience with Japanese bikes is the parts are obsolete in just a few short years. There is no aftermarket for those parts, so the used ones are canibalized. Unlike HD's which have a great support aftermarket
39:34 😂😂😂
@@martincvitkovich724 we're talking bikes here.
KTM/Husky/Gas-Gas are the better brand of MX and Off-Road bikes now.
Well that was great. When I was a teen I met Burt Munro in Christchurch New Zealand at a race meeting. I actually had a chat with him and yes saw his bike. I don't know how he could ride that thing it was so close to the ground. I also raced my bike on the beach at Invercargill where he did his work. It was a timed quarter mile I think. I stalled at take off silly me and was disqualified. Lovely days for me touring the country on my bike with mates. Cheers.
The BMW motorcycle production videos are the best in cycledom. I do prefer their un-narrated versions, however. I ride a BMW so this is especially meaningful to watch. Fabulous industrial engineering in setting up a plant like this one. Incredible.
Got a chance to tour this facility back in 2018, mighty impressive.
Very cool video. Personally I'd never buy a BMW bike. My 08 Zx-10 has been through hell over it's 15k miles. Only issue was the voltage regulator that Kawasaki covered via recall. Literally change the oil, race, change tires and enjoy. Oh... I had to replace the clutch cable one time. Every friend that had a BMW always had issues and messed up our rides.
45k on my BMW. Change the tires, brakes, and fluids and renew the clutch.
I met chaps in England in the mid '70's with 200k-300k miles on their old BMW Boxers....but they are simple machines comparatively
The way they make the big end by laser scoring them then cracking them apart is genius. I learned something. It will be tragic when all this engineering beauty is replaced by a battery and a motor.
But current battery technology is actually worse than internal combustion engine's so in all honesty not going to happen for a good while yet. Tree huggers can cry into there carrot juice iff they wish but lithium batteries are stuffing up the world more and my diesel will in its lifetime before the owner even signs the log book
I know here we are evolving with the combustion motor, i mean really bringing out every inch of power possible and ride freindlly, i doubt 60 years ago theyd see the amazing machines of today being made, and the crazy tree huggers want it no more, i do think its going to be some time before they get there way but they eventually will so hang on to those early muscle cars and bikes because they are going to be worth millions one day and the oil giants have a good bit of pull so until theyre defeated either by no more oil to be drilled or idiots with pea size brains which ever comes first, im just glad my life time got to experience the V8 and V twin rumble, nothing like it
In December 2023 I had booked a few days in Berlin to see the Christmas Markets. I then found that BMW Motorrad offered factory tours and there was one during the time I was in Berlin, so I booked it. You don't get to see the engine manufacturing shop but you do get to see the bikes being assembled and some of the test stations. For anyone interested in manufcaturing or motorbikes, it's well worth it (IMHO). The BMW motorbike factory is in Spandau on the outskirts of Berlin
I watched a youtube video of the #1 Chinese Motorcycle Manufacturer Chin Shin. It was a single cylinder 250 cc bike. The guy put the exhaust system on in less than 10 seconds. I can't guarantee it stayed on the bike after the customer rode it but it went on quick!
90% of the comments are angry over grammar, or talking trash about BMW. LOL... dudes need to relax. Its just a video about manufacturing. If you split hairs this much, how can you even ride a motorcycle? frekin chill
Not liking a BMW is "splitting hairs"?? 🤔🤨
Fascinating. I learned a lot and enjoyed every minute.
By using the K5GSXR as a template; BMW hit a home run the 1st time out in 2010. It was Bike of the year too (‘10). This bike is the reason why the Big Japanese 4 went back to drawing board and made their bikes better than ever. Any year S1K is a solid choice for road/track. Most pick it if only 1 bike were in the garage. Nothing made 178whp in 2010 (999cc). Heated grips was a 1st on a SS from factory too.😊
Part of being a biker is having a lovely sounding engine AND being able to switch off from the world n not having loads of data & connectivity from the world thrown in your face. The only thing you want is to have things that'll make your ride safer n that's it.
The K46 hasn't been produced since 2018. So this video is at least five years old. Bring us the production video of the K67 please.
What a fantastic documentary i loved every second of that
I Am a Harley guy but i must admit bmw goes all out building these.great video
Hmmmm🤔, an "online" 4 cylinder engine. BMW must have a new secret weapon😅
Copied directly from the gsx1000
Equipped with "Conrads"!
Someone allways takes the bait
Internet of things
With Bluetooth final drive !
This should end the soft vs hard break in discussion. Dude was absolutely ripping on it as soon as it left the assembly line lol
BMW isn't the end all, know it all, of engine technology. They have their way, and others have their way. Put it this way, I've NEVER seen an owners manual for ANY internal combustion engine powered vehicle that states in the owners manual to "absolutely rip on" the brand new vehicle the second it leaves the lot. In fact, a new Corvette's engine ECU limits the power it can produce for the first 500 miles, and THEN it opens up and allows full power. Just because some schmuck at the factory rips on the bike right as it leaves the line, does NOT mean that it is the proper way to break it in. It was most likely done because a video crew was filming it. I had a 1000+ h.p. big block built for one of my drag cars. The builder didn't simply strap it to the dyno, fill it with oil, start it up, and immediately start making 1000h.p. pulls. He ran it in for some time, heat cycled it several times, and changed the oil, before the pulls started.
@@davelowets I was at The Bologna Ducati Factory back in 2019, I watched a Panigale taken straight off the Production line to the glass dyno at the end, it was revved to the red line in every gear and held flat out in top for around 20 seconds. It was warmed up though.
Yu aren't the end all either@@davelowets I think BMW knows more than you.
it was rev'd without load for probably less then a minute. just pumping air.
He only took it up to less 1/2 of it’s advertised top speed. I wouldn’t consider that ripping. Plus it was only for a short period of time.
Fantastic mechanical engineering and good documentary. No word, shot or time was wasted, just like efficient work pace and use of time in the factory. 10 stars 🌟
The U shape assembly line was invented by the Japanese after visiting Americas straight lines. On a U line you can do your job then another one on the other side of the product.
@@fukhue8226 Very efficient and intelligent
I still say all the machines, robotics and how precision they have to be. Moreover the folks that keep all that infrastructure in order blows my mind. Hats off to those fine people.😂❤❤
This was like a big huge BMW commercial. Hope you were paired well.
Great video. Very detailed and with great filming and narration
Documentary says 8 days ago but a meticulous knows this was at least 4 years ago. Headlights
And the outdated instrument cluster.
I saw this video somewhere else several years ago. Still re-watched it though. A bike is still a bike no matter what flavour you prefer.
I like the asymmetrical headlights. Gives it “personality”
Tank lady needs a pay raise
Takes me all day, to change a tire. Now I really feel inferior.
You will have to pick your game up mate 😂😂
@@paulbarnes6124 Old split rims, that occasionly get rusted/ stuck to the rim, which makes for a worst case scenario. They can be pretty stubborn.
Fascinating stuff 👍
Enjoyed this very much.☺️☺️
Quite an improvement over my 1954 BSA 650CC Golden Flash.
So much for the liberty a motorcycle use to inspire
Super interesting video and probably similar to what goes on in any of the modern motorcycle factorys. What differs most about BMW vs the major Japanese manufacturers is seen at the very end of the video; shipping their expensive product in a shrink-wrapped see-thru metal framed container. Back in the 80s when I worked at a Yamaha shop that had BMW as a side-line, they shipped them in wooden containers that were open about 2' in the middle and only covered by plastic, sort of like a box-kite is made, but horizontal. Still have a bunch of the straps that were used to hold the bikes in place. I think their philosophy is that if the freight-forwarding employees can see what their handling, they'll be more careful not to stick a fork thru the container. Gotta wonder if it works.
The conrod manufacturing was awesome. Thanks for sharing. Great doc overall!
Tester has the dream job. I think the testing is automated now.
If BMW could be more competitively priced to the Japanese bikes I’d love to have one. I sold BMW cars 20 years ago. But I bought my 2023 Hayabusa in October it is as refined and powerful and I got it brand new marked down to $15,300. You’ll never see a BMW priced like that.
A Hayabusa is a boat anchor compared to a BMW S1000RR.
@@vxe6vxe6 Your ignorance of nuance is showing child. This from someone who rides a KLR comical.
At 31:32, the (automated?) narrator says, "Filters in the last 65 meters of the conveyor belt are responsible for the fuel tank, the fairing, and the electronic system", and the video's transcript confirms those words. As "filters" don't do anything in the assembly process, I would think that the intended word may be "fitters", referring to the humans who fit parts onto the bikes. Interestingly, the word "filters" sounds different from the other words in the video, as if it was patched in as a correction.
Very astute observation. I heard it too, but didn't give it a whole lotta thought, but have heard similiar mis-pronunciations in other videos that were narrated by someone who obviously was just reading a script.
Yes very astute observation. Your mother must be proud.
Perfection....
Kawasaki have 4 divisions to it that work on their motorcycles the Germans can’t compete
It's like their preparing themselves for something big.
14:45 faces stiff competition from Japan, and... the United States? We could only wish, but not really. Great documentary no doubt, just a few years old.
I had a chuckle at that too. AI generated script much? I suppose Austria and Italy will one day build a competitive sportbike 😐
@@rjanzen3810Ducati...
Fun fact: this plant had to add another shift just to keep up with all the bikes Max Wrist crashes
This is where the worker becomes a robot and timed to the second. What happens if you need a dump?
They probably have a robot to take care of that so the worker doesn't have to leave his station. I think they call it the wipeyurasswhileyoukeepworkingschmittunstink.
@@parsonscarlson7984 😅😅😅
The future of motorcycling is dire. Connectivity is a disease in cars and bikes. its just an abolition of skills, responsibility, engagement and fun.
What?? 🤔
I love the looks and performance of bmw bikes. I will probably never own one because of the expensive parts, specialty tools/software, less reliable than Japanese bikes and limited dealer support. Same with bmw autos.
what an uninformed opinion. I ride a RnineT and all I've ever had to do is change the oil every season. There's a reason the most popular and produced police bike in the world is the BMW R 1250 RT-P.
@@rwa96 I hope you have a nice savings for those major repairs coming soon😁
I think you have a misguided opinion of BMW Motorrad, at least I don't ride a total POS vtwin harley.@@opichocal
🐝🏁 Great video 💯👍 Time to work on a fastest Ebike! BMW, there here to stay.🤔
They demonstrated e v bikes when I was in the Island years ago, they lapped at 100 mph but could on do one lap.
Right on 👍
2:00 "...1 every 65 seconds" Well NOW we know why the BMW s1000RR has been having SO many issues. Maybe you should SLOW DOWN a bit and do some QC stuff before shipping the product? Just an idea...
238xs per sec up and down on piston is amazing, if the eyes could see everything working internally it would look as tho nothings moving yet its revolutions are crazy fast
Very nice video.
In 73, I tested my 71 Rd 350, 2 stroke, under " real world" conditions. At 16, in the mountains, with a good buzz on, a hit of acid, and a few beers. How I lived this long, not sure. I ride an R1 now. Cheesh.
I know someone just like that😂 except now I ride a Kawasaki Z 400 way below the radar
clear varnish, or clear epoxy? I've never heard of varnish being sprayed on a motorcycle.
Amazing
very good sir!
This is cool.
And a beautiful bike it is too.....
So cool.
So the initial drivetrain break-in is going all out!
300 kph comes out to 186.411 mph. That's movin'!
Installing the “Conrads” 😂
there seems to be a problem with the sound quality on this video, at about 32.0 mins is it goes a bit quiet and after, at several places, then at 47:26 mins it disappears completely!.. BMW would not allow such poor quality to leave their assambly plant so why is this video depicting theit manufacturing allowed to do so??
Copyrighted music I’m assuming. Had to be edited after posting
That is a big engine for a motorcycle. 🙂
Yeah not too sure about that future they have laid out for us! Awesome stuff though from bmw wish they were easier to work on though!
Yet Yamaha #1 in reliability. I know. I had a 03 R6 and now MT10. Still, great motorcycles these BMWs.
Yamaha regularly tops many reliability rankings while BMW typically lands somewhere in the middle of the reports. If people purchased motorcycles strictly on reliability then all the Italian brands should have been out of business decades ago.
Honda too!
@@thekenthouse6428Absolutely. Style and trick parts were Italian hallmarks but despite high retail prices, you often couldn’t rely on them.
6:41 Funny how he says it could not be done so quickly and *_cleanly_* by a human hand, while the robot is making a mess at that very second, as well as a bit messy finish as well.
Looking at the title, I thought this was going to be about Orange County Choppers.
My dream job. Being a test rider on all of the continents for the bike's research.
Powersports are in trouble for a more than a decade now. What a shame
Wow, impressive work as an employee. It's incredibly soothing, and robots would be your companions.
"ride gently for the first 1000km" - guy on the rolling road at the end 👀
I always wanted to design a bike where the block is the frame and everything bolts to it, Swing arm front shocks pegs etc.. Then i would build the turbo into the block and it would be oiled and cooled as one system.
Bought a new K75 back in 93. Nothing but a lemon. Was told it had a porous casting of the head. 🤔
I want one!
Amazing factory, if I can even call it that old terminology!!!😂😂😂😂😂😂
You said that bmw face stiff competition from Japan and usa. It's not usa it's UK triumph.
Wait... so it is built beginning to end in two hours, but once the line is full, and going, how many bikes are produced per hour or day?? I imagine that depends on how long the line is?? Or can we say the line is "two hours long"?? I'm saying this bc Tesla is producing a car even sixty (?) seconds... that is what they said in one of their meetings.
800 scooters and motorcycles every day
one two-wheeler every 65 seconds
Lead time is the time from the start of final assembly to the end of final assembly for the same motorcycle. Takt time is the time between two motorcycles coming off the end of the assembly line. The number of stages is at least the Lead time divided by the takt time. The average stage time is about 80% of the takt time, since it varies, and you want to avoid stalling the whole assembly line. Welding the twin spar aluminum frame was cool.
@@MikusVilsons 800 schoolers AND motorcycles every DAY, that is 24 hours a day... meaning 800/24....33.3333333333333 ??? Right? But the question was how many MOTORCYCLESSSSSS a day or hour... I do thank you Sr, I do... but why can no one give a straight answer?? for someone familiar with the factory it SHOULD roll down the tongue easily. Or am I asking the wrong question bc there are other factors?? Just read the answers and see... it should be a single whole number; or a range between two numbers like, How many motorcycles a day?? between 600 to 900 or something like that. Why is that so difficult?
@@ggrthemostgodless8713you said "bikes" not motorcyclesssssss. That's why it's so difficult. *scooters. schoolers lol
i was a tech and test rider for BMW Motorrad for a while in the US. My first time test riding the S100RR i immediately asked my boss "where do we turn in my speeding ticket and what am i supposed to do with my erection" lol. Those bikes are nuts, had no clue they went together so fast!
No you weren't. 😅 So full of shite
neat
Correction. The plastic rods are for protection, to not Knick the crankshaft journals.
"I work at the BMW high-performance engine plant.." "Oh, wow. What do you do there?" "Umm, I plug holes in the engine with rubber caps, and insert 2 long bolts so that the crane can pick it up." "😒🤨"
Humans are brilliant
Only because they've been made in the image of God. (Genesis 1:26,27)
Just a few out of billions
Driver? How does one drive a motorcycle? Is there a steering wheel?
The woman putting stripes on the bike has crazy eyes.
Nothing like having a brand new bike after the nice young men get their hands on it.
lol
Sounded like I was going in and out of water the whole time
inline, online, con rod, con rad...
Still waiting on mine...
I know these bikes are for few people, but I'm happy to see that some things can't be made in China or India.
4:29 "...four little ends..." wrong, these are the connecting rod BIG ends, the little ends go onto the gaugeon pins in the pistons (shown here at 3:38). 5:32 Cylinder head goes on without valves then miraculously 5sec later they found a way to be installed, with springs no less. Who does your editing?
I want to know what the job tiers are. Who gets paid the most and who are the beginners?
The worker with the most tattoos have the seniority and get paid the most unless it's a Japanese or Harley tattoo.
I just visited a motorcycle factory in China. They also said they are biggest in the world.
Good job. Now swap it all over and start making them electric. I want it cheap too! I’m poor!
Couldn't squeeze out 1 more for each, to get it to 200 HP, 1L, 300 KM/H?
That would take it out of the street-legal market in many countries.
RR bay bee 😎
Don't know how old this video is, but the RR has 210BHP, not 199BHP.
Very impressive. However: no one can explain why these powerful racing machines (an many others) are being allowed to run on public rds. They belong on a racetrack, not public rds. A lotta people who buy them, have no experience of racing on closed circuits. Its a lethal combination...
Is there a naked motor bike version? Too many body plastics hide engines worth showing.
So sorry the females had to wear their work clothes during the filming of this video
Conrods and crankshafts cast?😮 I hope not!
20:40 - Dynanometer?😂
I doubt that any politician will agree to remove the requirement for a crash helmet on a motorcyclist. Remember the C1 in some markets.
or as most people refer to them, connecting rods, DYE-NA-MOM-EH-TER is the machine that measures torque and power output. varnish? that's a new one. is it a wooden bike? i need to re-watch it. i had no idea.
My favorite was the “online” 4-cylinder engine. You wouldn’t download an engine
"One bike made every 65 seconds". Why does the dealer charge 2 hours and $300 to change my oil? Limp mode is even quicker, happens in a millisecond but takes 8 months to fix.
I didn't see the part where theybuild in reliability.....
They build one every 90 minutes. I dismantled mine in 9 seconds after cartwheeling it over the tyre wall racing. 😅
And to think, you did it without BMW special tools.