Here is the summary of the information that I gleaned from my factory tour:
I learned that I was not going to learn when the 2017 models would be announced.
I learned that you could not take photos inside the factory.
I learned that there were 2017 models being assembly-tested somewhere in view in the factory, but I sure didn't notice anything that looked different than the 2016 models.
I learned that the factory area was a lot larger and the testing equipment was a lot more sophisticated than what existed during my last tour in December 2012 - plus a new building has been added to the factory.
I learned that the standard factory Zero vehicle output is between 15 and 17 units a day, with 17 being the goal.
I learned that factory will be installing all of the wiring for the Power Tank units, so that that intricate work will not have to be performed by your dealer. And I believe that I heard that the entire Charge Tank units would be installed at the factory. In both cases, you would be pre-ordering the PT and CT models from your dealer and they would be built to order within a week and shipped to your dealer, upon quality testing. They would arrive in about a week, depending upon the distance from the factory to your dealer.
I learned that the factory uses a whole lot of Delta Q chargers to charge up the batteries for testing and for installation into the production bikes. Also the batteries in the new bikes are sent out fully charged and will likely not be needed to be topped off by the retail dealer. Also, the batteries will stay fully charged for a long period of time, without the on-board charger being needed to be plugged in.
I learned that a lot of attention is paid to waterproofing the battery cases and their individual BMS boards. Each battery case is carefully sealed, the boards coated in waterproofing compound and every battery spends at least 10 minutes in a water shower tank to be sure that they are completely waterproof.
I learned that the swing arm must be removed to replace the drive belt, but that it is relatively easy to do, requiring only the disconnection of the rear shock from the swing arm and the removal of the swing arm from the frame.
I learned that the aluminum frame and swing arm assemblies are hand welded by a Chinese company who builds the components to Zero's specifications. The frame only weighs 22 pounds.
I learned that there are 6 specific ABS programs in use, one for each of the Zero models, which were developed through collaboration by both Zero and Bosch. They are specifically designed for the bikes' weight, tire type, usage, etc. If you modify your Zero, such as by changing the wheels or tires (as an example) the ABS may not function as intended. Also two Zero factory engineers spent about 1.5 months in Germany getting the ABS programming just right for each model.
I learned that Zero continues to manufacture the mil-spec bikes (MMX?) and there was one that was being built for a foreign military service on a stand. Interestingly it contained a switch that allows the battery packs to be fully drained by using the final 10% available in the battery pack in an emergency. While this might kill the batteries, it is better than having the rider suffer a similar fate.
Finally I learned that the factory has only 135 employees, world-wide. Which to my mind is a pretty efficient operation.
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Topic: Zero 10th Anniversary Reunion (Read 2024 times)