Optimizing Operational Processes in Bicycle Testing: A Case Study

Abstract

Testing bicycle components is an essential procedure for guaranteeing quality and compliance with legal requirements. The tests are performed following normalized procedures, involving specialized equipment operated by qualified technicians. This study analyses the processes carried out in a Mobility Laboratory, with the emphasis on optimizing the assembly process for fatigue tests on bicycle frames, simulating the cyclist’s pedal stroke. Data were collected and analysed. The diagnostic approach adopted took into account the application of Pareto’s Law, thus enabling a structured and detailed assessment of the organization’s current situation. Data analysis and the adoption of lean tools revealed the process could be optimized and the costs brought down taking advantage of appropriate management methodologies and opportunities for improvement. A set of initiatives were proposed to increase operational efficiency and reduce the tests’ non-value-added activities by 31%.