TWIKE – A lean production facility for optimized processes

The new TWIKE 5 is manufactured in our production facility in Rosenthal. We carry out the final assembly there in our modern production hall. The processes are kept as simple as possible and are significantly less complex than in automobile production. We want to have 500 new vehicles “rolling off the production line” in the coming year.

The TWIKE is a much simpler vehicle than a car and in many respects is more comparable to a motorcycle. We also benefit from this when it comes to production. This is because the final production facility essentially consists of an optimized work platform on which all the necessary final assembly steps are carried out.

Material flows to the vehicle instead of the other way around

While in car manufacturing the vehicle flows to the material via a production line, with us the material flows to the vehicle. In contrast to car manufacturing, we also don’t need a paint line, which saves us a lot of space and energy. For the complete production of the previous TWIKE 3, we previously needed a 250 square meter hall. For the changeover to the production of the TWIKE 5, we have added another spacious 300 square meter hall.

All components required for final assembly are manufactured by experienced suppliers who can look back on many years of expertise in the automotive sector. After delivery, the components are added at pre-assembly stations and assembled into larger assemblies. Examples of sub-assemblies are the battery, the aluminum frame, the drive module, already completed with the camber-active rear axle and the 3-in-1 synchronous drive, as well as the front axle, the windscreen frame with roll bar or the canopy. The pre-assembly stations allow the completed assemblies to be tested for functionality.

Production is designed for 500 new TWIKE 5s per year

The actual main assembly then takes place on two work platforms optimized for this purpose. The pre-assembled modules are delivered there at two-hour intervals and each vehicle is completed within eight working hours. Specific customer requirements are then fulfilled in a separate studio area. This customizing is designed in such a way that it can also take place at a supplying partner.

Next year, we want to produce ten new TWIKE 5s per week. Our target for the following 12 months after the start of series production is 500 vehicles. However, demand for the new TWIKE 5 is significantly higher. We currently have around 1,700 pre-orders. With the experience we are gaining from the production of the TWIKE 5, we want to reduce production costs in the future. The follow-up model will then be offered at a lower price and produced in larger quantities.

At the same time, we are prepared to accept a certain loss of performance for the vehicle, which is currently designed for a top speed of 190 km/h. This is because we believe that the demand for a mobility offering such as TWIKE is significantly greater and that if we can reduce production costs with the experience gained over the next year, we can appeal to a broader market.