Inside the EBIKE Factory
4 assembly lines · in-house battery production · 6,000 m² workshop · 15,000+ units monthly
Volume Without
Compromising Quality
Four parallel assembly lines build e-bikes, e-scooters and trikes with a shared quality system. Every unit passes 26 inspection points before it leaves the floor.
- 15,000+ units per month, expandable to 25,000
- Mixed-line flexibility: run 5+ models in the same week
- Torque-controlled tools with digital traceability per VIN
- Peak season capacity reserved for OEM partners
Machines That Make It Happen
Battery Pack Line
In-house pack assembly: cell sorting, spot welding, BMS programming, charge/discharge aging tests up to 72V systems.
Automated Frame Line
Robotic welding cells and powder-coating ovens for frames of 6061 aluminum and high-tensile steel.
Final Assembly Lines
4 parallel lines with torque-controlled electric tools, digital work orders and per-unit quality passports.
Test & Inspection Lab
Motor dyno testers, brake test rigs, IP54 water testing and battery thermal chambers (see Quality page).
A Typical Day on the Line
Every shift follows a standardized takt time across all four assembly lines. Below is the production rhythm for a standard city e-bike — from bare frame to a cartoned unit ready for the container.
| Station | Operation | Takt Time | Operators |
|---|---|---|---|
| Station 1 | Frame Prep — headset press, bottom bracket threading, cable routing, decal application | 90 s | 2 |
| Station 2 | Welding — robotic MIG welding of motor bracket and battery mount to frame, seam inspection | 120 s | 1 + robot |
| Station 3 | Wheel Lacing — motor hub spoke lacing, rim truing to ≤0.5 mm lateral runout, tire mounting | 105 s | 2 |
| Station 4 | Battery Install — BMS functional test, pack insertion, connector torque check, waterproof seal verification | 75 s | 1 |
| Station 5 | Brake & Drivetrain — caliper mount torque at 18 N·m, rotor alignment, chain tension, derailleur limit set | 95 s | 2 |
| Station 6 | Electrical QC — throttle response, brake cutoff, display readout, lights, horn, walk-assist function | 85 s | 1 |
| Station 7 | Final Test — dynamometer roll at 0-25 km/h load ramp, IP54 water spray at 10 L/min for 3 min, insulation resistance ≥1 MΩ at 500V DC | 240 s | 2 |
| Station 8 | Packing — handlebar removal, foam cushioning, moisture barrier bag with desiccant, carton sealing, serial number label, pallet stacking | 100 s | 2 |
Total cycle time per unit: ~910 seconds (15.2 minutes) across 8 stations. Each station's torque and test data is digitally logged to the unit's quality passport. Daily output target: 480 units per line across two 8-hour shifts. Actual output varies by model complexity — folding e-bikes average 520/day; cargo e-tricycles average 220/day due to larger frame handling time.
How Your Order Moves Through the Factory
The customer-facing timeline is covered in How It Works. Below is the factory-side view — what happens inside the building from the moment your PO is confirmed.
Order Confirmation & BOM Freeze
Your PO is entered into our ERP with a frozen bill of materials. Cell, motor, frame and component suppliers are booked against the confirmed delivery date. Any specification change after BOM freeze moves the order to the next production slot — our engineers flag this before you sign, not after.
Material Kitting
All inbound parts pass IQC on arrival and are staged in the kitting area 3 days before line start. Painted frames are checked for coating thickness (40–60 µm), battery cells for voltage balance, and motors for winding resistance — each with a traceable batch record.
Line Production & Inline QC
Four assembly lines run in parallel with the 26-point inline inspection protocol. The 120-second takt time means roughly 30 units per line per hour. Random line audits every 2 hours compare live units against the frozen BOM — deviation stops the line, not the shipment date.
Final QC, Cartoning & Loading
Every unit passes the 26-point final check plus a rolling-road functional test before cartoning. Pallets are shrink-wrapped, container-loading photos are taken at each row, and the loading list is signed by both QC and logistics — you receive the complete photo record with your shipping documents.
Book a Video Tour or On-Site Audit
Walk the lines with our export manager on a live video call — or schedule a physical audit at our Shenzhen plant. FOB and CIF terms available.
