Hausbesuch: Fazua E-Bike Antriebssysteme


Welcome MTB-News, I’m Felix and work for Fazua and we’ll be showing our offices here in Ottobrunn, close to Munich Just follow me, and we’ll take a look at where the Evation motor system is created, who works here, how it all began and how we have now managed to establish ourselves as a viable mid-sized business. If the name Fazua doesn’t mean anything to you, we have developed a slim and lightweight E-Bike motor system that can be beautifully integrated into the down tube and, remarkably, is completely resistance free above 25 km/h which means that sporty riders that want to ride more quickly than that limit can keep pedalling under their own power without being slowed down by the system as you might expect from other more traditional systems. We’ve had a quick look but what we’re going to do, I’m going to introduce you to who ganz who is behind the company, who developed the system and the team that is making sure that we are constantly developing and adapting our system. Just follow me and this is the Product Development team where are engineers are hard at work finding new opportunities to make E-Bikes even sportier as well as improving the design, and making it more modern so that it feels more natural to than other systems. Hi, my name is Philipp and I co-created the company in 2013 and since then have always played a part in our development. That was two of us as founders really starting with the overall packaging and design developing that, and sourcing external motors, external batteries even the electronics were externally sourced to begin with, but we’ve now brought that all in-house and have built up our capacity and we’ve now got eight people here in Product development. Then we’ve got electronics over there, the electronics team harwdware development, software developement, all around the riding software and of course all the ties to our external development partners. We do a lot with electronics with the boards for power supplies, we’ve got all the equipment standing around here we have to test these parts a lot and try things out, that’s really where the magic happens with the system software. Over here we have a second development team, that’s basically our internal development team that works on production equipment and end of line test apparatus or test software, we have an interface that we use for everything to communicate with the motor that we also use in our end of line test stations and here, right at the back we have two more test engineers that test the whole thing to check it’s as it should be. After we’ve taken a look at what Philipp is working on down here we’ll go straight up to our two Managing Directors and they‘ll tell you a bit about the history of Fazua and Hannes will show you how the motor system gets put together here in Ottobrun Now we’re directly in front of Hannes’ office, the inventor and founder of Fazua when this sign is on then he’s usually working on something or inventing something brilliant and we shouldn’t really disturb him. I’m going to knock now anyway and he might have a bit of time for us Hi, I’m Hannes, nice that you’re here. I’d like to show you quickly what we’ve been working on here since we started in 2012 and what we’ve achieved. It’s easiest if I show you our production because you’ll be able be to see clearly what we’ve built up here We’ll start with our receiving department. You can see our logistics where we receive our parts from all over the world They get delivered here and then everything that arrives here gets logged into the system, that happens here where you can see Gitti at work. She logs the items and does a pre-assembly too. Our Production Manager sits here who manages the shift. Then we move on to quality control where all the parts get checked against our QA plan and sorted, and everything that’s fine gets stored and from here, moves on to production. We get the parts from Europe and German, especially the more complex parts like gears electronics, a large part of our injection moulded parts and aluminium casts come from the Far East as well That makes a lot of sense mixing here, because we need to balance the quality with our costs. Here in Ottobrun We produce four modules. What we don’t do is the battery that’s manufactured completely externally and delivered to our customers Here on the production line we can see the final assembly of the drivetrain where the first step is to connect our motor-gear module with our electronics, and then in the second step fit both in the motor housing and finished. It’s very important to maintain traceability of all our individual components and they are scanned into the system in batches or even by serial number and traceability is maintained throughout the production process allowing us to guarantee traceability from the beginning of production all the way to our customers and service Our most important safety feature is the 100 % end of line testing station. All the systems are 100% tested, just those systems that really test at 100% and pass gets packed up and leave the factory. For our final testing two things are looked at, firstly we look at the maximum power and the maximum efficiency. If these two match the expected values we’re satisfied and the motor gets labelled and packaged. At this point the product is basically ready, it’s assembled and tested and it just needs to go through the last step where it’s inscribed with our laser. After that, a quick clean, it gets packed up and once everything is done you can see a lovely brand new Fazua system, labelled and clean and now, I‘ll have to put it back down here so that it can be wiped down again. We’ll continue to our warehouse. Here, everything from production gets stored, this is all the finished parts and whenever we get an order, the necessary parts are picked up here and go to packaging up here Now we’re in the basement, where two modules are screwed together the gearbox and our HMI. Another huge challenge and in the last few months is that we’ve grown the team we’ve got a great team here. This is our ESD protected area which is marked to protect our sensitive electronic components which can be damaged easily. All our workers have ESD protective clothing and also, we do a body scan to check the grounding of them. There’s no exceptions for me either – testing, pass and then we can go in. It’s good because once you’re grounded you can pick up all these parts and take a closer look The mounting of the gearbox starts with preparing the housing and sensors. These parts come from Asia that’s the aluminium casting and gets prepared for assembly We can see here how our assembly engineer is preparing the housing We press in eyelets that ease the tolerances for frame mounting. Upstairs and downstairs we‘ve streamlined the assembly line That means every step takes about 2.5 minutes and with our workers that have been working with us for a while, we can produce up to 220 units per day. Calculating that per year that’s about 30 000 systems. Our facilities here in Ottobrunn were designed for a maximum capacity of about 120000 When that’s not enough anymore, then we’ll have to have a think where our next offices will be. And now to finish, our historical origin, our first ever motor. We actually made this in granddad’s garage. It’s got everything all the drive stuff in the downtube. As you can see, battery, control unit, motor it’s all there. That’s

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how it started. Now of course it’s a much sleeker and finished product. Thanks a lot, see you soon. Hi, I’m Michel, I’m responsible for testing and this is our validation and testing area. We can go inside and have a little look around and as you can see, we’ve got different long-term test stands where we can examine different things like durability and different usage scenarios different loading cycles. While we‘ve got all the long-term testing here where parts are tested 24/7, over here we’ve got various E-Check stations for software validation. We can also load and run different scenarios, constant loads, peak loads, all the things that our customers are likely to experience while out riding. We have another area for testing, that’s just around here This is, what we like to call the Faker which basically does max testing of everything as much mechanical load as we can put on it Okay, I’m Faber, I’m one of the co-founders here, one of the Managing Directors and I’m just going to take you through this part of the building here. There’s lots of bikes standing around here, it‘s kind of important that we we bring in a bit of style with the bikes, here there’s an artwork made by Claudia together with the bike, real nice. These projects are steered by the marketing team in here, in there Felix and Elena. Exactly, unfortunately it’s still a bit bare because we’ve just redone the offices. Exactly, in there is our buying department, be quiet, there’s some hard bargaining going on as you can see, and Saskia sits here. Unfortunately two of the team are in Asia at the moment and are introducing our company out there and looking at suppliers. And then probably one of our most important departments at the back here, and also completely abandoned our sales department but with good reason, you can see our bikes our rental fleet, often in high demand, it’s often relatively empty in sales and everyone is in meeting at the moment, that’s why it’s often quite empty up here, but that’s everyone up here we’ve kind of combined all the important functions on this floor , as far as the slightly drier subject matter is concerned that’s it, and then we’ll go up to to our last stop, servicing I think. That’s where you are, but this isn’t the whole team there’s someone missing, we have another colleague maybe even a few more in Nice depending on how you look at it, they do servicing in French, Italian and Spanish So the most important functions here are the head desk, which is the point of contact for dealers and customers over the phone, and then it’s also the workshop down in the basement which is where we repair things and also, important find out what has has happened, but also the qualifications and certification of dealers, that’s mainly what Julia here does and she also puts together the documentation that dealers need in order to do servicing at their end, just as you’d expect them to be able to do with some of the bigger brands. We’ve just started a big round of teaching and education, which starts, when was it Oli? With our dealer education programme we want to certify as many dealers as possible because we think the investment is worth it, because the better informed the dealers are the easier it becomes for us if a motor needs to be serviced, at the moment we’re at 220 certified service partners in all of Europe and in the next year we’re planning for around 500 certified dealers meaning it will get easier for the end user as well if they ever encounter a problem because they’ll be able to solve the problem quickly. So that would be the end of our tour through the hallowed halls of Fazua hopefully you enjoyed yourselves, if you enjoyed it then why not check out our new products, we‘ve also launch an app together with Komot, that you can find in the app store, you can link your Fazua unit with the app for extended functionalitiy. Then there’s a cut I think… At the press of a button you can convert your 13.5kg heavy E-Hardtail into a sub-10kg normal bike. We’ll keep you updated on our homepage, our Facebook page and our Instagram and we would be happy to hear from you. Thanks for the visit and see you soon