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Stream/Area:
-
Subject:
-
Paper ID:
IJSREM67264
Volume:
10 |
9 |
Sep 2026
Pages:
1-6
Publication Frequency:
Monthly (12 issues per year)
License:International Journal of Scientific Research in Engineering and Management follows the Creative Commons Attribution 4.0 (CC BY 4.0) License, allowing free use and distribution with proper attribution.
Mechanical Engineering
Sau Sundarbai Manik Adsul Polytechnic, Chas, Ahilyanagar, India
Mechanical Engineering
Sau Sundarbai Manik Adsul Polytechnic, Chas, Ahilyanagar, India
Mechanical Engineering
Sau Sundarbai Manik Adsul Polytechnic, Chas, Ahilyanagar, India
The electric two-wheeler industry is rapidly developing in India due to increasing demand for energy-efficient, low-emission and economical transportation. Manufacturing electric scooters and bikes involves several precision assembly operations in which production efficiency and quality control play an important role. This research paper presents a case study of selected assembly operations associated with electric two-wheelers at Kinetic, Ahilyanagar, with particular emphasis on tail light assembly, cluster sub-assembly, quality inspection and the vehicle assembly line. The study examines the sequence of operations, material handling, component fitment, fastening, electrical connections, inspection procedures and final quality verification. Tail light assembly requires correct positioning, connector engagement, fastening and functional testing. Cluster sub-assembly requires proper mounting of the instrument cluster, electrical connector connection, display verification and dimensional alignment. The assembly line integrates these sub-assemblies with other vehicle systems such as the chassis, battery, motor, wiring harness, brakes, suspension and body panels. Quality-control techniques such as Poka-Yoke, visual inspection, torque control, functional testing, first-pass inspection, defect analysis and traceability can be used to reduce assembly defects. The study identifies important quality parameters and suggests improvements in workstation ergonomics, standardized work instructions, error-proofing, digital traceability and end-of-line testing.
KEYWORDS
This research presents a study of production and quality practices associated with electric scooters and bikes, focusing on tail light assembly, cluster sub-assembly and the vehicle assembly line at Kinetic, Ahilyanagar. The study demonstrates that quality cannot be achieved only through final inspection. It must be built into every stage of the production process. Correct component identification, standardized assembly, controlled fastening, connector verification, functional testing and end-of-line inspection are essential for reliable electric two-wheelers. Tail light assembly requires particular attention to mounting, connector engagement, fastening and illumination testing. Cluster sub-assembly requires accurate mechanical mounting and verification of electronic functionality. The integration of Poka-Yoke, 5S, Kaizen, standardized work, torque monitoring, digital traceability, SPC and systematic defect analysis can help improve both production efficiency and product quality. Future research should use actual Kinetic production data to quantify improvements in cycle time, rejection rate, first-pass yield, rework, defects per vehicle and assembly-line efficiency.
1. Kinetic Engineering Limited, manufacturing and infrastructure information. 2. Kinetic Engineering Limited, company publications and investor information. 3. Automotive Industry Action Group, Advanced Product Quality Planning (APQP). 4. Automotive Industry Action Group, Production Part Approval Process (PPAP). 5. ISO, ISO 9001 – Quality Management Systems. 6. IATF, IATF 16949 – Quality Management System Requirements for Automotive Production and Relevant Service Parts Organizations. 7. Automotive and electric-vehicle manufacturing research literature. 8. Technical literature on electric two-wheeler production and battery-electric vehicle systems.
Publication Date
9/13/2026
Peer Review Type
Double-Blind Peer Review
Review Rounds: 2
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Conflict of Interest
The authors declare no conflict of interest related to this research work.
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