Low Cost Manufacturing Methods (PDF)

LOW-COST MANUFACTURING
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Abstract
Electrification has been considered as the most viable alternative to the fossil-based sources of
energy as it reduces effects on the environmental degradation(Cherry et al., 2009). This has made
a tectonic shift towards electrically powered cars which are mushrooming in our big cities and
towns. Electrical scooters are in the family of such cars which has championed the innovation
using a lead-based battery for its electric power supply(Chou and Hsiao, 2005). In this report, we
review the various components of the electrical scooters their effect on the environment,
economic value additions that can be tapped in to improve their acceptance by many countries.
The report employed some case studies to analyse the method of production of the electric
scooter which are linear and suggest areas of the production which could be made circular to
reduce the effect on environment of some of the components of the scooter which they were
created to conserve since they are viewed as green method of transportation compared to the
fossil-based counterparts which have a larger carbon footprint(Hsien and Lee, 2001, Tso and
Chang, 2003). The report further analysis the market share of the various scooter manufacturers
and the method of production they utilize to achieve a circular mode of production which has
been the talk of the various global conferences which suggests that the circular economy model
of production will save mother nature from some human activities which include ozone layer
depletion and soil conservation. The report finally concludes with a summary of the various
components of the electric scooter that be recycled rather than being wasted and suggests to the
company various approaches to achieve this recycle which will benefit the company by
producing at low cost while maximizing profit from the sales of the scooter. The company also
remains compliant to some of the regulatory bodies that protect the mother nature from being
depleted (Hsien and Lee, 2001).

Introduction
Several scientists, organization and the policymakers have discussed in major global conferences
on the best way to reduce the carbon footprint of the current carbon-based
automobiles(Johansson and Luttropp, 2009). The solutions rest with the use of electrically
powered automobiles such as e-vehicles and e-scooter to replace the conventional vehicles. This
goodwill from the policymakers so a remarkable production of battery-powered cars and scooter
to act as proof of concept that really the carbon-based cars can actually be replaced (Platt et al.,
2014).The work started in 2010 with now many global manufacturing agencies have joined the
electric powered cars bandwagon. Despite few success, the uptake of this new machines has been
generally on a lower scale and people wonders if they will really compete for their counterparts
which are based on carbon. Even with the ever-increasing global fuel prices, the electric cars
have not been able to penetrate this automobiles industry. Scooter however has been gradually
catching up in its uptake since they are ideally used for a short distance in urban
cities(Schroeder, 2011). They can typically travel a mistake of about ten kilometers. Their circuit
system is powered by a rechargeable battery which is either based on the lead or lithium metals.
A new debate has emerged on the linear economy model of producing this electric scooters. The
lead-based scooter are side to be a double cutting edge. Despite reducing environmental
degradation by being a green source of energy, scientist have expressed concerns on the lead-
based scooter which is said to be very poisonous to human beings if not well disposed of. Several
suggestion have been made to to production models of this scooter and most electronic
components, The paradigm is shifting to the new circular economy which in theory ensure
component that can be recycled is taken to a recycling plant where treatment is done and then

introduced to the production chain as input. This method is going to be discussed in the report to
establish how the company can re-engineer their production strategies to accommodate this new
economy model of missing cost while maximizing profit(Weiss et al., 2015).
Literature Review
China is the leading manufacturer and exporter of e-scooter than any other Asian country thanks
to their technological advancements and favorable government policies (Weinert et al., 2007a,
Cherry and Cervero, 2007). There has been an outcry from the e-scooter users that the design of
some is so poor due to their limited speed, limited driving range, and less comfort while using
them leave alone their high pricing. This has been a direct reason why its acquisition in some
countries. The report tries to analyzing the Chinese method of e-scooter production in the
methodology and suggests a way to incorporate them in the company. Poorly designed battery
unit has led to underperformance of some scooter especially in on a rainy day. This was not only
a major problem for South East Asia but the negative public perception of the e-scooter due to
the massive failure of those scooters sold in the late 1990s(Tso and Chang, 2003).
Table 1Indian Scooter Sales 2017
Models 2016-17
Honda Activa 2759832
TVS Jupiter 613817
Hero Maestro 378347
Hero Duet 266223
Suzuki Access 265181
Honda Dio 264516
Yamaha Ray 213312
Yamaha
Fascino 182028
Heor Pleasure 146404
Honda Aviator 108683

2016-17
Honda Activa TVS Jupiter Hero Maestro Hero Duet
Suzuki Access Honda Dio Yamaha Ray Yamaha Fascino
Heor Pleasure Honda Aviator
Figure 1 Indian Sales distribution 2017
There is generally an influx in sales of e-bikes in the EU with a record sale of about 904,000
vehicles. This represented a 5% European market share and a 2% global share. The largest
destination markets include Germany and Netherlands(Weinert et al., 2007b). With a whopping
sales ranging from 410000 and 192000 respectively. A peculiar difference exists between the
models sold in China and their counterparts in the EU(Shang and Pollet, 2010). The Chinese
models use a lead-based battery to power its power supply unit while their counterparts in the EU
are equipped with a lithium-based batteries for its power supply. The latter are more expensive
but with a high energy capacity of up to 140Whkg-1 thus gives them more long life cycle. The
economy prediction has suggested that the global sales volume may reach over 40 million by
2015(Fairley, 2005). Although the potential of larger e-vehicles being manufactured are less
likely. In the EU alone, scooter sales have reached 15000 which is a share value of 1 %globally.
The American market nor the Asian’s have penetrated the market of the mid-sized vehicles.
Another forecast suggests that the global sales of e-scooter and other two-wheeled vehicles may
reach about 4.3 million by 2015 but this value can only by 10% with the current fuel prices.

From the data above, it is estimated that the capacity of the battery of the e-scooter and other
two-wheeled electric vehicles fleet is (125 ±42 GWh)1 will pass the global-based fleet which is
(4±2 G Hh) by 30. Although there is no a direct correlation between the technology of the battery
and battery size, its illustrated below that the size of market share and its respective technological
advancement among the e-vehicles(Fishman and Cherry, 2016).
Environmental performance
General Considerations
A typical scooter does not have an exhaust pipe tailing it but it is well equipped with a power
supply from batteries which are either based on lead or lithium. The former is a major
environmental hazard to human beings if not well disposed of. Contrary to the known belief of
vehicular pollution, the impact on the environment caused by this scooter is during the
production stage, recycling treatment and during the power generation. Some manufacturers
have shifted to locate their plant outside major urban reach to keep away the hazardous chemical
used in the production of these new e-vehicles. Such due care has a potential to reduce the
environmental impact to the humans. The only serious concern the amount of energy consumed
by this new beasts. Their usage if not controlled could increase the energy used and come with
some serious environmental crisis(Kotter, 2013).
Economic performance
There is a general parity between the price ranges for both the Chinese models based on the lead
battery to those of EU based on the lithium battery. The Chinese model has a market value of
100€ as of 2012 while their EU counterparts have a market price of about 560€ as of 2012.
German sold their two-wheeled machines between 2400±1300€. Based on the 2012 data. But
larger models can cost a whopping 14000€.

It is estimated that Chinese models have been declining in their real prices at a rate of 8 ± 5%,
this represents an inflation rate of 30% in price between the years 1999 to 2005. This decline in
prices has hit Chinese models thanks to the decreasing cost of production which has been made
possible by cutthroat competition, large-scale economies of scale, the circular economy model in
production. The major cause of the significant disparity in the pricing of various models in single
rest with the battery technology since it represents the largest production cost. The circular
economy model has potential to level this parity by enabling the manufacturer to recycle some
parts of the power supply and obtain some inputs for the next line of production instead of
purchasing new inputs for every production line. This has potential to conserve the environment
since less lead nor lithium shall be emitted to the environment in their harmful state.
Social performance
The impact analysis of the e-scooter has many variables tides to it. First the region’s social and
economic environment and the terrain not to mention the general climatic condition. The general
market penetration by e-scooter, their mode-shift.This is summarized in the figure below
Figure 2 Electric scooter social effect

The impact o these e-scooters on the urban infrastructure is generally the same compared with
their counterparts in the carbon niche but the only peculiar difference is a great reduction in noise
pollution which the carbon-based ones are well known for. The above is summarized below(Chiu
and Tzeng, 1999),
Urban mobility and Infrastructure
The e-scooter and the conventional two-wheeled vehicles share some characteristics in terms of
the provision of a door service, they generally require less parking space and they provide the
fast and reliable transport mode in urban cities. The speed seems the most important factor
considered by the customers who have a preference for the e-scooter to the other transport
modes. Despite this promising merits, there is likely a major effect on electricity supply. The
onboard power supply becomes handy in this scenario but they require frequent recharging. Most
cities lack adequate recharging facilities due to the limited power supply from the national
grid(Colella, 2000).
Impacts on public health and safety
The introduction of the e-scooter has greatly reduced pollution especially the air and noise when
they replace the traditional modes of transportation. Users of these new beats also benefit from
the cardiovascular effects of this reduced pollution. A major problem the e-scooter have solved is
ensuring the mobility of the elderly and physically impaired members of the society remain
mobile as possible. However, there is no innovation with no demerits, the e-scooter is not an
exception to that written law. Operational hazards associated with the e-scooter is inevitable
thanks to the high acceleration speed and absence of noise from the engine. Safety concerns are
the major issues with the regulatory bodies who insist the manufacturer must implement good
safety standard prescribed by the authorities. Several innovations have been suggested to help
improve their safety. This includes but not limited to

 Substantial reduction in weight by replacing the lithium-based power supply battery with
the less weight lead base.
 Ensuring the non-discretional minimum noise is implemented t aid in enhancing
audibility and to a greater extent visibility.
 Most towns have established a dedicated infrastructure for their usage to help reduce
speed clashed with the conventional ones.
 Authorities to implement speed limits for their engines.
The above literature has exploited in dept the current situation of our e-scooter and looked
through various design categories that can be implemented to achieve a circular mode. To
better understand the parts which are potential for recycling the methodology below will
explain in greater depth the internal working of the scooter especially the engine part which
is the key element in the e-scooters(Mohan, 2002).
Methodology
The company e-scooter are no different from the standard requirements of the e-scooter. The
detailed parts of the e-scooter are divided in the following major components which shall be
discussed hereinafter,

The various parts perform a specific function and all work in collaboration to help the e-scooter
in motion(Khateeb et al., 2004), the majors component include
1. The electrical part
2. Structural part
3. Motion system
4. Power Train
The Electrical part
This is perhaps the most important component of e-scooter since it the one responsible for power
supply to make the scooter be in motion. Contrary to the traditional vehicles, the e-scooter lacks
a fuel tank, this new scooters use either a lithium battery or lead battery to power its electrical
subcomponents. This has replaced the fuel tank. This is again the part that most mechanical
engineers have expressed interest that they can be recycled to enhance the circular economy
model as proposed by most opinion leaders and decision makers(Dalke and Raut). The main
components such as the lithium battery or the lead battery are very harmful to the human and
hence its disposal needs a new paradigm shift from them being considered as wastes to be being
considered an important input in the next cycle of assembly after they have gone through some
recycling plant to decompose the several components from the electrical components.
This component is further subdivided into two subsystems based on their functionality,
1. Electrical subsystem
2. Signaling subsystem
1. Electrical subsystem

This sub-system is responsible for the whole wiring of the e-scooper from the power
supply to other sub-systems that require electrical energy to function. Its main
component is the lithium or lead-based battery energy supply which in most cases is
rechargeable. The power generation uses the principle of electrolysis using the anode,
cathode and electrolyte combination to generate clean energy. This is transported to
other component using this subsystem(Itou et al., 1998).
i. Signaling system
This sub-component is mainly used for the logical control of the e-scooter from the
programs that control the indicator signal lights and other basic indicators. This sub-
system is crucial for the e0-scooter safety requirements since it helps other road users
don’t crush with the e-scooter when making diversion or braking(Sirbu, 2017).
2. Structural Component
The structural component is mainly made of the body, frame, chassis, and seat. The body is built
with light materials to enhance it acceleration speed while riding it. The body is well balanced
with two wheels to reduce friction on the road thus enhancing its overall speed. The chassis
houses the engine part thus protecting it from the mechanical and environmental damages that
may occur while it is in motion. The seat is well fitted at a greater altitude to make it comfortable
to have a clear view of the road. This also reduces fatigue to the operator(Hughes and Baldwin,
2001).
3. Motion System
This is the crucial component for ensuring the kinetic energy produced by the electrical
component is well balanced and controlled to enhance the safety requirements of the regulatory
bodies. This component has five sub-components namely,

i. Steering system
ii. Wheels and tires
iii. Suspension
iv. Breaking system
v. Transmission
4. Power Train
This sub-system is the powerhouse of the e-scooter. It converts the stored energy into
kinetic energy. The most important sub-component is the lithium and or lead battery
which provides the power supply for the other subcomponents hereinbefore explained.
From this analysis, the e-scooter system is currently undergoing the linear economy of
production where the used component is written and no recycling is done to use them as
inputs. This method of production has cost many manufacturing companies a lot of
pennies and our is no different. It is in this regard, that the report analyzed each
component and made suggestions on what can be done to the contemporary component to
make them circular as possible. Making them circular is advocated due to its know merits
that stretches from lowering the cost of production and reducing environmental pollution
from some of the wastes products especially the lithium and lead-based batteries which
are very harmful to the humans(Sheu, 2008).
Results and Analysis
E=scooter is the green alternative mode of transportation that has not been fully tapped due to the
higher cost of manufacturing which is reflected in higher prices per unit. Despite China using a

lead-based battery to for powerhouse power supply for their scooter, the methodology has been
discouraged by opinion leader that it pollutes the environment due to bad waste disposal methods
leaking poisonous lead metal to the human beings which is very poisonous metal. The analysis of
the various e-scooter parts brings some light at the end of the tunnel since they can be recycled
thanks to the circular economy model. The components which are particularly interesting is the
power supply which is discussed below among other recyclable components(Hershaft, 1972).
Proposed Components: Power Supply
Several proposals are hereinafter proposed to replace the traditional lead-based power supply
which is particularly an environmental pollutant. First, the companies who insist on the lead
battery need to have proper recycling policy to ensure there is a complete life cycle of the metal
decomposition. This can be achieved by liaising with the government recycling plant to reduce
the metal to its individual metal like iron and cobalt which are profitable when sold and can be
used to produce more lead for the next cycle of production. This method is not only cost-
effective but also an environmental conservation methodology which will make the company
compliant with the various regulatory bodies. Another approach is to use lithium-based battery
component which is relatively expensive but less environmental pollutant. The lithium can also
be taken to a recycling plant to reduce its presence in the environment. The recycling will
produce some other core metals from the lithium. This includes the nickel metal and iron which
can be used in the subsequent cycle to produce some new e-scooters. This will lower the cost of
production in general and conserve the environment(Berzi et al., 2016).
Conclusion and Recommendation
E-scooter is a revolutionary invention that has promised to ensure all the carbon-based
automobiles are phased out of our roads. Despite community support, opinion leader support and

the major global superpowers support the innovation, there has been a generally lower
penetration of this next-generation invention. This is attributed to the higher cost of production
using the conventional linear model. The report aims at providing a better understanding of this
sorry state of affairs and deduced that the circular economy model shall be particularly the best
approach to reducing the cost of production since it will enhance reusability and recycling of the
e-scooter components thus not only reducing the cost of production but also conserving mother
nature(Liu et al., 2015).
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