Harley-Davidson's York, PA Plant as an Example to the World (photos)
Harley may make traditionally styled bike that look like they rolled out of the 1950s, but inside their factory is the latest state of the art production machines. If you are in Pennsylvania you ought to take the tour, but here's a little taste for you.
1. Technology and Innovation
The motor company has come a long way from its Milwaukee shed where the founders handcrafted their first motorcycle. In 1973 a 400,000 square foot assembly plant dubbed, Harley Davidson Vehicle Operations In York, Pennsylvania was constructed, where hundreds of bike per day are produced. Motorcycle production was upgraded and all assembly operations for Softail, touring, CVO, and trike models happen at this plant. Powertrain operation assembly, as well as Sportster, Street, and Dyna production remained in Milwaukee and Tomahawk.
2. The Age of Modern Assembly
The company has come a long way since the beginning, but the overall goal is the same, to produce world class motorcycles designed with the assembly process in mind so different models can be built on the same line. Many other manufacturing operations are performed as well, like making and testing frames.
3. Bare Bone Transformation
Bike start off as naked frames rails and come out a fully assembled bike, complete with any factory customization ordered. This plant has been consolidated compared to the other manufacturing campuses, but daily bike production has increased. Blue-collar employees sometimes work in six to 14 person teams, testing and spot checking ever system and surface.
4. Tobor The Steel Bender
Gigantic hydraulic presses capable of tons of pressure transform sheets of metal into fender, fuel tanks and tailpipes. Robot arms bend and weld tubes into frames and swingarms. Harley-davidson wanted one system for all of its plants, which allows for production to be ramped up or throttled back as needed, saving the company money by allowing most bikes to be made at any plant if demand for one model suddenly explodes.
5. Labor of Love
Actual human technicians add that personal touch that machines can't. Quality control is closely monitored and expected at every step, and bikes are examined for defects in fit, finish and function. Harley's York plant represents an alternative to the mindless, soulless manufacturing of other plants, both American and Japanese.
6. Pick Your Poison
This York plant makes three basic styles of bikes: Touring, Softail, and Trike. But each has about 1,200 customization options, including paint, wheels, handlebars, seats, etc. Even so, a new bike rolls off the assembly line every 89 seconds.
7. The Zenith of Productivity
If you take the tour, you can watch the bikes travel by conveyor to various work stations for attachment of parts. Workers are lined up along a central track that moves the bike from station to station. Each worker has 80 seconds to complete their jobs before the bike moves on to the next. One bike is completed every 89 seconds, using this format.
8. Seal of Approval
Presidents have marveled at the allure of this American Icon. Ronald Reagan, Bill Clinton, George Bush, George W. Bush, and Donald Trump, have all visited Harley plants, or headquarters. They all spoke proudly about Harley-Davidson as an example to the world as innovation and leaders in motorcycle technology.
9. Pinnacle of American Society
In 1903 William Harley and Arthur Davidson built their first motorized bicycle in a shed in Milwaukee; fast forward 114 years, the company is #433 on the Fortune 500. Still headquartered just a block away from the original shed, last year about 7,400 employees built 260,000 Harley's generating over $5.9 billion in global sales. The York Plant contributes 60% of the company's bikes, and ships them all over the world.
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