Optimizing Operational Processes in Bicycle Testing: A Case Study

Menezes, Joana; Nadais, Gil; Almeida, Jorge; Farinha, José Torres; Mendes, Mateus

doi:10.3390/pr13051482

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Open AccessArticle

Optimizing Operational Processes in Bicycle Testing: A Case Study

by

Joana Menezes

¹

,

Gil Nadais

²,

Jorge Almeida

¹,

José Torres Farinha

^1,3,*

and

Mateus Mendes

^1,3

¹

Coimbra Institute of Engineering, Polytechnic University of Coimbra, Rua Pedro Nunes-Quinta da Nora, 3030-199 Coimbra, Portugal

²

Abimota, Rua Ramiro Soares de Miranda 133, 3750-866 Águeda, Portugal

³

RCM2+ Research Centre for Asset Management and Systems Engineering, Rua Pedro Nunes, 3030-199 Coimbra, Portugal

^*

Author to whom correspondence should be addressed.

Processes 2025, 13(5), 1482; https://doi.org/10.3390/pr13051482

Submission received: 26 March 2025 / Revised: 3 May 2025 / Accepted: 7 May 2025 / Published: 12 May 2025

(This article belongs to the Special Issue Applications of Artificial Intelligence Technologies in Energy, Manufacturing and Automatic Control Processes)

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Abstract

Testing bicycle components is an essential procedure for guaranteeing quality and compliance with legal requirements. The tests are performed following normalized procedures, involving specialized equipment operated by qualified technicians. This study analyses the processes carried out in a Mobility Laboratory, with the emphasis on optimizing the assembly process for fatigue tests on bicycle frames, simulating the cyclist’s pedal stroke. Data were collected and analysed. The diagnostic approach adopted took into account the application of Pareto’s Law, thus enabling a structured and detailed assessment of the organization’s current situation. Data analysis and the adoption of lean tools revealed the process could be optimized and the costs brought down taking advantage of appropriate management methodologies and opportunities for improvement. A set of initiatives were proposed to increase operational efficiency and reduce the tests’ non-value-added activities by 31%.

Keywords: lean manufacturing; lean tools; process optimization; bicycle testing; operational processes; quality control

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MDPI and ACS Style

Menezes, J.; Nadais, G.; Almeida, J.; Farinha, J.T.; Mendes, M. Optimizing Operational Processes in Bicycle Testing: A Case Study. Processes 2025, 13, 1482. https://doi.org/10.3390/pr13051482

AMA Style

Menezes J, Nadais G, Almeida J, Farinha JT, Mendes M. Optimizing Operational Processes in Bicycle Testing: A Case Study. Processes. 2025; 13(5):1482. https://doi.org/10.3390/pr13051482

Chicago/Turabian Style

Menezes, Joana, Gil Nadais, Jorge Almeida, José Torres Farinha, and Mateus Mendes. 2025. "Optimizing Operational Processes in Bicycle Testing: A Case Study" Processes 13, no. 5: 1482. https://doi.org/10.3390/pr13051482

APA Style

Menezes, J., Nadais, G., Almeida, J., Farinha, J. T., & Mendes, M. (2025). Optimizing Operational Processes in Bicycle Testing: A Case Study. Processes, 13(5), 1482. https://doi.org/10.3390/pr13051482

Note that from the first issue of 2016, this journal uses article numbers instead of page numbers. See further details here.

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Optimizing Operational Processes in Bicycle Testing: A Case Study

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