All In a Day's Work

It’s all in a day’s work (well it’s still night time inside my body) producing bikes for Tommaso Bicycles. This is my 7th trip to Asia and I still get excited walking down the streets of Taipei, Hong Kong or Shanghai. The first step is to trick your body into the 15-hour time difference. I do this by changing my watch as soon as I get on the plane. I also pick flights that land and get me to the hotel in the evening. This way I go to bed and start getting on the new schedule. After a 14-16 hour flight sleep comes quick.

Overseeing bike production is a fast-paced week to 10 days depending on the amount of bikes in production. I usually arrive to see the final part of frame preparation. The decals and paint have already been approved and a couple hundred bare frames are ready to be dressed with paint, decals, clear coat and components. Production has been scheduled months in advance so when it’s time…it’s time. There is no waiting or delaying the process.

Outside the main manufacturing arm of the factory is a huge room full of ordered parts including derailleurs, bars, wrap, saddles, tires and everything else you need to make a complete bike. Collecting and having a precise inventory of these parts is a massive job and takes a couple weeks and a couple people to complete the task. If one part is missing the production train comes to a halt…that is not good. Standing in a room with enough parts to build a thousand bikes or so makes you wish you brought an extra suitcase or shopping cart!

The first time I walked into a bike factory my mouth fell to the floor. The process is amazing and the people involved are very talented. The skilled hands of the wheel builders can throw spokes through a hub flange in seconds. They actually can do eight spokes at a time! This makes for four quick shots per 32 spoked wheel. Then it is laced up, tensioned and put through a machine to check for tolerances. As you walk through each station there is always action and movement. The artist with the torch welding frames and the masters with the paint guns working the paint booth are something I could watch all day.

Turn the corner and the hand applied decals procedure is an art form in itself. The frames are marked off with masking tape to show the exact spot on the frame for the decal. Then as the bike comes by on a padded hook the decal applying crew pulls the water transfer decals from a large pan of water and goes to work. They line up and apply the decal perfectly while the frame is in motion! I can’t even put a sticker on my bike straight when it is locked down in a repair stand.

Once a frame is finished it goes to the assembly line to be adorned with components. The frame is then placed on the assembly line upside down. The line has seat post nubs that hold the frame in place in the seat tube. This allows the bike to be rotated and worked on from any side. It starts as a frame on one end and finishes a complete bike at the other end. The final touch is pulling the bike off the nub and pairing it up with the proper seat post and saddle.

This is a quick overview of the actions on the production floor. Of course there are many other details that I will gladly share during my visit to Tommaso Bicycle production. Stay tuned!