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To support their rapid expansion, they recently moved to a larger 50,000 sqft site in Coventry where they could upscale their assembly and testing facilities. This would involve streamlining and enhancing the existing assembly process to increase throughput capacity as well as minimise the requirement for manual lifting. The set-up process for the new factory took three months to complete, ready for Maeving to ramp up the volume of motorcycle production to meet growing demand.

Setting The Scene

Based in Coventry, Electric motorcycle manufacturer Maeving is committed to redefining urban travel by creating beautiful, practical and sustainable electric motorcycles. Based in the heart of the Midlands, Coventry has a long heritage in motorcycle design and engineering and their team have over 100 years of combined experience in the industry. Their unwavering dedication to motorcycle manufacturing excellence, drives their innovative designs across a range of fully electric motorcycles, which epitomise style and combine performance with comfort and practicality.

electric bike

Maeving Electric Motorcycles

The Challenge

Having moved to a larger premises, the enhanced footprint provided the opportunity to streamline the process of motorcycle assembly with a focus on health and safety. L-A-C worked in conjunction with Maeving to fully understand the assembly process and how improvements could be made through the integration of conveyors and semi-automated elements.


The unique nature of the skilled, manual assembly process meant the conveyor design would need to be bespoke and incorporate a number of health and safety features, allowing for one smooth process of assembly throughout each of the defined stages before the motorcycle would be complete and ready for testing.

bike warehouse


Following in-depth discussions, L-A-C designed and installed a fixed length of roller conveyor which included three sections of integrated platens or slave boards – a flat sheet of aluminium – which would act as a solid base on which to fix the motorcycle frame in order to easily and safely assemble the various components required for each model. 


Using an overhead hangman lift to initially place the motorcycle onto the first section of conveyor, the frame is securely fixed with its tyres held in place by red steel jigs. Additionally, the yellow steel uprights hold the frame adjacent to the foot pedals to provide further stability. 


The roller conveyor sections allow for easy and smooth progression of the motorcycle frame from one assembly zone to the next with no need to lift the frame manually.


Underneath the length of gravity roller conveyor there are three lift sections with a foot switch to operate the lift. This enables the motorcycle to be lifted so the assembly personnel can work on the motorcycle frame at a raised height with no manually handling required which also eliminates the potential for physical injury. Additionally, the lift enables the frame to be turned 180 or 360 degrees, which streamlines the assembly process as personnel no longer have to walk around the full conveyor structure to work on the opposite side of the motorcycle. 


At the end of the full assembly process, the motorcycle is unfastened from the holding jig and rolled off the final conveyor section via a ramp ready for internal road testing to ensure all components are fitted and working perfectly. The conveyor section with holding jig and platen is then removed from the section of roller conveyor and transported via rollers to the start of the conveyor line where it is fixed back onto the conveyor starting point for the next motorcycle frame to begin its assembly.

The Benefits

The L.A.C. design has provided Maeving with a highly effective conveyor solution for skilled component assembly, with significant health and safety features integrated throughout the line.


The new conveyor line offers Maeving a number of operational efficiency benefits including increased throughput and integrated lift, rotation and brake capabilities to enhance a seamless and safe process for their motorcycle assembly.


Maeving’s Head of Production Liam Moriarty commented, “Our intent has always been that we are on a mission to spread the joy of riding an electric motorcycle to as many people as possible because we believe they are a faster, cleaner, and more enjoyable way to get around town. The new conveyor solution from L-A-C perfectly aligns with our vision of a high-quality, sleek design, that is safe and practical to use.”

electric bike on conveyor


L-A-C’s team of experts are here to support you from concept to the finished system, working together to design and deliver a bespoke solution that meets your current objectives and future growth expectations, with favourable ROI. 


Across semi-automated and fully automated systems, L-A-C has the expertise and range of products to provide flexible and scalable solutions that will significantly enhance your operations and keep you agile as your business evolves. 


Join us on a pivotal journey towards a more efficient, productive, cost effective and sustainable future with L-A-C’s innovative automation technology solutions.

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