“As long as it runs, I don’t really care who makes the engine,” may be a common refrain amongst snowmobilers. Though many snowmobilers are passionate brand loyalists, I would bet that only a few fully appreciate the complexity and engineering that goes into producing the engines that push them through the snow so efficiently.
I was intrigued by the possibility of touring the Rotax engine plant in Gunskirchen—a small suburb of Linz, Austria. Rotax, now known as BRP-Powertrain GmbH & Co KG, has been building snowmobile engines for Bombardier since 1962. In other words, Ski-Doo has never had another engine supplier since J. Armand Bombardier invented the first commercially viable snowmobile back in the late 1950s and early 1960s.
With a vacation trip to Austria on my agenda, and after much back and forth with Ski-Doo’s public relations department, I found myself standing in the bright early morning sunshine, on the Linz Bahnhoff (train station) platform awaiting the arrival of the Uber Pasching train to Gunskirchen.
The tour begins
Upon my arrival in Gunskirchen, I was whisked through the village’s winding streets by a Turkish cab driver to the Regionales Innovations Centrum (RIC) a fancy name for the Rotax factory. Once inside the massive building it is quickly evident that this is more than an engine manufacturing facility.
According to a corporate brochure, “The RIC is best described as a facility which houses a unique collaborative network of individuals who combine their superior theoretical know-how and practical knowledge to create efficient powertrain technologies of the future. Considered the 'innovation and education engine’ of Gunskirchen, the RIC plays an important role in the economic and cultural growth of the region by providing job opportunities while attracting a diverse and highly educated group of individuals from all over the world.”
I was welcomed to the Rotax factory by public relations co-ordinator Alexandra Reisinger, who in turn introduced me to Anton (Tony) Stranzinger, one of the key managers at the plant. He explained that the RIC was a consortium owned 75 per cent by BRP, 24.5 per cent by the Municipality of Gunskirchen and .5 per cent by the local Oberbank of nearby Wels. In addition to being an ultra-modern factory—completed in 2009—the centre is also a training and education centre for BRP and the surrounding community.
I happened to arrive just in time for a shift change. I was quickly caught up in the stampede of over 1,100 employees heading for home. These highly skilled employees are all involved in the development and manufacturing of innovation 4- and 2-stroke engines for snowmobiles (Ski-Doo and Lynx), watercraft and sportboats (Sea-Doo), ATV’s and roadster (Can-Am), motorcycles (BMW and Aprilia), karts and ultra-light and light aircraft engines.
A hub of activity
I quickly got the impression that this was one very busy facility. This was confirmed when my tour guide pointed out that 143,500 engines were produced here last year. Rotax celebrated building its six millionth engine back in 2006. This production centre is one of two BRP facilities in the world; the other one is located in Juarez, Mexico.
Tony Stranzinger guided me through the entire manufacturing complex. Its multiple assembly lines buzzed with activity as workers churned out engine after engine. He said that 355 engines are completed per shift. Every critical step of the process is carefully documented with a parts list and visualization diagram—all documented on a electronic bulletin board above the assembly line, showing exactly how the procedure is to be accomplished. The assembly line works in teams of four or five people and a supervisor.
Upon completion each engine is hot-tested and a process inspector does a product quality audit to ensure the engine is up to standard. This audit may include a complete disassembly of the engine and a random durability test. All with the view of producing the best quality engines in the industry.
Stranzinger is especially proud of the how each of the production teams work together in so many facets of the assembly process. “Our teams meet on a weekly basis to discuss everything pertaining to their jobs. Safety issues, quality and production targets, problem-solving, scheduling and line linkage are all topics the team will review,” he explained.
Each specific engine has its own unique demands and requirements. For example, an Ski-Doo engine must function flawlessly in extreme temperatures and elevation variants; whereas Sea-Doo engines must function both salt and fresh water situations.
A process of evolution
The biggest transformation in the industry is the switch to four-stroke engine production. Only a few years ago the majority of engines made were two-stroke, but because of heightened environmental concerns, the entire industry has transformed to start producing greener and quieter technology. This meant an entire re-tooling of the assembly and manufacturing process.
This includes introducing leading edge technology that has BRP leading the power sports industry in its drive to lower cost and offer the consumers a greener ride. This pioneering technology involves the plasma coating of cylinder heads. This approach allows for more oil absorption along with a reduction of overall oil consumption, eventually the same technology will also be used in crane shaft and camshaft production. This will be the first power sports application of this particular technology.
“Its all about striking the right balance,” said Stranzinger. “Our customers demand power but they also demand greener technology. Its sort of the same issue as the power-to-weight ratio issue, we are always striving to strike the right balance.”
As I wrapped up my tour, I thanked Tony and Alexandra for the behind-the-scenes look at one of the world’s finest manufacturing facilities. As I waited outside for my taxi to arrive, I glanced across the parking lot and saw a number of specially marked parking stalls. On closer inspection, I saw they were designated for Spyder parking. I hesitate to guess this may be one of only places in the world where Spyder riders get their own parking spots. Just another perk for the employees of the BRP Rotax.
