BCA Basic Masters

venture partner to build their BCA45 coach An Introduction to their specifications. Joint Venture to The requirements were somewhat substantial since BCA was looking for a joint venture partner who would build the Bus and Coach America BCA45 to their engineering plans while allowing BCA staff to monitor the production process and assure quality control. For several reasons, BCA selected the Zhengzhou Yutong Bus Co., Ltd. of Zhengzhou, China. Yutong is highly automated and the largest bus builder in the world. They became interested in this partnership since it has a presence pretty much all over the world other than in North America. This partnership introduces advanced North American market expectations and tech- nologies to Yutong, such as stainless steel construction and EPA 2013 emission con- trols. It also means that the BCA staff is split between North America and China with some people crossing back and forth on a regular basis. Key BCA staff members include Lawrence (Larry) Brennan, as president and CEO. Brennan is a former military officer with past experience with motor vehicle dealership operations as well as operations, sales, marketing, financing and logistics. In addition, he helped achieve the first U.S. reg- ulatory (FMVSS) compliance for a Chinese- built commercial vehicle. by Larry Plachno Photos courtesy of the author unless otherwise noted Canadian-born Andrew (Andy) Fung is a licensed professional engineer responsi- ble for operations, manufacturing, engi- The first production BCA45 coach was photographed at the Yutong plant prior to being shipped neering, research and development and pro- to the United States. Designed specifically from the ground up for the American market, the coach duction. His background includes is 45 feet long, 102 inches wide and will fit through a 12-foot garage door. The standard drive train engineering for Hughes Aircraft and Unisys includes a Cummins engine and an Allison transmission. plus many years with MCI in the areas of design and development as well as after us and Coach America has appeared Work was soon underway in developing sales support and parts. He also has previ- at some trade shows and is announc- and engineering products that meet these ous experience working with Chinese-built Bing the debut of their first production criteria. Plans called for developing a 45-foot buses although in spite of this and his own coach to the North American market. As a coach called the BCA45 followed by a com- personal heritage, he is still learning to speak result, we have received several inquiries panion 40-foot coach known as the BCA40 Mandarin. from readers asking for information on Bus followed by a transit bus. and Coach America. Who are they and Chen Sheng is an electrical engineer by what are they doing? Since the people from A total of three years of work went into training and manages BCA’s China oper- BCA were kind enough to provide infor- developing the BCA45 for the North Amer- ations. He has worked with Toyota and mation and even invite us to see some of ican market. In addition to the U.S. design King Long Bus where he received an “Out- what they are doing, we can share their and engineering, the BCA staff became standing Electrical Engineer” award. His story with you. involved with research and development experiences include heavy-duty multiplex and they also worked with vendors and systems as well as clean energy power BCA was founded in 2010 to develop, partners before following up with road trains. build and sell buses particularly geared for testing. the North American market. Many of the Another Canadian is Jean-François (J.F.) people involved have a strong background BCA is a bus manufacturer with its own Gagne who grew up in the motorcoach in the bus industry. In general, their VIN numbers. Plans are to manufacture or business in the Montreal area as the third avowed goal is not to build an elaborate assemble buses in the United States to com- generation involved in the industry. He bus nor a cheap bus but rather a bus that ply with Buy America provisions as holds a degree in Mechanical Engineering provides good value for North American required by customers. However, since with a minor in manufacturing and struc- bus operators. BCA did not yet have their own manufac- tural design. Prior to coming to BCA, turing plant, they began looking for a joint Gagne worked for motorcoach companies and managed projects for Cirque du Soleil. 20 • National Bus Trader / February, 2014 Yutong builds a wide variety of buses in significant numbers. These units Here, an engine drops down from above on Yutong’s highly automated were noted at the end of one of many production lines. and high-quality chassis production line at the original plant. He supervises design, manufacturing and Yutong lines and something like 500 individual quality control of BCA production. models. Currently, Yutong has a market Zhengzhou is located approximately 450 share of 26.7 percent of the Chinese bus mar- Other key members of the BCA staff miles south of Beijing, China. What became ket and about 12 to 13 percent of the world include Harry Black, CPA, who serves Yutong was originally founded in 1963 as bus market. BCA as CFO and who has more than 20 the Zhengzhou Bus Repairing Factory. In years of public accounting experience. 1985, the name was changed to the Yutong is currently in the process of Robert W. Miller, BCA’s executive chair- Zhengzhou Bus Factory to reflect the expan- building a second huge bus plant they call man and director, is a former commercial sion into building buses. In 1993, the their New Energy Plant. It is already in oper- banking executive who also served as Zhengzhou Yutong Bus Co. was founded ation and will eventually produce 30,000 chairman of TriRod Motorcycles. Another and in 1997, Yutong became the first bus units annually. Both bus plants are located director is Maggie Lau, Ph.D., who has industry company listed on the Shanghai outside of the city in a fairly open area. Both substantial experience in management, Stock Exchange. In 1998, Yutong became the are cities in themselves with their own fire business development, marketing, pro- largest bus builder in Asia. departments, cafeterias for the staff and duction and operations. She currently housing for some staff. Most of the staff serves as vice chairman of the China Cities The Zhengzhou Yutong Bus Co. is a part wears uniforms, workers in blue and qual- Sustainable Economy Development Com- of the Yutong Group that is involved in ity inspectors in red. mittee. Also serving as director is Richard buses, construction machinery, automotive Shepherd, an accomplished executive and parts and components as well as real estate. Technology and automation is very high managing member of On-site Energy Solu- Today, Yutong is the largest bus builder in at Yutong. The company builds its own tions and managing member for Lom- the world with 51,688 buses and coaches chassis for many of its body-on-chassis bardy Cambridge Partners. BCA has a full- delivered in 2012. While many of these units buses. The chassis assembly line is not only time presence in China and the U.S. are body-on-chassis and smaller buses, the high quality but is also state-of-the-art. The numbers are still mind-boggling. The com- Yutong body-on-chassis buses we saw pany has approximately 50 major product were relatively high quality. State-of-the- To improve safety in transporting school children, Yutong has developed Yutong also builds several different types of recreational vehicles. This a line of school buses very similar to those found in America. one is built on an Iveco chassis and has a traditional RV interior. National Bus Trader / February, 2014 • 21 Your editor checks out the engine compartment on the new BCA45. Par- Your editor had a brief opportunity to drive the BCA45 at the Yutong plant. ticularly fascinating were the modulating water valves for heat. The state-of-the-art electronic suspension system provided a very stable ride. art robot arms are used for painting and Yutong was also named Coach Builder of hydraulic fan drive is used for cooling. some of the welding is automated. It is the Year for 2012. Cruise control is standard and a Parker interesting that Yutong uses PPG paint. Multiplex System ties the systems together. Yutong extends the life of its buses made The BCA45 Dual 100-amp alternators are standard as from carbon or mild steel by dipping them are the usual dual 8D batteries. intact in a series of treatment and electro- The BCA45 was designed and engineered coating tanks using a procedure that is by BCA for the American market; it is not an All three axles come from ZF. It is note- automated. existing Yutong, but a clean-sheet BCA worthy that the state-of-the-art ZF inde- design. Because of the quality required, it pendent front suspension system is pro- The diverse Yutong product line includes will be built on Yutong’s Special Vehicle vided. In addition, the BCA45 has both transit buses and coaches but also has assembly line under the supervision of BCA state-of-the-art electronic suspension con- some interesting models. To improve safety staff embedded at the factory. Construction trol with kneeling, high ride and low ride for children, Yutong is working with the gov- and components are essentially state-of-the- settings. ernment to produce school buses that are art in many areas. much like American school buses and are Knorr-Bremse disc brakes are provided even painted bright yellow.

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