AL MidSem Report

A Report

on

“The Overall Functioning of Ashok Leyland, Hosur (Unit-1)”

By

Anuj Gupta

Ashwin Bose

Ashwin Jaishanker

Prabhudatta Das

Ronak Shah

Sai Charan P

Vinay Ram B

at

Hosur (Unit-1)

A Practice School-I Station

of

Birla Institute of Technology and Science, Pilani

June 2012

ii

A Report

on

“The Overall Functioning of Ashok Leyland, Hosur (Unit-1)”

By

Anuj Gupta

Ashwin Bose

Ashwin Jaishanker

Prabhudatta Das

Ronak Shah

Sai Charan P

Vinay Ram B

Required in partial fulfilment of the

Practice School-I Course

BITS C221

at

Hosur (Unit-1)

A Practice School-I Station

of

Birla Institute of Technology and Science, Pilani

June 2012

iii

ACKNOWLEDGEMENT

I would like to thank Mr. Ravichandan and Mr. Venkatsubramanyam for providing us this opportunity. I am grateful to the many executives and operators who took time off from their work and shared with us a lot of information about the unit. I express my sincere gratitude to Mr. John.O.J, Div. Manager, Plant Engineering, Mr. R. Srinivasan, Div. Manager, H-series assembly, Shop II, Mr. Deepu Zacharia, Snr. Manager, MDV assembly, and Mr. Joyi J, Snr. Manager P15 machining, Shop 1, for giving valuable guidance and suggestions. I express my sincere thanks to Dr.B.V Prabhu for supporting us and sharing his rich experience with us and guiding us from time to time. I am extremely grateful to the PSD, BITS Pilani, for giving us a chance to be a part of this company.

Last but not the least I am extremely thankful to all that directly and indirectly helped me

in completion of this endeavour.

iv

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE PILANI (RAJASTHAN)

Practice School Division

Station: Ashok Leyland, Unit I, Hosur, Tamil Nadu. Duration: 2 Months Date of Start: 21-05-2012 Date of Submission: 13-7-2012 Title of the Project: The Overall functioning of Ashok Leyland, Hosur (Unit 1). Name: Anuj Gupta. 2010B1A8329P BE(Hons.) Electronics and Instru Ashwin Bose. 2010A4PS033G BE(Hons.) Mechanical Ashwin Jaishanker 2010B1A4770P BE(Hons.) Mechanical Prabudatta Das. 2010A4PS660G BE(Hons.) Mechanical Ronak Shah. 2010A4PS230P BE(Hons.) Mechanical Sai Charan P 2010A8PS388G BE(Hons.) Electronics and Instru Vinay Ram. 2010B3A8453G BE(Hons.) Electronics and Instru Name of the Expert: Mr. Joyi J Designation: Senior Manager, P15 Machining Name of the PS faculty: Dr.B.Vittaldasa Prabhu Key Words: H-series, P15 engine, Shop, Layout

Project Areas: Management of Large Scale Industry, Machining

v

ABSTRACT

Ashok Leyland is one of the largest commercial vehicle manufacturers in India with a

turnover of US $ 2.5 billion in 2011-12. Their vehicles safely carry 70 million

passengers to their destinations every day. The objective of this report is to provide

an overview of Ashok Leyland Unit I located at Hosur, Tamil Nadu. This report gives

a detailed outline about the different shops and units within the plant.

Signature of student(s) Signature of PS Faculty

Date: Date:

vi

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE

PILANI (RAJASTHAN)

PRACTICE SCHOOL DIVISION

Response Option Sheet

Station: ASHOK LEYLAND, UNIT 1 Centre: HOSUR ID No. & Name(s): ANUJ GUPTA 2010B1A8329P ASHWIN BOSE 2010A4PS033G ASHWIN JAISHANKER 2010B1A4770P PRABHUDATTA DAS 2010A4PS660G RONAK SHAH 2010A4PS230P SAI CHARAN P 2010A8PS388G VINAY RAM 2010B3A8453G Title of the Project: THE OVERALL FUNCTIONING OF ASHOK LEYLAND, UNIT I

Code No. Response options Course No.(s) & Name

1. A new course can be designed out of this project

NO

2. The project can help modifications of the course content of some of the existing Courses.

NO

3.

The project can be used directly in some of the existing Compulsory Discipline Courses (CDC)/ Discipline Courses Other than compulsory (DCOC)/ Emerging Area (EA) etc. Courses.

NO

4.

The project can be used in preparatory courses like Analysis and Application oriented Courses (AAOC)/ Engineering Science (ES)/ technical Art (TA) and Core Courses.

NO

5.

This project cannot come under any of the above-mentioned options as it relates to the professional work of the host organization.

YES

vii

TABLE OF CONTENTS

Overview…………………………………………………………...…viii

Ashok Leyland, Hosur (Unit-1)………………………………...xxviii

Shop Floor 1………………………………………………………...xxx

Shop floor 2……………………………………………………….xxxiv

Shop Floor 3……………………………………………….……xxxviii

Shop Floor 4………………………………………………………….xli

MDV Assembly………………………………………………………xlii

Shop Floo 5…………………………………..................................xlv

Shop Floor 7………………………………………………………..xlvii

Shop Floor 9……………………………..……………………………lii

Conclusion………………………………………..…………………..lv

viii

1. Overview

1.1 Automotive Industry

Developing economy’s transportation needs are growing exponentially. As

India’s transport network is developing at a fast pace. Indian automobile Industry is

growing too. All kinds of vehicles are produced by the Automobile Industry.

1.1.1 Indian Automobile Industry includes the manufacture of

Trucks

Buses

Passenger cars

Defence vehicle

Two-wheelers

1.1.2 The industry can be broadly divided into

Car manufacturing

Two-wheeler manufacturing

Heavy vehicle manufacturing units

1.1.3 The major car manufacturers are

Hindustan Motors Limited

Maruti Suzuki India Limited

Fiat India Private Ltd.,

Ford India Ltd.,

General Motors India Private Ltd

Honda Siel Cars India Ltd.,

Hyundai Motors India Ltd.,

Skoda India Private Ltd.,

Toyato Kirloskar Motor Ltd.,

ix

1.1.4 The two-wheeler manufacturing is dominated by companies like

TVS

Honda motorcycle & scooter India (Pvt.) Ltd.,

Hero Honda

Yamaha Motors

Bajaj

1.1.5 The heavy motors manufacturers are

Tata- Telco

Ashok Leyland

Eicher Motors

Mahindra and Mahindra

1.2 Ashok Leyland

Figure 1: Ashok Leyland Logo

6 Decades of business

Existence In over 50 countries

Moving millions of people & goods

Flagship Label of the Hinduja Group

Produce large commercial vehicles

Turnover ~ $2,5bn (2011~12)

AL Buses carry 70 million passengers / every day

Joint Ventures

50:50 (Nissan Motors) – LCVs

John Deere (USA) – Construction Equipment

Continental (AG) Germany – Automotive Infortronics

x

Alteams Germany – High Press die – To cast aluminium

casting components

International Manufacturing Facilities

Prague (Czech Republic)

Ras Al Khaimah (UAE)

1.2.1 History of Ashok Leyland

1947

The birth of Ashok Motors

Founded by Raghunandan Saran, Ashok Motors was set up in collaboration

with Austin Motor Company, England and incorporated on September 7th for

the assembly of Austin cars.

1948

The first A40 assembled

Production began in September at the factory situated at Ennore, south of

Madras, and soon the first indigenously assembled A40 Austin car was rolled

out.

1949

The first A40 assembled

1950

Ashok Motors and Leyland, UK agree to collaborate

1951

Assembly of Leyland chassis commences

The first Leyland chassis assembled by Ashok Motors at Ennore were four

Comet 350-engines tippers sold to the Mangalore Tile Factory.

xi

1954

Government approval for manufacture of commercial vehicles

The Government approved the progressive manufacture of Leyland

commercial vehicles and a license for the manufacture of 1,000 Comets a

year was granted.

1955

Ashok Motors becomes Ashok Leyland

Named after Raghunandan’s son, Ashok, the company was renamed ‘Ashok

Leyland’ with equity participation from Leyland Motors, Ltd.

1967

India’s first double-decker arrives

‘Titan’ - The first Indian-made double Decker with 50% indigenous

components was launched.

1969

A revolution in steering

1970

A specially designed vehicle for the Indian Army

1972

Production target upped to 10,000 vehicles a year

1974

Ashok Leyland’s turnover for the first time crossed Rs. 1,000 million

1976

The Viking appears

xii

1978

A Cheetah bounds into the frame

1980

Hosur plant starts operations

Two major new truck introductions

1982

India’s first Vestibule bus introduced

Manufacturing footprint expands northwards

1990

Technical Centre ready

1992

First Indian auto company to receive ISO 9002 certification

1995

First driver training facility set up

1996

Hosur Plant II inaugurated

1997

The Stallion rides for the Indian Army

India’s first CNG bus launched

2002

Another innovation in alternate fuel technology

2005

First Indian auto company to receive BS 7799 certification

A Stag crosses the border

xiii

2006

Acquisition of AVIA

Agreement inked with Ras Al Khaimah Investment Authority

2007

Joint Venture forged with Nissan Motor Company, Japan

Joint venture with Continental AG, Germany

Carrying the dreams of a nation.

Joint Venture with the Alteams Group, Finland

2008

Joint Venture inked with John Deere, USA

Albonair, GmbH established

2010

India’s first Hybrid CNG Plug-in Bus

Pantnagar plant inaugurated

The U-Truck platform launch

Stake in Optare plc.

2011

A full range player with DOST

Enters the construction equipment space

2012

Jan Bus

U-3723

xiv

1.3 The Wide Reach of Ashok Leyland

Ashok Leyland – Head Office (Corporate)

No.1, Sardar Patel Road, Guindy, Chennai – 600 032

Phone – 044 22206000

Fax – 044 – 22206001

Total Number of Plants = 7

Figure 2: Plants of Ashok Leyland Across India

1. Mother Plant

Ennore, Chennai

135 acres

40% of overall production of Ashok Leyland Group

Manufactures – Engines, Gear Box, Axles & Key

in-house component

Ashok Leyland

Hosur I Hosur II Hosur III Alwar BhandaraEnnore

Ennore Foundries

Mother Plant Est.1948 Commercial Vehicle manufacturing• Lorries (comet 8 )ton• Passenger Busses• AL Engines

• Engine Units (major) • Multi Axle Vehicles• Hipo Dumper

• Cargo Vehicles MDV’s (7-9 ton)• e Comet

Pressing Unit

CNG Passenger Assembly

Machining Plant• Gear Manufacturing• Axles

Sister Concern

Ashok Leyland

Hosur I Hosur II Hosur III Alwar BhandaraEnnore Hosur I Hosur II Hosur III Alwar BhandaraEnnore

Ennore Foundries

Mother Plant Est.1948 Commercial Vehicle manufacturing• Lorries (comet 8 )ton• Passenger Busses• AL Engines

• Engine Units (major) • Multi Axle Vehicles• Hipo Dumper

• Cargo Vehicles MDV’s (7-9 ton)• e Comet

Pressing Unit

CNG Passenger Assembly

Machining Plant• Gear Manufacturing• Axles

Sister Concern

xv

2. Hosur – Plant 1 (H1)

1980- Engine Manufacturing Centre

103 acres

Diesel, CNG Engine, HINO Licensed Engine

Heavy duty & special vehicles

3. Hosur – Plant 2 (H2) + Press Shop

1994, 236 acres

Painting, Finishing & Assembly Facilities

Press Facility (frame side members)

With eye for the future, it has acclaim of

automotive experts

4. Hosur – Plant II A

Cab Panel Press Shop

99 acres

60,000 metre square lawn & green cover

Rainwater harvesting

INR 1350 million – Investment

State of the art facility

210m press shop

5. Alwar Plant – Rajasthan

1982, Rajasthan

Assembly Plant

Passenger Chassis, CNG Buses

6. Bhandara Plant – Maharashtra

Synchromesh transmission

Assembly facility

xvi

7. PantNagar Plant @ Uttaranchal

190 scenic acres

200,000 sq.ms of built up area

Best in class industrial architecture

Latest manufacturing technologies

Highly energy efficient

Remarkably operator friendly

1.4 Ashok Leyland – Competitors

Telco

Volvo

Eicher

Force Motors (Mann)

Chrystler

Volkswagan

General Motors

1..5 Market Share

Figure 3: Market Share of Ashok Leyland

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1.6 Products

Buses

City Bus

Sub-Urban Bus

Inter-City Bus

School & Staff Bus

Special Bus

Trucks

Long haul

Mining and Construction

Distribution trucks

U Truck

AVIA Truck

Light Commercial Vehicle – DOST (`1.25 T)

Joint Venture with Nissan Motors, Japan (50:50)

Figure 4: Awards Received by the DOST

Defence vehicle – Colt & Super Stallion

xviii

Global Alliances with

Figure 5: Global Partners of Ashok Leyland

Power Solutions

Brand name – Leypower

Provides power for running generator sets

Also provides marine applications

It powers the technology for earth-moving equipment, compressors,

cranes, harvester combines and the like.

1.7 Ashok Leyland – Marketing network

• Regional offices – 10

• Areas offices – 18

• Regional sales offices – 19

• Parts warehouse – 7

• Main dealers – 43

• Dealer outlets – 177

• Authorized service centres – 145

• Service bays – 2352

1.7.1 Marketing strategies and plans of Ashok Leyland

New product launches

The company is expected to launch a slew of new products in the markets

which is expected to propel the demand for its products.

xix

Increasing global footprint

The company is now targeting new strategic markets with increased thrust

on the Asian and African countries

Plans to meet the growing needs of the market

The company is constantly reviewing their strategies. They are moving into

higher value added jobs because it becomes very important to engage

workmen fully and also their efficient utilization

1.8 Share Price

Figure 6: Share Price of Ashok Leyland

1.9 Vision

Achieving leadership in the medium / heavy duty segments of the domestic

commercial vehicle market and a significant presence in the world market

through transport solutions that best anticipate customer needs, with the

highest value to – to – cost ratio.

xx

1.10 Mission

Identifying with the customer

Being the lowest cost manufacturer

Global benchmarking of our products, processes and people against

the best in the industry

1.11 Values

We consider our stake holders as our most valuable asset and are committed

to provide full encouragement and support to them, to enhance their potential

and contribution to the company’s business.

The stake holders includes

Employees

Customers

Vendors & Suppliers

Distributors

Share holders

Society

xxi

1.12 Policies

1.12.1 Quality Policy

Figure 7: The Quality Policy of Ashok Leyland

xxii

1.12.2 Environmental Policy

Figure 8: The Environmental Policy of Ashok Leyland

xxiii

1.13 Certifications

1991 – Certification to ISO 9002 Standards

1993 – Certification to ISO 9001 Standards

1998 – Certification to QS 9000

2000 – Certification to ISO 14001 Standards

2006 – Certification to ISO / TS 19649: 2002 & ISO 14001: 2004

2006 – Self Certification Status for Defence Suppliers

1.14 Awards

2006

Energy Efficient Unit Award – CII (All India Basis)

2008

NDTV Profit Car & Bike award 2008 – For CV Manufacturer of the year

2009

Ranked 8th in the Business Today – Mercer – TNS Survey of India’s

best employers – January 2009

2009

Golden Peacock Environment Management Award

Various awards related to quality were won from NIQR, CII & QCFI

xxiv

1.15 Mission Gemba – Work Place Improvements @ Ashok Leyland, H1

Figure 9: Mission Gemba

An empowered Gemba team, armed with skills and information takes full

responsibility for Quality, Cost and Delivery.

Mission Gemba moving toward manufacturing excellence through “New 7

initiatives” + 1:

1. Increase the number of Gemba Units – To improve communication and

participation – currently at 104.

2. EEI (Effort and Ergonomy Index) – To reduce employee fatigue

3. CMI (Cost Management Initiative) – To structure CMI in a standardized

manner Gemba – wise across all units

4. Inventory Management – To maintain optimum inventory levels through

Gemba – wise focus

5. Identification of Critical Machines – To improve OEE and machine uptime

through Gemba – wise focus

xxv

6. Quality systems – To monitor and sustain PPM levels at all Gemba Units

7. 5S – To implement 5S for clean and safe working environment at all Gemba

Units

8. 1 – ISO/TS 16949

Total Employee Involvement

Cross Functional Team

Quality Circles

Small Group Activities

Suggestion Scheme

RISE Recognition

RISE i Recognition

Skill Competition

Gemba Ratna

100% Club nomination

1.16Organization Structure – Ashok Leyland (H1)

1.16.1 Strategic – Plant Level

Figure 10: Plant Level Strategy

Classification - Salary Basis

Classification - Principle Basis

Over all Plant Ashok Leyland

H1

Management

Corporate Category (CC)

96 (4.5%)

Non - Corporate (NC)

357 (16.6%)

Union Category

Monthy Rated (MR)

77 (3.58%)

Daily Rated (DR)

1620 (75.3%)

xxvi

1.16.2 Business Structure

Figure 11: Pyramid Depicting the Business Structure followed at AL

1.16.3 AL – H1 (Personnel & Admin Structure)

Figure 12: Managerial Hierarchy at Ashok Leyland

Chairman

MD/ CXOs

CG 32 - SeniorDirector

CG 31 - ExecutiveDirector

CG 30 - Plant Director

CG 29 - General Manager

CG 28 - Deputy General Manager

CG 27 - Assistant General Manager

CG 26 - Divisional Manager

CG 25 - Senior Manager

CG 24 A - Manager

CG 24 - Deputy Manager

CG 23 - Assistant Manager

CG 22 - Senior Officer

CG 21 - Officer

GM

Mr. Akbar Khan

DGM

Mr.M.Shanavaskhan

Deputy Manager

Mr. Bhaskar

Manager

Industrial Relations

Mr. Padmanabhan

Canteen

Mr. T.Ganesan

Canteen & Welfare

Mr. T.K. Vinayagmurthy

Tranport & Admin

Mr. M Ganesan

Senior Manager -Safety

Mr. A.Pio Fernandez

Manager - Safety

Mr. K.Vijayamaruthi

Divisonal Manager

Mr. S. Ravichandran

Manager HR

Mr. H.S. Sivashankar

Pay Roll - Associates

Mr B.Suganthan

Recruitment

Mr. E. Kannan

Manager HRD

Mr. Venkatasubramaniam

xxvii

1.16.4 Global Business Structure (Ashok Leyland)

MAMANGING DIRECTOR

CFO ED INTERNAL AUDIT

ED PRODUCT

DEVELOPM-ENT

ED HR

ED &

COMPANY SECRETARY

SPECIAL DIRECTOR

BUSINESS PLANNING

ED CONSTRUC-

TION & ALLIED

BUSINESS

SPECIAL DIRECTO

R PLANNING &

PORTFOLIOM

GMT

ED SALES

& SERVICE

ED INTERNATIONAL

OPERATIONS

EDPRODUCT PLANNING

ED MKTG

ED Manufacturing

WHOLE TIME

DIRECTOR & COO

xxviii

2. Ashok Leyland, Hosur (Unit-1)

Land – 102.5 acres

Built up area – 40.66 acres

Greenery area – 19.45 acres

Trees – 1850 Nos.

Total Employees – 2134

Water Consumption / Day – 6.5 Lakh litres

Recycled Water / Day – 3.0 Lakh litres

Power Consumption – 85,000 Units / Day

2.1 About Hosur

Total town area = 12.62 Sq. Km

Altitude = 950 m above sea level

Temperature = 29~36 Deg C (March ~ May)

= 11~15 Dec C (December ~ May)

Annual Rainfall = 54 cm

It’s a flower export hub for places as far and as wide as Paris!!

2.2 Employee Classification @ H1

Management = 447 + 3 (contract executives) – [CC, NC]

Associates = 1684 (6 Associates got retired on last week of May 2012)

– [MR,DR]

xxix

2.3 H1 – Shop over View

Figure 13: Overview of ALH1

2.4 CSR – Corporate Social Responsibility

Arogya Health Centre

Career Guidance for school children

Planting saplings

Education & nutritious food sponsor for HIV+ (2 children)

General Medical Camps

Orphanage visit and Medical Check-up

Program on Environment Management

Career Guidance and Counseling

AIDS Awareness

School Initiatives on Road Safety through SURAKSHA

Dental Screening

Train the Trainers – Positive Attitude Program for Staff

Eye Test

xxx

3. Shop Floor 1

3.1 Introduction

Shop-1 is responsible for the machining of two of Ashok Leyland’s prime products-

the evergreen H-series engine components as well as the cylinder block and head of

the new P-15 engine.

3.2 H-series Machining

The right half of shop-1 is responsible for the H-series. This engine design was

bought from Hino Motors and is Ashok Leyland’s most popular product, utilized for

most of its MDVs. It is available with 4 pistons and with 6 pistons. The components

of the H-series 4 piston engine machined here are:

Component Machined Production per day

Cylinder Block 96

Cylinder Head 86

Rocker Lever 120

Connecting Rod 88

Cam Shaft 176

Flywheel Housing 60

Timing Gear Case 55

Flywheel 139 Figure 14: Table of Components Machined in Shop-1

3.3 Features of the H-series engine

The H-series engine is the most popular engine used in most of the Ashok Leyland

manufactured trucks. It is highly versatile and available in different power ratings,

torques and rpm. Some of its key features are:

Available with 4 cylinders or 6 cylinders.

Bore of 104 mm, Stroke of 118 mm

Cubic capacity of 4009 cc

Compression ratio of 17.9:1

Weight of 540 kg

Rpms of 11500, 1800 or 2000

3.4 Gemba

This gemba is responsible for handling the operations involved in machining of the

above components. There are 11 executives and 165 associates in this gemba.

xxxi

Figure 15: Layout of Shop 1, H-series machining

xxxii

3.5 P15 Machining

The left half of shop-1 is in charge of machining the cylinder block and head for

Ashok Leyland’s latest product, the DOST. This engine was designed in

collaboration with NISSAN and is responsible for Ashok Leyland’s entry into the LCV

market.

3.6 Features of the DOST P15 engine

The DOST is fast gaining popularity among consumers due to the following features

of the P15 engine:

1.5 L, 3 cylinder TDCR engine with a flat torque curve

Provides a power of 55 HP(40.5 kW) at 3300 rpm leading to powerful pick-up

Cubic capacity of 1478 cc.

Torque of 150 Nm at 1600-2400 rpm

Also, the DOST provides power steering, air conditioning and greater payload

capacity when compared to its competition.

3.7 Production

The machining of the cylinder block and cylinder head of the P-15 engine are done

here. The castings of both these components are obtained from the Hinduja

Foundries Limited, Ennore. A unique aspect of the cylinder head is that it is made

entirely of aluminium leading to improved efficiency and lighter weight.

Component Production per day

Cylinder Block 38

Cylinder Head 38

The modernization of this unit is simply amazing. The entire machining process is

almost fully automated and requires very few associates. State-of-the-art CNC

machines from international heavyweights such as Makino and MAG make this unit

the most modern unit in the entire plant. All in all there are 48 CNC machines

present in this plant.

3.8 Gemba

This gemba is responsible for handling the operations involved in machining of the

above components. As this unit is highly automated, there are 11 executives and

only 28 associates in this gemba.

Mr. Vinod Koshy Skaria is the Divisional Manager in charge of this sector of Shop-1.

He is associated by numerous senior managers.

xxxiii

Figure 16: Layout of P15 Machining Unit

xxxiv

1. Shop Floor 2

Shop 2 is responsible for the assembly and testing of the P-15 and 6 cylinder H-

series engine.

4.1 Process mapping

Initially the major engine parts i.e. the cylinder block and cylinder head of the

engines are washed and painted.

After the painting process, they are transferred to the main assembly line, where

the numerous components are fitted together to make up the engine. Refer

Figure 17 and 18 for detailed assembly process.

From the assembly line the engines are sent to ETP, where some components

such as turbocharger are added to the engine and sent to the Test-Bed where

the engines are tested.

Once tested, if the engines are given the go ahead, they move forward to the

dressing area where they seal the engine to prevent the internals of the engine

from environment. However, if they are rejected, the engines are sent to the RR

area where the problems involved with the particular model are rectified.

1.2 Production

The assembly process for both engines is very well monitored. The H series

engine assembly has a cycle time of 9 minutes and consists of 15 engines at a

time on the conveyor belt. The P15 engine assembly is relatively new and

consists of highly sophisticated equipment. This engine assembly has a cycle

time of 10 minutes and similar to H-series assembly, consists of 15 engines on

the conveyor belt at any given point of time.

Engine Production per day

H series 6 cylinder 126

P-15 3 cylinder 107

xxxv

Figure 17: Process Mapping of H-series Assembly

STAGE 1 •Loading.

STAGE 2 •Camshaft, Idler gear, Oil pump fittment and number punching.

STAGE 3 •Flywheel housing, rear end oil seal, TG case fitment.

STAGE 4 •Flywheel, Fuel injection Pump, FIP support bracket fitment.

STAGE 5 •Piston, Oil strainer, and Oil pipes to FIP and compressor fiitted.

STAGE 6 •Water pump, crank pully, oil pan fitment.

STAGE 7 •Cleaning and fittment of cylinder head. Cylinder head and valve cap fitment.

STAGE 8 •Rocker arm assembly and inlet manifold sub assembly fitment.

STAGE 9 •Automated tightening of rocker arm assembly.

STAGE 10 •Turbo charger and turbo oil pipe fitment.

STAGE 11

•Marking injection timing on flywheel and FIP. Fitment of vent house, nozzle and holder, and fuel injection pipes to pump and nozzle.

STAGE 12

•Fitment of top clamps over injection pipes, rocker cover, thermostat case, camshaft dummy plate and exhaust manifold with gasket.

STAGE 13

•Fitment of air compressor, water filter, oil seperator, alternator bracket, water pump pully, ait intake pipe and starter motor.

STAGE 14 •Filling of oil in sump.

STAGE 15 •Unloading.

xxxvi

Figure 18: Process Mapping of P15 Assembly

STAGE 1 •Loading.

STAGE 2 •Engine number marking and fittment of dowels.

STAGE 3

•PCN & upper bearing shell assembly, crank shaft and lower bearing shell assembly.

STAGE 4

•Piston assembly, Connecting rod bolt tightening, Front and rear oil seal assembly, housing assembly and pressing.

STAGE 5 •Fittment of crankshaft pully, oil strainer assembly.

STAGE 6 •Liquid sealant application in oil sump and oil sump assembly.

STAGE 7 •Cylinder head, Timing belt, Cam shaft pulley, crank pulley, idler pulley assembly.

STAGE 8

•Tensioner, Timing Belt, Timing gasket, Top cover, crank pulley cover, Damper pulley assembly.

STAGE 9 •Coolant inlet pipe assembly, injector, common rail stud and dowel assembly.

STAGE 10 •Coolant temperature sensor, degassing adaptor and FIP assembly.

STAGE 11

•Common rail, high pressure pipes, thermostat, coolant outlet body, flywheel assembly.

STAGE 12

•Cylinder head mounting, crank speed sensor, vacuum oil drain, oil cooler, oil filter, alternator and vacuum pump assembly.

STAGE 13

•Power Steering pump, pulley and belt, Stud-EMF, starter motor, exhaust and inlet manifold, cam sensor, Tubocharger and Turbo oil drain pipe assembly.

STAGE 14

•VSV(BS-3), EVRV(BS-4), engine mounting bracket and dipstick Assembly followed by Oil Filling.

STAGE 15 •Unloading.

xxxvii

Figure 19: Layout of Shop Floor 2

xxxviii

5. Shop Floor 3

5.1 Introduction

Located next to the MDV assembly shop , shop 3 or the plant engineering

department plays a vital role in controlling 3 main factors:

1. Machine Availability

2. Maintenance Cost

3. Statutory

The plant is headed by Mr John O.J, Divisional Manager, Plant Engineering.

5.2 Sub Departments

The main sub departments under Plant engineering, shop 3 are :

Plant Engineering Stores

Plant Engineering Library

Fork Lift Maintenance

Fork Lift Spare

General Works Engineering

Hand Tools Repair and Testing

Reclamation Stores

Battery Charging area

Fork Lift Charging area

5.3 Heat Treatment Plant

Located behind the maintenance section this pant contains several heat treatment

machines few of which are :

Shot Blasting Machine

Thumb Blasting Machine

Tempering Furnace

Muffle Furnace

Index Hardening Machine

Gas Carburizing Machine

The gemba in charge of this plant is called the Win Gemba.

xxxix

Types of Heat Treatment

Figure 20: Methods of Heat Treatment

Heat Treatment

Softening

Annealing

Normalizing

Process Annealing

Stress Relief Annealing

Spherodization

Tempering

Martempering

Hardening

Diffusion Treatment

Carburizing

Nitriding

Carbonitriding

Direct Hardening

Selective Hardening

Material Modification

Cryogenic Treatment

Spring Aging

Stress Relieving

xl

Figure 21: Layout of Shop 3

xli

6. Shop Floor 4

6.1 Introduction

The older part of shop 4 is devoted to minimal number of activities while the newer

machines are located in the adjacent MDV Assembly which is an extension of shop

4.

Shop 4 mainly deals with machining all the parts of an axle which are not bought.

The shop also carries out other activities such as gear grinding and steering lever

machining.

The shop has machines that are as old as 40 years.

Apart from these activities, there is limited use of this shop.

The most important area is its extension which is the MDV Assembly which is

discussed in depth in the next section.

Figure 22: Layout of Shop Floor 4

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7. MDV Assembly

7.1 Introduction

The MDV Assembly shop which is an extension of Shop 4 ,handles the very

important function of assembling the trucks that are produced in Hosur-1. MDV

stands for Medium Duty Vehicle and typically has a tonnage of 16 – 25 tones. The

vehicles with a greater tonnage than this are considered HGP vehicles (Heavy

Goods and Passenger vehicles) and those with a lesser tonnage are considered as

LCV vehicles (Light Commercial Vehicles).

In the MDV assembly,25 vehicles are manufactured per shift. There are 18 stages

which include 5 frame assembly stages,4 laydown stages and 9 conveyor belt

stages.

Effectively, the cycle time 16.4min .(8hrs minus 70min of lunch and tea

break=410mins410/25=16.4min)

Some of the main models assembled are:

210 WB VIKING

193 WB LHD FALCON

222 WB LHD FALCON

1616 BS3 142IN WB TIPPER

ESO 632

ESO 761

PANTHER

E3 CTTP

ESO755A1-VKG RHD

1616 BS3 142IN WB

7.2 Significance of Model Number for Ashok Leyland Vehicles:

Most of the trucks that are assembled in the MDV are given an unique serial number

which ahs its own meaning. For example- 2516 CTTP refers to a 25tonnes Gross

vehicle weight with its engine having a power rating of 16*10 = 160 HP. CTTP stands

for Cowl Tipper Tractor Program

7.3 Gemba Equipe

The above gemba is the gemba that is responsible for handling operations in the

MDV assembly. There are 16 MDV Executives and nearly 240employees including

both shifts. The MET(men engagement time) of MDV assembly conveyor-hosur1 has

increased from 75% to 90%.

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The MDV Assembly shop is headed by Mr. S. Subramanian who is the AGM for

vehicle assembly. He is assisted by Mr. R. Palavesa Murugan and Mr. Deepu

Zacaharia Joesph, who are both senior managers.

7.4 Capacity realization –conveyor production capacity

Volume of trucks-97% achieved

Volume of domestic buses-73% achieved

Volume of ESO buses-71% achieved

The bottleneck here is the achievement of buses. The Strategic objective includes

180000 buses and trucks manufacturing by 2014-2015.

7.5 Vehicle Off-track Loss

In spite of the committed efforts of the associates belonging to the gemba there have

been off track loses of trucks due to various reason some of which have been listed

in a systematic order in the next page. Also, the pie chart in Figure 23 illustrates an

overview of the Vehicle off track analysis for the month of June 2012.

Figure 23: Overview of Vehicle Off Track Analysis for June 2012

Purchase 15%

PC 1%

PEP 0%

Maint 0%

Engine 19%

Stores 0% Quality

3%

Axle 0% Prodn &IR

0% No plan

0%

Others 62%

Vehicle Offtrack loss Analysis - June 2012

Purchase PC PEP Maint Engine Stores Quality Axle Prodn &IR No plan Others

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7.6 MDV Assembly Process Flow

8. Shop Floor 5

STAGE 1 •Fitment of flitches/cross members/side members.

STAGE 2 •Assembly of spring brackets (FSF, FSR, RSF, RSM, RSR)

STAGE 3 •Fitment of Engine Mounting front bkt, Cab mtg front bkt.

STAGE 4 •Fitment of Steering Box mtg bkt, & Cab mtg bkt.

STAGE 5 •Fittment of Engine Mtg Rear Bkt, FUPD bkt & Shock Absorber bkt. Torque check.

STAGE 6 •Changing orientation. Radiatior mtg bkt, Air tank bkt, Air cleaner bkt, battery carrier.

STAGE 7 •Clutch oil pipe and clamping, First axle spring mtg, grease nipple fitment.

STAGE 8 •Rear spring, shackle fitment. VIN punching.

STAGE 9 •Axle mtg, First Axle break setting, inter axle prop. Shaft Bolt tightness.

STAGE 10 •Front axle dressing, Front & rear break adjustment, Trunion end cover mounting.

STAGE 11 •Air piping clamping and routing, Front break piping, and Shock aborber fitment.

STAGE 12 •Engine mtg, Air cleaner bkt mtg, Air lock remover-Fuel line.

STAGE 13 •Radiator mtg, Radiator pipe clamping, clutch rod assy, Radiator connections.

STAGE 14

•Exhaust pipe & break fitment, silencer fitment, 2nd prop shaft mtg bolt tightness, tail pipe & clamping.

STAGE 15

•Tyre mtg & tightening, Rain hood & clamp, Air cleaner connections, max cut and wheel alignment.

STAGE 16 •FES mtg, MK III cab mtg tightness. Stg. UJ connections and tightening.

STAGE 17

•FES rear mtg bolt tightening, circular white reflectors(all models), FES wiring/ Air hoses connection, RUPD fitment.

STAGE 18

•Accl. connections & max setting, Break pedal & Clutch pedal free play, Function of gauges/ horn. Wheel nut torque(475-525 lbs.ft), and clutch pedal fitment.

Figure 24: Process Mapping of MDV Assembly

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7. Shop Floor 5

8.1 Introduction

Shop 5 is divided into two parts:

1) H-series engine Machining

2) H-series engine Assembly

8.2 H-series engine Machining

The Machining area manufactures:

Camshaft

Connecting rod (con rod)

Timing gears

Cylinder block

Cylinder head

Oil cooler case

Flywheel

Bearing cap

The machining area includes of 430 machines in total, manufacturing the above

mentioned items

There are 340 associates, overall in the machining area.

Per day manufacturing statistics are as follows:

166 Cylinder block

170 Cylinder head

100 Connecting rod

200 Camshafts

260 Timing gears

8.3 H-series engine assembly

Initially the major machine parts like cylinder block and cylinder head are washed

and then painted.

Later on they are transferred to the main assembly line, where about 87 fitments are

fitted together to make up the engine.

There are about 10 executives and 160 associates involved in engine assembly

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There are 100 engines manufactured per day, from which 80% of the engines

produced are 6 cylinder engines and the remaining are 4 cylinder engine.

The takt time for the engine assembly is 7.5 minutes and the testing time for the

engine is 1 hour.

Figure 25: Layout of Shop Floor 5

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9. Shop Floor 7

9.1 Introduction

An axle is a central shaft for a rotating wheel or gear. On wheeled vehicles, the axle may be fixed to the wheels, rotating with them, or fixed to its surroundings, with the wheels rotating around the axle. In the former case, bearings or bushings are provided at the mounting points where the axle is supported. In the latter case, a bearing or bushing sits inside the hole in the wheel to allow the wheel or gear to rotate around the axle. Sometimes, especially on bicycles, the latter type is referred to as a spindle.

On cars and trucks, several senses of the word "Tandem axle" co-occur in casual usage, referring to the shaft itself, its housing, or simply any transverse pair of wheels. The shaft itself rotates with the wheel, being either bolted or splined in fixed relation to it, and is called an "axle" or "axle shaft". However, it is equally true that the housing around it (typically a casting) is also called an "axle" (or "axle housing"). An even broader (somewhat figurative) sense of the word refers to every transverse pair of wheels, whether they are connected to each other or not. Thus even transverse pairs of wheels in an independent suspension are usually called "an axle".

9.2 Vehicle axles

Axles are an integral component of a wheeled vehicle. In a live-axle suspension system, the axles serve to transmit driving torque to the wheel, as well as to maintain the position of the wheels relative to each other and to the vehicle body. The axles in this system must also bear the weight of the vehicle plus any cargo. A non-driving axle, such as the front beam axle in Heavy duty trucks and some 2 wheel drive light trucks and vans, will have no shaft. It serves only as a suspension and steering component. Conversely, many front wheel drive cars have a solid rear beam axle.

In other types of suspension systems, the axles serve only to transmit driving torque to the wheels; The position and angle of the wheel hubs is a function of the suspension system. This is typical of the independent suspension found on most newer cars and SUV's, and on the front of many light trucks. These systems still have a differential, but it will not have attached axle housing tubes. It may be attached to the vehicle frame or body, or integral in a transaxle. The axle shafts (usually C.V. type) then transmit driving torque to the wheels. Like a full floating axle system, the shafts in an independent suspension system do not support and vehicle weight.

"Axle" in reference to a vehicle also has a more ambiguous definition, meaning parallel wheels on opposing sides of the vehicle, regardless of their mechanical connection type to each other and the vehicle frame or body.

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9.3 Differential

A differential is a device, usually, but not necessarily, employing gears, which is connected to the outside world by three shafts, through which it transmits torque and rotation. The gears or other components make the three shafts rotate in such a way that , where , , and are the angular velocities of the three shafts, and and are constants. Often, but not always, and are equal, so is proportional to the sum (or average) of and . Except in some special-purpose differentials, there are no other limitations on the rotational speeds of the shafts. Any of the shafts can be used to input rotation, and the other(s) to output it. See animation here of a simple differential in which and are equal. The shaft rotating at speed is at the bottom-right of the image.

In automobiles and other wheeled vehicles, a differential allows the driving roadwheels to rotate at different speeds. This is necessary when the vehicle turns, making the wheel that is travelling around the outside of the turning curve roll farther and faster than the other. The engine is connected to the shaft rotating at angular velocity . The driving wheels are connected to the other two shafts, and and are equal. If the engine is running at a constant speed, the rotational speed of each driving wheel can vary, but the sum (or average) of the two wheels' speeds can not change. An increase in the speed of one wheel must be balanced by an equal decrease in the speed of the other.

Shown in the following figures are the front axle, rear axle and rear axle assembly of

a truck

Figure 26: Front Axle

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Figure 27: Rear Axle

Figure 28: Rear Axle Assembly

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9.4 Process Flow

9.5 Work Force

Shop 7 Axle Assembly is located opposite to the MDV Assembly shop and houses

the assembly machine for bot front as well as rear axles.

The number of associates present in the shop is 60 and the number of executives is

around 2.

9.6 Productivity

Number of rear axles produced = 70

Number of front axles produced = 70

The shop is managed by Mr. Upliraj.

STAGE 1

• Load axle casting, Clean axle casting and load on trolley, load brackets on trolley.

STAGE 2

• Brake shoe mounting, Anchor bracket fixing. Assembling of break shoe into axle shoe, and tighten bolts with SPG washers.

STAGE 3

• Hub wet setting. Application of grease, asesemlbling of gasket into hub, fix split pins, mud flinger into gasket.

STAGE 4

• Axle shaft mounting. Assembling axle shaft gasket with grease. Axle brake drum mounting(both sides). Check up differential(only for rear axle). Check up break drum rotations.

Figure 29: Process Mapping for Axle Assembly

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Figure 30: Layout of Shop Floor 7

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10. Shop Floor 9

10.1 Introduction

Shop 9 is the main area where the pre delivery inspection routines are carried out.

The main aim of this shop is to ensure that the trucks that are dispatched to the

sales department are free of any technical snags and are ready for sale. The PDI is

a very important functional area of unit I as it provides a continuous feedback to the

MDV shop and its activities are directly co-related with those of the MDV Assembly.

Any delay in the truck assembly results in a delay in PDI

10.2 Process Flow

STAGE 1 •Vehicle brought from MDV to roller test bed.

STAGE 2 • Speed test is performed in the RTB.

STAGE 3

•Vehicle sent to one of the 16 PDI groups for testing the peripherals.

STAGE 4

• If it passes the quality test, it is sent for painting to the Chasis paint booth.

STAGE 5 • If a vehicle fails the quality test, it is sent to the outer PDI.

STAGE 6

•The shortcomings are fixed in the outer PDI and sent to the chasis paint booth.

STAGE 7

•The vehicle is then sent to CMVR where noise sheilds, triangles, RUPD, SUPD and FUPD are added.

STAGE 8 • ZKM audit done.

STAGE 9 • Firewall audit where the final rechecking is done.

STAGE 10 •Waxing for the ESO vehicles and wiper rod fitments done.

Figure 31: Process Mapping at PDI

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10.3 Work Force

The main executives of the PDI include:

M.R.Venkatraman Sr.MGR - PDI

Bernard Joseph MGR PDI

Akbar Hussain MGR PDI

Gurunathan MGR PDI

The number of executives is: 4

The number of associates is: 50

10.4 Productivity

Inventory in days = 265 lacs/10 lacs = 26.5 sets = 26.5/25 RPD = 1.06 days

Total Process Time = 480 tact time/50 = 9.6 min/vehicle = 9.6x16 stages = 153.6 min

Process Ratio = 2.01

10.5 Main Parameters Checked

Some of the main parameters that are checked while the vehicle is in the roller test

bed are:

Clutch Function

Headlamp / Flasher Lights

Oil Pressure

Water Temperature

Steering Function

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Figure 32: Layout of PDI

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11. Conclusion

This report discussed the overall layout of Ashok Leyland, Hosur (Unit 1). This plant

is one of the Ashok Leyland largest plants. It is responsible for the manufacture of

Ashok Leyland’s renowned H-series engine and the recently developed P-15

engines. Also, the Medium duty vehicle and heavy goods and passenger vehicle are

developed here. The report has elaborated in detail about the various shops and

units within the plant.