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

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

ii

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.

iii

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. Ashwin Bose. Ashwin Jaishanker Prabudatta Das. Ronak Shah. Sai Charan P Vinay Ram.

2010B1A8329P 2010A4PS033G 2010B1A4770P 2010A4PS660G 2010A4PS230P 2010A8PS388G 2010B3A8453G

BE(Hons.) Electronics and Instru BE(Hons.) Mechanical BE(Hons.) Mechanical BE(Hons.) Mechanical BE(Hons.) Mechanical BE(Hons.) Electronics and Instru 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

iv

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) Date:

Signature of PS Faculty Date:

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. 1. 2.

3.

4.

5.

Course No.(s) & Name A new course can be designed out of this NO project The project can help modifications of the NO course content of some of the existing Courses. The project can be used directly in some NO of the existing Compulsory Discipline Courses (CDC)/ Discipline Courses Other than compulsory (DCOC)/ Emerging Area (EA) etc. Courses. The project can be used in preparatory NO courses like Analysis and Application oriented Courses (AAOC)/ Engineering Science (ES)/ technical Art (TA) and Core Courses. This project cannot come under any of YES the above-mentioned options as it relates to the professional work of the host organization. Response options

vi

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 Assemblyxlii

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

Shop Floor 7..xlvii

Shop Floor 9..lii

Conclusion....lv

vii

1. Overview
1.1 Automotive Industry Developing economys transportation needs are growing exponentially. As Indias 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.,

viii

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

ix

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 7 th 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.

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 Raghunandans son, Ashok, the company was renamed Ashok Leyland with equity participation from Leyland Motors, Ltd.

1967 Indias 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 Leylands turnover for the first time crossed Rs. 1,000 million

1976 The Viking appears

xi

1978 A Cheetah bounds into the frame

1980 Hosur plant starts operations Two major new truck introductions

1982 Indias 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 Indias 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

xii

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 Indias 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

xiii

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

Ashok Leyland
Ennore Hosur I Hosur II Hosur III Alwar Bhandara Ennore Foundries Pressing Unit Mother Plant Est.1948 Commercial Vehicle manufacturing Lorries (comet 8 )ton Passenger Busses AL Engines Machining Plant Gear Manufacturing Axles Sister Concern

CNG Passenger Assembly

Cargo Vehicles MDVs (7-9 ton) e Comet Engine Units (major) Multi Axle Vehicles Hipo Dumper

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

xiv

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

xv

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 xvi

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

xvii

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 Areas offices Regional sales offices Parts warehouse Main dealers Dealer outlets Authorized service centres Service bays 10 18 19 7 43 177 145 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.

xviii

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.

xix

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 companys business.

The stake holders includes Employees Customers Vendors & Suppliers Distributors Share holders Society

xx

1.12 Policies 1.12.1 Quality Policy

Figure 7: The Quality Policy of Ashok Leyland

xxi

1.12.2 Environmental Policy

Figure 8: The Environmental Policy of Ashok Leyland

xxii

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 Indias best employers January 2009

2009 Golden Peacock Environment Management Award

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

xxiii

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
xxiv

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

Over all Plant

Ashok Leyland H1

Classification - Principle Basis

Management

Union Category

Classification - Salary Basis

Corporate Category (CC) 96 (4.5%)

Non - Corporate (NC) 357 (16.6%)

Monthy Rated (MR) 77 (3.58%)

Daily Rated (DR) 1620 (75.3%)

Figure 10: Plant Level Strategy

xxv

1.16.2 Business Structure

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

Figure 11: Pyramid Depicting the Business Structure followed at AL

1.16.3 AL H1 (Personnel & Admin Structure)

GM Mr. Akbar Khan

DGM Mr.M.Shanavaskhan

Divisonal Manager Mr. S. Ravichandran

Deputy Manager Mr. Bhaskar

Manager Industrial Relations Mr. Padmanabhan

Senior Manager -Safety Mr. A.Pio Fernandez

Manager HR Mr. H.S. Sivashankar

Manager HRD Mr. Venkatasubramaniam

Canteen Mr. T.Ganesan

Canteen & Welfare Mr. T.K. Vinayagmurthy

Tranport & Admin Mr. M Ganesan

Manager - Safety Mr. K.Vijayamaruthi

Pay Roll - Associates Mr B.Suganthan

Recruitment Mr. E. Kannan

Figure 12: Managerial Hierarchy at Ashok Leyland xxvi

1.16.4 Global Business Structure (Ashok Leyland)

MAMANGING DIRECTOR

CFO

ED
INTERNAL AUDIT

ED
PRODUCT DEVELOPMENT

ED HR

ED
&
COMPANY SECRETARY

SPECIAL DIRECTOR
BUSINESS PLANNING

ED
CONSTRUCTION & ALLIED BUSINESS

SPECIAL DIRECTO R
PLANNING & PORTFOLIOM GMT

WHOLE TIME DIRECTOR & COO

ED
Manufacturing

ED
MKTG

EDPRODUCT
PLANNING

ED
INTERNATIONAL OPERATIONS

ED
SALES & SERVICE

xxvii

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 Altitude Temperature = = = = Annual Rainfall = 12.62 Sq. Km 950 m above sea level 29~36 Deg C (March ~ May) 11~15 Dec C (December ~ May) 54 cm

Its 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]

xxviii

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

xxix

3. Shop Floor 1
3.1 Introduction Shop-1 is responsible for the machining of two of Ashok Leylands prime productsthe 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 Leylands 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 Cylinder Block Cylinder Head Rocker Lever Connecting Rod Cam Shaft Flywheel Housing Timing Gear Case Flywheel

Production per day 96 86 120 88 176 60 55 139

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.

xxx

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

xxxi

3.5 P15 Machining The left half of shop-1 is in charge of machining the cylinder block and head for Ashok Leylands latest product, the DOST. This engine was designed in collaboration with NISSAN and is responsible for Ashok Leylands 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 Cylinder Block Cylinder Head

Production per day 38 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.
xxxii

Figure 16: Layout of P15 Machining Unit

xxxiii

1. Shop Floor 2
Shop 2 is responsible for the assembly and testing of the P-15 and 6 cylinder Hseries 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 H series 6 cylinder P-15 3 cylinder Production per day 126 107

xxxiv

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. Marking injection timing on flywheel and FIP. Fitment of vent house, nozzle and holder, and fuel injection pipes to pump and nozzle. Fitment of top clamps over injection pipes, rocker cover, thermostat case, camshaft dummy plate and exhaust manifold with gasket. Fitment of air compressor, water filter, oil seperator, alternator bracket, water pump pully, ait intake pipe and starter motor. Filling of oil in sump.

STAGE 11

STAGE 12

STAGE 13

STAGE 14

STAGE 15

Unloading.

Figure 17: Process Mapping of H-series Assembly

xxxv

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

STAGE 4

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. Tensioner, Timing Belt, Timing gasket, Top cover, crank pulley cover, Damper pulley assembly. Coolant inlet pipe assembly, injector, common rail stud and dowel assembly.

STAGE 8

STAGE 9

STAGE 10

Coolant temperature sensor, degassing adaptor and FIP assembly.

STAGE 11

Common rail, high pressure pipes, thermostat, coolant outlet body, flywheel assembly.
Cylinder head mounting, crank speed sensor, vacuum oil drain, oil cooler, oil filter, alternator and vacuum pump assembly. Power Steering pump, pulley and belt, Stud-EMF, starter motor, exhaust and inlet manifold, cam sensor, Tubocharger and Turbo oil drain pipe assembly. VSV(BS-3), EVRV(BS-4), engine mounting bracket and dipstick Assembly followed by Oil Filling. Unloading.

STAGE 12

STAGE 13

STAGE 14

STAGE 15

Figure 18: Process Mapping of P15 Assembly

xxxvi

Figure 19: Layout of Shop Floor 2

xxxvii

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.

xxxviii

Types of Heat Treatment

Annealing Normalizing Process Annealing Softening Stress Relief Annealing Spherodization Tempering Martempering Diffusion Treatment Carburizing Heat Treatment Nitriding Hardening Carbonitriding Direct Hardening Selective Hardening Cryogenic Treatment Material Modification Spring Aging Stress Relieving

Figure 20: Methods of Heat Treatment

xxxix

Figure 21: Layout of Shop 3

xl

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

xli

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%.

xlii

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.

Quality 3%

Stores 0%

Axle 0%

Engine 19% Maint 0%

PEP 0% PC 1% Purchase 15%
Purchase PC PEP Maint Engine

No plan Prodn &IR 0% 0%

Others 62% Vehicle Offtrack loss Analysis - June 2012

Stores Quality Axle Prodn &IR No plan Others

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

xliii

7.6 MDV Assembly Process Flow

Fitment of flitches/cross members/side members.

STAGE 1

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

STAGE 15

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. 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.

8. Shop Floor 5

STAGE 18

Figure 24: Process Mapping of MDV Assembly xliv

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
xlv

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

xlvi

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.

xlvii

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

xlviii

Figure 27: Rear Axle

Figure 28: Rear Axle Assembly

xlix

9.4 Process Flow

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

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.

Figure 30: Layout of Shop Floor 7

li

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. Vehicle sent to one of the 16 PDI groups for testing the peripherals. If it passes the quality test, it is sent for painting to the Chasis paint booth. If a vehicle fails the quality test, it is sent to the outer PDI. The shortcomings are fixed in the outer PDI and sent to the chasis paint booth. The vehicle is then sent to CMVR where noise sheilds, triangles, RUPD, SUPD and FUPD are added. ZKM audit done.

STAGE 3

STAGE 4

STAGE 5

STAGE 6

STAGE 7

STAGE 8

STAGE 9

Firewall audit where the final rechecking is done.

STAGE 10

Waxing for the ESO vehicles and wiper rod fitments done.
lii Figure 31: Process Mapping at PDI

10.3 Work Force The main executives of the PDI include: M.R.Venkatraman Bernard Joseph Akbar Hussain Gurunathan The number of executives is: 4 The number of associates is: 50 Sr.MGR - PDI MGR PDI MGR PDI MGR PDI

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

liii

Figure 32: Layout of PDI

liv

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 Leylands 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.

lv