al midsem report
TRANSCRIPT
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
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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.,
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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.
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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
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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
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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
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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
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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
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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.
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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
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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
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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%)
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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
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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.