The Industrial Training In Ashok Leyland

(Bhandara Unit) Presented By: -

Yogendra P. Tembhurne

Introduction• Founded in 1948• India's leading manufacturers of commercial vehicles, such as trucks

and buses, as well as emergency and military vehicles. • AL transmission exists over the Globe in 40 countries.• Bhandara Unit established in 1984.

1St , 2nd 3rd, 4th, 5th And Reverse Gear On Main Shaft1. Shape Clutch Teeth2. Hobbing3. Washing4. Clutch Teeth Chamfer5. Gear Chamfering6. Taper Roll Clutch Teeth7. Washing

Constant Mesh (CM), 3rd, 4th And 5th Gear on Lay Shaft

1. Hobbing2. Gear Chamfering3. Washing

GEAR HARD LINE• Bore Grinding• Grinding Route• Teeth Grinding• Shaving Route• Noise Testing• Final Inspection- Baker Gauge

Input Shaft, Lay Shaft And Main Shaft Shoft Line• Part No. Punching• Hob Spline• Hob Gear Teeth• Chamfering• Shape Clutch Teeth• Skin Turning• Drill Oil Hole• Washing

Shaft Hard Line• OD Grinding• ID Grinding• Shaving Rout• Grinding Rout• Teeth Grinding• Noise Testing• Final Inspection

SOFT LINE WORKING OF SYNCRO HUB• Broaching• Washing• Hobbing• Deburring• Drilling• Slot milling• Washing• Part No. Punching

SOFT LINE PROCESSING OF SYNCHRO CONE

Input Broaching Washing Hobbing

Washing Oil GrooveTooth Chamfering

Finish Turning

Washing Part No. punching Output

SOFT LINE PROCESSING OF SYNCHRO SLEEVE

Input Part No. Punching Broaching Washing

TurningTapper Turning

Scoop milling

Correction Broach

Tooth Chamferin

g

Finish Turning Washing Output

IN HEAT TREATMENT SHOPS

Input Loading in fixture Preheating Carburizing

Oil quenchingWashingTemperingShotBlasting

Air cleaning QC inspection Output

GEAR BOX ASSEMBLY (GBA)• Washing• Sub assembly• Main assembly• Testing• Dressing• Final passing

TESTINGTesting consists of -• Noise testing• Engagement of gear• Leakage

RECTIFICATION & REASSEMBLY• In rectification GB is de-assembled manually and any problem is

rectified by operator.• There are many vibration problems due to any defect during

machining such defects are removed by charging that gear/sleeve/synchro component.

CASING LINE

InputPart No. Punching

No. of m/c 2Infeed loading

MachiningNo. of m/c 6

Outfeed unloadingDeburring

WashingNo. of m/c 1

Helicoil fitment Output

TQM• GEMBA• 5S:- Seiri (Sort out and arrange properly) Seiton (Set right or set in order) Seiso (Cleaning) Seiketsu (Standardize work practices) Shitsuke (Self discipline)• EEI (Efforts and Ergonomics Index)• Waste reduction • CMI (Cost Management Initiative) • Suggestion scheme and • Six sigma

ConclusionAshok Leyland is one of the biggest Units of the Bhandara district employing thousands of people. Creating the one of the best and reliable gear box (Transmission) for the Latest vehicle to be in race with the heavy load moving worldwide automobile industrial developments.

Thank You