isuzu ghandhara industries limited

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S. NO. # NAME # ROLL NO. #

1. Muhammad Ehsan 08-Dcet-Ind-314

2. Muhammad Owais 08-Dcet-Ind-336

Date of Submission:24-01-2010

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S. No. # Department # Time Spent # Page No. #

1. Engineering Works(Plant) 09/12 to 16/12 3 to 10

2. Maintenance (plant) 17/12 to 18/12 11 to 13

3. Service 21/12 to 24/12 14 to 16

4. P R & D 28/12 to 01/01 17 to 19

5. P & D 04/01 to 06/01 20 to 22

6. Parts 07/01 23 to 25

7. GNL Plant Visit 08/01 26 to 28

8. REMARKS ------ 29

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In the plant the work, which is done on a large scale, is of Body Fabrication.Fabrication: The act of making something (a product) from raw materials or The actof constructing something as a piece of machinery.

The body is fabricated for different types of vehicle. It is classified in two groups.

Truck body Fabrication Bus body Fabrication

1. Truck Body Fabrication:In the truck body fabrication the body is fabricated for different models (of trucks),including:

FTS 33 Truck

FTR 33 Truck

FTR 33 (Heavy Duty Truck)

NPS Truck

NPR Truck

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Steps Involve in Truck Body Fabrication:

o Material Preparation:In this step material is selected and cut in the required shape and length as given in thedrawings from Isuzu Japan, also some parts are modified here as well using thestandard CAD technology, the machines used for this purposes are:

Shearing Machine (For cutting):This the machine used for cutting metal sheet. The machine works by first clampingthe material with a ram. A moving blade then comes down across a fixed blade toshear the material. For larger shears the moving blade may be set on an angle or"rocked" in order to shear the material progressively from one side to the other; thisangle is referred to as the shear angle. This decreases the amount of force required,but increases the stroke.

Press Machine (For Bending):This machine is used for bending the metal sheets in the required size and shape.Bending is a manufacturing process that produces a V-shape, U-shape, or channelshape along a straight axis in ductile materials, most commonly sheet metal.Usually bending has to overcome both tensile stresses as well as compressive stresses.When bending is done, the residual stresses make it spring back towards its originalposition, so the sheet must be over-bent to achieve the proper bend angle. When sheetmetal is bent, it stretches in length. The bend deduction is the amount the sheet metalwill stretch when bent as measured from the outside. The bend radius refers to theinside radius. The bend radius depends upon the dies used, the metal properties, andthe metal thickness.

Machine Shop:Machine shop consists of the following machine, which are also being utilized asrequired.

Lathe Machine Shaper machine Milling machine Planner machine Surface grinding machine

Machine shop also provides certain dies and tools used in the machines.

Galvanizing:Some material is galvanized before using in the process of fabrication. Galvanizing isthe practice of immersing clean, oxide-free iron or steel into molten zinc in order toform a zinc coating that is metallurgically bonded to the iron or steel's surface. Thezinc coating protects the surface against corrosion by providing protection to the ironor steel The process consists of the following steps.

Surface preparation Prefluxing Galvanizing Finishing

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The preparation steps consist of cleaning and pickling operations that free the surfaceof dirt, grease, rust and scale. The preflux step serves to dissolve any oxide that mayhave formed on the iron or steel surface after pickling and prevents further rust fromforming. Clean, oxide-free work is galvanized by immersion into molten zinc.Finishing operations include quenching, removing excess zinc and inspection.

After material preparation the process of fabrication is started.

o Fabrication Process For FTS 33 Truck:The process consists of the following main steps.

Flooring:For the floor of the FTS 33 truck 14 cross member and 2 long members is used.Length of the long members = 5100 mm, andLength of the cross members = 2440 mm.Sheet for both long members and cross members is M S Sheet of Thickness = 4 mmSheet used for floor is of thickness 3 mm and also two types of sheet is used like:Plane sheet: It is used at the sides of the floor, andChukker sheet: It is used in the middle of the floor, which provides much morestability and gripped for walking on it or prevent from being slipped on the floor.Then welding is done on it, to join it permanently. The welding mostly used is arcwelding.Arc welding uses a welding power supply to create an electric arc between anelectrode and the base material to melt the metals at the welding point. They can useeither direct (DC) or alternating (AC) current, and consumable or non-consumableelectrodes. The welding region is sometimes protected by some type of inert or semi-inert gas, known as a shielding gas, and/or an evaporating filler material. The processof arc welding is widely used because of its low capital and running costs.

Panelling:In panelling the side walls or sections are attached to the floor of the body. Panellingconsists of:

Side panelsFront panelTale gate panel

Panels consists of a metal sheet and pillar usually made from the sheet metal bybending the sheet metal. The thickness of the sheet metal usued for side panels isabout 2 mm and for the pillar, the thickness of the sheet is 2 mm. The pillar and thesheet metal is joined by Spot welding.Spot welding is a process in which contacting metal surfaces are joined by the heatobtained from resistance to electric current flow. Work-pieces are held together underpressure exerted by electrodes. Typically the sheets are in the 0.5-3.0 mm thicknessrange. The process uses two shaped copper alloy electrodes to concentrate weldingcurrent into a small "spot" and to simultaneously clamp the sheets together. Forcing alarge current through the spot will melt the metal and form the weld. The attractivefeature of spot welding is a lot of energy can be delivered to the spot in a very shorttime (ten to one hundred milliseconds. That permits the welding to occur without

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excessive heating to the rest of the sheet.After preparing the panels, then it attachedwith the floor.From out side pillar is welded with the floor, and inside the panel sheet is welded withthe floor, to strongly held the panels with the floor. The welding used here is CO2welding.CO2 welding is used for the welding of carbon and low alloy steels from 16 gage(0.059 inch) to 1/4 inch (6 mm) or heavier. CO2 welding overcomes the restriction ofusing small lengths of electrodes as in manual metal arc welding (SMAW) and overcomes the inability of the submerged arc welding process to weld in various positions.CO2 is basically a semi automatic process, in which the arc length and the feeding ofthe electrode wire into the arc are automatically controlled. CO2 welding can be donein any weld position, it is easy to weld in the down hand position. For making buttwelds, the root run is laid by moving the electrode, back and forth along the seam. Forthe filler runs of the multipass weld, the electrode is moved. The finishing run isdeposited by weaving the electrode. Fillet, Vertical, horizontal and overhead weldscan also be made using CO2 welding. After the weld is complete, the end cratershould be filled.

Through the process of welding the side panel and front panel is attached with floor,but the tale gate is attached with the floor through hinges. Hinge is a type of bearingthat connects two solid objects, typically allowing only a limited angle of rotationbetween them.Here bow pipes is also attached with the piller of the panels.

Painting:As the body fabrication is nearly completed, then it is sent into paint shop, painting isdone through the following steps:Decreasing is done by washing the body by hydro-chloric acid, which reduce variousoxides formed on the surface othe body, then it is cleaned by hot water and dryed upthrough air pressure. Then if something (i-e decreased material) is present on thesurface of the body is cleaned by steel wool.Filling is done on the rough surface, (i-e joints, welds, spots formed by spotwelding). The material used for filling is usually polykote, which is fast body fillingmaterial. After filling polykote is appllied then the surface is finished bu rubbing thesurface through hands or machines.Priming ensures better adhesion of paint to the surface, increases paint durability, andprovides additional protection for the material being painted. A primer is apreparatory coating put on materials before painting.Final Paint is done after all the above processes. The paint used is a mixture of an airdry paint and thinner, after painting the body, then it is allowd to dry out as requiredand also when to produce large amount of vehicles, it is smply kept for some time inan oven depending upon the temperature of the oven, as it is set. In the oven the paintis dryed up quickly.

Body Drop:After painting, the whole fabricated body is drop over the chassis, which is assembledin the GNL Plant (Chassis is a skeleton of vehicle consisting of a steel framesupported on springs that holds the fabricated body and engine). It consist of a 6cylinder, 4 stroke direct injection, water cooled OHC diesel engine.

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As the fabrication process of the FTS 33 truck is completed. After completing theprocess, then several persons of quality controll department check the body and otherthings as required. In the quality chech they manually checks all the parts, joints andseveral other things. They check and remove any problem, if they found.Then after proper documentation,then it is supplied as per demanded…………………

2. Bus Body Fabrication:In the bus body fabrication the body is fabricated for different models (of busses),including:

MT 133 Bus

NPR BusLT 132 BusCNG Bus

Steps Involve in Bus Body Fabrication:

o Material Preparation:The procedure adopted for the truck material preparation is also used for bus materialpreparaiton but the change is in the size and shape of the parts used.

o Fabrication Process For MT 133 Bus:The process consists of the following main steps.

Flooring:Number of cross member used in the floor = 13, sheet used for cross members is M SSheet, having thickness = 4 mm, and length of the cross member is 2388 mm.The cross members are attached with the chasses (consisting of a 6 cylinder, 4 strokewater cooled In line OHC direct injection diesel engine) through mounding brackets,and some support pipes or tube are placed with the cross members, in order to providesufficient support to the floor sheet placed on the cross members. They all are joinedthrough arc welding. Finally fiber board/wood is used for flooring.

Panelling:In the bus body fabrication,the panelling is of much more importance and is alsomuch more complex. It is done on jigs and fixture.Jigs and fixtures are production tools used to accurately manufacture duplicate andinterchangeable parts. Jigs and fixtures are specially designed so that large numbers ofcomponents can be machined or assembled identically, and to ensureinterchangeability of components.

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The economical production of engineering components is greatly facilitated by theprovision of jigs and fixtures. The use of a jig or fixture makes a fairly simpleoperation out of one which would otherwise require a lot of skill and time.Both jigs and fixtures position components accurately; and hold components rigid andprevent movement during working in order to impart greater productivity and partaccuracy. Jigs and fixtures hold or grip a work piece in the predetermined manner offirmness and location, to perform on the work piece a manufacturing operation.A jig or fixture is designed and built to hold, support and locate every component(part) to ensure that each is drilled or machined within the specified limits. Thecorrect relationship and alignment between the tool and the work piece is maintained.Jigs and fixtures may be large (air plane fuselages are built on picture frame fixtures)or very small (as in watch making). Their use is limited only by job requirements andthe imagination of the designer.The jigs and fixtures must. be accurately made and the material used must' be able towithstand wear and the operational (cutting) forces experienced during metal cutting.Jigs and fixtures must be clean, undamaged and free from swarf and gritComponents must not be forced into a jig or fixture.Jigs and fixtures are precision tools. They are expensive to produce because they aremade to fine limits from materials with good resistance to wear. They must beproperly stored or isolated to prevent accidental damage, and they must be numberedfor identification for future use.Panelling is done in the following steps:

Side Panelling:It consist of pillar tube of 2.5 mm thickness, the plane surface of the tube is 70 mmand the width of the tube is 50 mm. And the outer panel is of 1.6 mm thickness.

Also a curvature is given to the outer panel and then All the tubes and pillars arejoined through arc welding, and between the outer panel and inner panel thermoporeis fitted.And also the outer zone A and B is attached to the structure.

Front and Rare Panelling:The front and rare panels are made from fiber by moulding the fiber material in themould to get the desired shape and structure.

Roof Panelling:Roof panelling is done by the same process as adopted for the side panelling, but hereonly the difference is curvature given to the side panels and also the size.

support tube (50 x 30 x 1.6 mm)

support tube (50 x 50 x2 mm)

pillar tube (70 x 50 x2.5 mm)

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Painting:Painting is done through the following steps:

a. Dents are removed ,either by heating the area and then working on it or bysimple working on it.

b. Polykote is applied on the rough surface and the joints area.c. Then the surface is finished bu rubbing the surface.d. Primer is applied on the surface, which ensures better adhesion of paint to the

surface, increases paint durability, and provides additional protection for thematerial being painted.

e. Again the surface is check to find if there is any dent still present or any otherproblem.

f. Then the surface is again finished by rubbing the surface.g. At last the final paint is applied to the surface, the paint is usually a mixture of

an air dry paint and thinner.

Trimming:As trimming is the process or act of adding decoration, therefore in trimming processthe interior and exterior decorative work is done.It consists of:

a. Fitting windowb. Doorc. Seatsd. And Some electrical work

(like indicators, lights, horn, and other connections).e. If the bus is an AC bus, then the ducts and other requirements for an AC is

fulfilled here.

Final Finishing:In the last the whole bus body is finally finished,Fianl finishing consists of:Buffing (to remove buffs i-e dust particle, if present any).Polishing (to polish the surface).The AC work in the bus if demanded by the customer is carried out by NihonEngineering Company, they use high performance products imported from Itsly,Turkey, etc. and also provides tools for wniter season as well, like certain heaters.

As the fabrication process of the MT 133 bus is completed. After completing theprocess, several persons of quality controll department check the body, roof and otherthings as required. In the quality chech they manually checks all the parts, joints andseveral other things. They check and remove any problem, if they found.Then after proper documentation,then it is supplied as per demanded…………………

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Maintenance, repair, and operations (MRO) involves fixing any sort of mechanicalor electrical device should it become out of order or broken (known as repair,unscheduled or casualty maintenance).

It also includes performing routine actions which keep the device in working order(known as scheduled maintenance) or prevent trouble from arising (preventivemaintenance).

MRO may be defined as, "All actions which have the objective of retaining orrestoring an item in or to a state in which it can perform its required function. Theactions include the combination of all technical and corresponding administrative,managerial, and supervision actions".

MRO operations can be categorised by whether the product remains the property ofthe customer, i.e., a service is being offered or whether the product is brought by thereprocessing organisation and sold to any customer wishing to make the purchase.

In Engineering or In general, the term maintenance has the following meanings:

a) Any activity — Such as tests, measurements, replacements, adjustments andrepairs (intended to retain or restore a functional unit in or to a specified statein which the unit can perform its required functions).

b) For material — All action taken to retain material in a serviceable condition orto restore it to serviceability. It includes inspection, testing, servicing,classification as to serviceability, repair, rebuilding, and reclamation.

c) For material — all supply and repair action taken to keep a force in conditionto carry out its mission.

d) For material — the routine recurring work required to keep a facility (plant,building, structure, ground facility, utility system, or other real property) insuch condition that it may be continuously used, at its original or designedcapacity and efficiency for its intended purpose.

Manufacturers and Industrial Supply Companies often refer to MRO as opposed toOriginal Equipment Manufacture (OEM). OEM includes any activity related to thedirect manufacture of goods, where MRO refers to any maintenance and repairactivity to keep a manufacturing plant running.

Industrial supply companies can generally be sorted into two types:

a) The ones who cater to the MRO market generally carry a broad range of itemssuch as fasteners, conveyors, cleaning goods, plumbing, and tools to keep aplant running.

b) OEM supply companies generally provide a smaller range of goods in muchlarger quantities with much lower prices, selling materials that will beregularly consumed in the manufacturing process to create the finished item.

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In Isuzu GIL the following types of maintenance work is carried out or planned.

Preventive maintenance Corrective maintenance

In the Preventive maintenance, they work or simply analyze that how they mightprevent an error, it may be a human error or fault of a machine as well.Whereas in the Corrective maintenance, they work and finds the different alternativesto get rid of the problems which they are facing.

Preventive maintenance (PM) has the following meanings:

a) The care and servicing by personnel for the purpose of maintaining equipmentand facilities in satisfactory operating condition by providing for systematicinspection, detection, and correction of incipient failures either before theyoccur or before they develop into major defects.

b) Maintenance, including tests, measurements, adjustments, and partsreplacement, performed specifically to prevent faults from occurring.

While preventive maintenance is generally considered to be worthwhile, there arerisks such as equipment failure or human error involved when performing Preventivemaintenance, just as in any maintenance operation. Preventive maintenance asscheduled overhaul or scheduled replacement provides two of the three proactivefailure management policies available to the maintenance engineer.

To make it simple:

a) Preventive maintenance: is conducted to keep equipment working and/orextend the life of the equipment.

b) Corrective maintenance: is sometimes called "repair", is conducted to getequipment working again.

In Isuzu GIL maintenance department, the most Corrective maintenance work carriedout is in there own Plant like generators, engines, and other machines used in theproduction plant.

The basic problems a machine might have are:

Mechanical problem or error. Electrical problem or error.

To overcome all the above problems the Isuzu GIL maintenance department isdivided in two sections, to overcome all sorts/types of probems properly and quicklyto decrease the break-down time of both the worker and the machine.

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A vehicle service is a series of maintenance procedures carried out at a set timeinterval or after the vehicle has travelled a certain distance. The service intervals arespecified by the vehicle manufacturer in a service schedule and some modern carsdisplay the due date for the next service electronically on the instrument panel.

The completed services are usually recorded in a service book which is rubberstamped by the service centre upon completion of each service. However at least onemanufacturer (Mazda) now records services electronically on a database and printsthem out for vehicle owners on request, so that it is not necessary for them to retain astamped service book. A complete service history usually adds to the resale value of avehicle. Services like DriverSide in the United States and Drive Archivein the UnitedKingdom are trying to create tools to help car owners track this service information.

Mechanics at Service Center.

The Service department of the Isuzu GIL is basically an after sale service departmentbut during a cetain period the different parameters of the service may be free of costlike labour cost, and other products like engine oil, oil filter, etc but to the vehicles notin the certain range of warrenty, they are fully cahrged but due to the highperformance of there workers, customers still wants to tune up there vehicles from thedepartment. The range of warrenty is of two types either complete one year or100,000 kilometers.All the products which they changed in a vehicle is mention in the service book and iscollected from the warehouse or parts department of the GIL.

They also have a mobile workshop team, which provides services to the door step of acustomer. In an service the following things are checked and also changed ifnecessary.

Change the engine oil Replace the oil filter Replace the air filter Replace the fuel filter Replace the spark plugs Tune the engine Check level and refill brake fluid Check level and refill power steering fluid Check level and refill Automatic Transmission Fluid

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Grease and lubricate components Inspect and replace the timing belt if needed Check condition of the tires Clutch Gearbox Car Battery Engine components (further inspections than MOT)

Mechanical parts that may cause the vehicle to cease transmission or prove unsafe forthe road are also noted and advised upon. Mechanical parts of the vehicle whichdeteriorated below pass standard since testing are inspected and advised accordingly.

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The phrase Product Research and Development (also P R and D or, more often,R&D), according to the Organization for Economic Co-operation and Development,refers to:"Creative work undertaken on a systematic basis in order to increase the stock ofknowledge, including knowledge of man, culture and society, and the use of this stockof knowledge to devise new applications".

New product design and development is more often than not a crucial factor in thesurvival of a company. In an industry that is fast changing, firms must continuallyrevise their design and range of products. This is necessary due to continuoustechnology change and development as well as other competitors and the changingpreference of customers. A system driven by marketing is one that puts the customerneeds first, and only produces goods that are known to sell. Market research is carriedout, which establishes what is needed. If the development is technology driven then itis a matter of selling what it is possible to make. The product range is developed sothat production processes are as efficient as possible and the products are technicallysuperior, hence possessing a natural advantage in the market place.

R&D has a special economic significance apart from its conventional association withscientific and technological development. R&D investment generally reflects agovernment's or organization's willingness to forgo current operations or profit toimprove future performance or returns, and its abilities to conduct research anddevelopment.

Research:Research can be defined as the search for knowledge or any systematic investigationto establish facts. The primary purpose for applied research (as opposed to basicresearch) is discovering, interpreting, and the development of methods and systemsfor the advancement of human knowledge on a wide variety of scientific matters ofour world and the universe.Generally, research is understood to follow a certain structural process. Though steporder may vary depending on the subject matter and researcher, the following stepsare usually part of most formal research, both basic and applied:

Formation of the topicHypothesisConceptual definitionsOperational definitionGathering of dataAnalysis of dataTest, revising of hypothesisConclusion, iteration if necessary

Innovation is a new way of doing something or "new stuff that is made useful". Itmay refer to incremental and emergent or radical and revolutionary changes inthinking, products, processes, or organizations. In the organizational context,

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innovation may be linked to performance and growth through improvements inefficiency, productivity, quality, competitive positioning, market share, etc. Allorganizations can innovate, including for example hospitals, universities, and localgovernments.In economics the change must increase value, customer value, or producer value. Thegoal of innovation is positive change, to make someone or something better.Innovation leading to increased productivity is the fundamental source of increasingwealth in an economy. Innovation is the most important thing for the human survival.Innovation is an important topic in the study of economics, business, design,technology, sociology, and engineering. Colloquially, the word "innovation" is oftensynonymous with the output of the process.However, economists tend to focus on the process itself, from the origination of anidea to its transformation into something useful, to its implementation; and on thesystem within which the process of innovation unfolds. Since innovation is alsoconsidered a major driver of the economy, especially when it leads to increasingproductivity, the factors that lead to innovation are also considered to be critical topolicy makers.

As from the above information it is easy to understand the purpose of the P R & DDepartment of GIL.The department work continuously and effectively for the improvement of thereproducts, to make it much more suitable for customers and also they try to modifythere products according to the customers demand and from the recent results or datagattered from the market and from the popularity of recent released models of thecompany.The department work on the new models as well and also study about themodification of the models, like for the FTS truck, 200 liters capacity of oil tank wasdesigned but according to there customer demand they modify it to 400 liters. Alsothey work that how to decrease the price of a model to make there model much moreeconomical.

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The phrase Procurement and Develpoment (Also known as P & D) is theacquisition of goods and/or services at the best possible total cost of ownership, in theright quality and quantity, at the right time, in the right place and from the right sourcefor the direct benefit or use of corporations, individuals, or even governments,generally via contract, or it can be the same way selection for human resource.

Simple procurement may involve nothing more than repeat purchasing. Complexprocurement could involve finding long term partners – or even 'co-destiny' suppliersthat might fundamentally commit one organization to another.

Almost all purchasing decisions include factors such as delivery and handling,marginal benefit, and price fluctuations.

Procurement generally involves making buying decisions under conditions of scarcity.If good data is available, it is good practice to make use of economic analysis methodssuch as cost-benefit analysis or cost-utility analysis.

Based on the consumption purposes of the acquired goods and services, procurementactivities are often split into two distinct categories.

The first category being direct, production-related procurement

And

The second being indirect, non-production-related procurement.

Direct procurement occurs in manufacturing settings only. It encompasses all itemsthat are part of finished products, such as raw material, components and parts. Directprocurement, which is the focus in supply chain management, directly affects theproduction process of manufacturing firms.

In contrast, Indirect procurement activities concern “operating resources” that acompany purchases to enable its operations. It comprises awide variety of goods andservices, from standardised low value items like office supplies and machinelubricants to complex and costly products and services like heavy equipment andconsulting services.

An important distinction is made between analysis without risk and those with risk.Where risk is involved, either in the costs or the benefits, the concept of expectedvalue may be employed.

As from the above, it is cleared to understand the scope and purpose of the P & Ddepartment of the GIL. The department have to manage different parts and materials(which is to produce locally) from different vendors in a certain time period, not todelay the manufacturing process. They also have to manage the different parts beingimported from Japan.

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They get the different parts or products from the different vendors, but normaly theytake the product from the one, who ensure the best quality and deliver the good in thegiven time frame and also form the one, whoes product is ecnomical compared to theother vendors, if the vendor have some problems and unable to provide the product intime then they have to response to other vendors as well.

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A warehouse is a commercial building for storage of goods. Warehouses are used bymanufacturers, importers, exporters, wholesalers, transport businesses, customs, etc.They are usually large plain buildings in industrial areas of cities and towns. Theyusually have loading docks to load and unload goods from trucks. Sometimeswarehouses load and unload goods directly from railways, airports, or seaports. Theyoften have cranes and forklifts for moving goods, which are usually placed on ISOstandard pallets loaded into pallet racks.

Stored goods can include any raw materials, components, or finished goods associatedwith agriculture, manufacturing, or commerce.

Some warehouses are completely automated, and require no workers inside. Palletsand product move on a system of automated conveyors, cranes and automated storageand retrieval systems coordinated by programmable logic controllers and computersrunning logistics automation software. These systems are often installed inrefrigerated warehouses where temperatures are kept very cold to keep product fromspoiling, and also where land is expensive, as automated storage systems can usevertical spacee fficiently.

Automatic storage warehouse for small parts Aisle with pallets on storage racks

For a warehouse to function efficiently, the facility must be properly slotted. Slottingaddresses which storage medium a product is picked from (pallet rack or carton flow),and how they are picked (pick-to-light, pick-to-voice, or pick-to-paper)

Some of the most common warehouse storage systems are:

Pallet rack including selective, drive-in, drive-thru, doubledeep, pushback, andgravity flow

Mezzanine including structural, roll formed, rack supported, and shelfsupported

Cantilever Rack including structural and roll formed

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Industrial Shelving including metal, steel, wire, and catwalk

Automated Storage and Retrieval System (ASRS) including: verticalcarousels, vertical lift modules, horizontal carousels, robotics, mini loads, andcompact 3D.

Traditional warehousing has declined since the last decades of the 20th century, withthe gradual introduction of Just In Time (JIT) techniques. The JIT system promotesproduct delivery directly from suppliers to consumer without the use of warehouses.However, with the gradual implementation of offshore outsourcing and offshoring inabout the same time period, the distance between the manufacturer and the retailer (orthe parts manufacturer and the industrial plant) grew considerably in many domains,necessitating at least one warehouse per country or per region in any typical supplychain for a given range of products.

Large exporters/manufacturers use warehouses as distribution points for developingretail outlets in a particular region or country. This concept reduces end cost to theconsumer and enhances the production sale ratio.

Due to the importance of a warehouse, the warehouse or parts deparrtment of the GILis specially designed to fulfill all the needs of there customers in the countryor simplyin the region. In the department all the products are IN through a proper process andalso it is utilize (i-e being used) through proper OUT process, i-e the IN & OUT of theproducts or parts is clearly describe in the warehouse book. Also this book contain allthe information about the parts either it is present or it is used.

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In the GNL Plant, chassis of assembling for different vehicals is carried out. Thevarious steps involve in the process are the following:

Step no # 1:In the first step the drilling and rivitting is done in the chasses long member, andchasses number is also punched here.

Step no # 2:Here the leaf spring and axial is attached with the chasses, and battery and fuel tankis also attached here.

Step no # 3:In this step tubes and pipes are attached for fuel and for air brack system.

Step no # 4This step is most important one, here engine is drop on the chasses, and the radiatorand exhaust assembly is also done here.

Step no # 5:Here cabin is drop on the chasses.

Step no # 6:Air cleaner assembly is attached to the chasses and connected with the engine andwith brake system.

Step no # 7:This is almost the last and final step of the assembly, here different types of oiling isdone as required like engine oil, brake oil, and clutch oil.

During the assembling process engine is drop on the chasses, but the engine is alsoassembled in the GNL Plant. Different parts, which is used during the assemblingprocess of the engine are:

Cylinder Head Rocker Arm Valve Cover Cylinder Block Flywheel Housing Timing Case Crankshaft Camshaft Flywheel Piston Oil Cleaner Oil Filler Oil Filter

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Oil Sensor Exhaust Manifold Turbocharger Intake Manifold Air Intake Air Filter Engine Suspension Engine Gasket Kits Filter Kits

In the assembling of the engine, first crankshaft and camshaft is attached withcylinder block, then cylinder head is attached. After thes things piston is attached tothe crankshaft with help of the connecting rods, then housing is done, after which flywheel is attached. Now the engine starts to get shape, as fuel injection pump andstarter morte is attached with the engine, then compressor is attached.Now the engine assembling is almost completed and then the engine test is carried oubefore droping the engine on the chasses. The engine test is done in specaillydesinged environment providing fuel and air directly form the cylinder. Very rarelythey get problems here but if the gets any, they quickly tries to satisfy or remove theproblem. The engine is sent to the chasses assembling line, where it is drop on thechasses.

The other department which we visit in the GNL is the warehouse. The warehouse ofthe GNL is similar to the warehouse of the GIL in several aspects, like the managingof the parts in the warehouse but there is also some difference, like here the productswhich are imported are tested properly and then sent to the department where it isutilized as required.

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We have completed our Internship in the GIL. We observed that GIL is awell organized automobile Industry. Each of its department is connectedwith each other by formally and working in very good coordination.Official documentation system is also very organized. Coordinationbetween workers and management is also very strong so that there iscontinuous manufacturing as required. Each kind of facility forproduction/body fabrication is available in GIL.

Management policy of GIL is effective but required some variation toincrease the productivity by applying time study and material handlingprocesses for manufacturing to gain more profit. There workers alsorequires some sort of benefits/incentives to work much more effectively,these sorts of things will motivate the workers towards work.

As for trainees, we don’t think that any organization is better than GILbecause each person from worker to management is too much trained andcooperative.

We gain a lot of technical knowledge form GIL which we will neverforget and also this will help us alot in our professional life.So we are too much thankful to GIL Staff for great cooperation with usduring our internship………………………………………………………

isuzu ghandhara industries limited

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