ENNORE, CHENNAI-600057

"To desire and strive to be of some service to the world, to aim at doing

Something which shall really increase the happiness and welfare and virtueOf mankind - this is a choice which is possible for all of us; and surely it isa good haven to sail for." - Henry Van Dyke, Author

INTRODUCTION

History:

In 1948, Ashok Motors was set up in what was then Madras (now Chennai), for the assembly of Austin Cars.

The Company's destiny and name changed soon with equity participation by British Leyland and Ashok Leyland commenced manufacture of commercial vehicles in 1955.

Early products included the Leyland Comet bus chassis, which sold to many operators.

The Comet was soon joined in production by a version of the Leyland Tiger.

The Ashok Leyland Titan was very successful, and continued in production for many years. Ashok Leyland vehicles have built a reputation for reliability and ruggedness.

In the populous Indian metros, four out of the five State Transport Undertaking (STU) buses come from Ashok Leyland.

In 1987, the overseas holding by Land Rover Leyland International Holdings Limited (LRLIH) was taken over by a joint venture between the Hinduja Group, the Non-Resident Indian transnational group and IVECO Fiat SpA, part of the Fiat Group and Europe's leading truck manufacturer.

In 2006, Ashok Leyland became the first auto company in India to receive the TS16949 Corporate Certification.

Ashok Leyland is a technology leader in the commercial vehicles sector of INDIA.

It is also one of the largest Private Sector Employers in India - with about 12,000 employees working in 6 factories spread over the length and breadth of India.

ASHOK LEYLAND is one of the world’s leading MNC’s operating from India, ennore, Chennai.

Board Members

R Seshasayee, MD

M K R Nair, GM-Special projects

Vinod K Dasari, COO

J N Amrolia, ED-HR

Branches of ASHOK LEYLAND

India Ennore Hosur Bandari Alwar

Finland Yugoslavia UAE Sri lanka USA

Mission “GEMBA” Gemba is a Japanese word meaning ‘real place’ where the real action

takes place. In a manufacturing business, Gemba is the shop floor; in a

service business, the place where the customer and the service cometogether.

It is also the quality of human interactions in the workplace- between co-workers, with customers and business partners.

Launched in June 2005 as acompany-wide initiative, MissionGemba’s objective is to provideInformation, develop skills andEmpower employees to reachWorld-class levels in quality,

Cost and delivery.

Shops visited

Shop1: final assembly

Shop2: engine assembly

Shop3: chassie assembly

Shop4: front and rear axle assembly

ENGINE ASSEMBLY

Principle:

The heat energy in the form of fuel (diesel) is converted into mechanical energy by the process of combustion.

The various parts of the engine such as cam shaft, connecting rod, crank case, crank shaft, pistons etc. are assembled in the engine assembly.

Components to be assembled as an engine

1. CAM SHAFT:

Purpose: It is a device which causes the valves of an engine to open or close at the correct time.

Material used: ENA forging material.

Processes involved in making a cam shaft:

Facing and centering: The material was faced and centered on both side by maintaining the same length throughout the material.

Straightening: Process of removing the bend in the cam shaft after the facing and centering.

CNC-turning: In this process four journal dia stem dia gear dia and collar thickness are made.

Straightening: Process of removing the bend in the camshaft. CNC-key way milling: In this process a keyway is cut at one end of journal dia which is used for fitting timing gear.

Cam milling: In cam milling euro-II type of cam was used. Gear hobbing: Using this process a spiral gear was made

in the cam shaft for lubrication purpose. Deep hole drilling (end drill): A deep hole was made

throughout on cam shaft for lubrication using special drilling machine.

Counter bore and tapering: Boring and threading is done. Oil hole drilling: Holes are drilled for lubrication. Number punching: Process of punching the number in

cam shaft. Indexing hardening: Process of improving the hardness

of the Material. Hardness checking: Process of checking the hardness of

the material. Tempering: It is a heat treatment process in which the

material get heated and then cooled in order to make it

Hard.

Straightening: Process of removing the bends in the cam shaft. External grinding: To make the smooth surface on the

journal dia and collar thickness. Cam grinding: To make the smooth surface on the 12

cam. Hardness checking: Process of checking the hardness of

the material after cam grinding . Crack testing: It is one of the non- destructive testing used to find the presence of crack.

Demagnetization: Process of removing magnetic properties in the

cam shaft.

Washing: After the magnetic properties are removed washing is done using coolant oil afterwards it is send to the Engine Assembly.

2. CONNECTING ROD:

Purpose: This is another important part of the engine. The main function of the connecting rod is to convert the linear motion into rotary motion.

Processes involved in making connecting rod:

Surface grinding: Process of grinding the surface for reducing the width and smoothing.

Reference milling: In this operation milling is done for the purpose of padding.

Chamfering: Process of removing sharp edges in the outer portion.

Multidrilling: In this operation drilling is done main holes on both the ends. Go and no-go gauge bar is used for checking the diameter.

Slitting and cutting: Process of cutting the larger end. Then it is washed by a coolant in which oil is mixed with sol voice powder.

Surface milling: Process of milling the surface on both the pieces of job done in operation 120.

Boring: Process of boring the hole in both the cut pieces.

Bolt facing: In this operation bolt facing is done in both the end of the cut pieces.

Notch milling: In this operation notch milling is done. Notch is made at the ring part of cut piece.

Gun drilling: In this operation gun drilling is done. In 402 type drilling is done for lubrication purpose.

Bolt assembling: In this operation the bolts are assembled.

Surface grinding: In this operation the Surface grinding is done in smaller end.

Surface grinding: In this operation the Surface grinding is done in larger end.

Fine boring: In this operation the Fine boring is done. Honing: In this operation the job is made smoother after

fine boring. Oil hole centering: In this material the extra material in

smaller end is removed by cutting and centering is done for putting oil hole.

Bush boring: In this operation the bush boring is done in small end using diamond point cutting tool. Weight dressing: In this operation the job is separated

and arranged into grades according to weights. Then the connecting rods is send to the Engine Assembly.

3. CRANK CASE:

Purpose: It is the main part of the engine. It is made up of white cast

iron and it was manufactured & supplied from Ennore foundry.

Important process done in crank case:

Deep hole drilling:

A deep hole of dia 10mm is made on crank case for lubrication purpose

Deep hole drilling:

Another deep hole is made of about 15.5mm dia Fuel from fuel pump is injected in to this hole

Milling:

Facing operation is carried on sump face and head face

Dowel pin holing:

A dowel pin and oil pin hole is made It supplies oil to the oil pump and oil filter

Surface milling: This process is used to make the smooth surface on the head & sump face

Bear cap residence milling:

This operation is used for fixing the bearing cap Plate fixing: Milling operation is carried for plate fixing in the crank case

Front & rear milling:

Milling operation is carried in front and rear end of crank case

Angular milling:

Milling operation is done on both the angular faces of crank case for fixing the angular plate

Crank bore milling:

In this process first rough bore milling is done and then finish bore milling is carried out.

Head face multi way drilling:

Using this process 48 holes are made in Euro-I type of engine and 39 holes are made in Euro-II type of engine

These holes are used to fix the cylinder head with crank case

Rough cam bore:

Four bores are made in rear inner, rear outer & front inner, front outer sides of about 8mm dia holes are made.

Idler dia of about 29mm are made on front and rear side of crank case.

Rough and linear bore:

Rough and linear bore are made in head face and linear bore is semi finishing bore

Multi drilling: Multi drilling operation is carried on rear end & front end

Oil pump body milling:

This operation is used for fixing oil pumpTapping:

Tapping is made for the operation no 170 which is made for making the water holes

Drilling:

17/64 drill holes are made in water jacket & tappet tower face

Tapping:

Tapping is carried in angular face, water jacket face & thread cover face

Gang milling:

A notch is made on inner side of crank case to fix the shell in order to avoid the shaking of crank shaft

Stud hole drilling:

Stud hole & sump hole drilling is made for fixing the oil sump

Tapping:

Tapping is made on stud hole & oil sump face and also for center dowel hole for fixing bearing cap

CNC-drilling & tapping:

This operation is done only in Euro-II type of engine for piston cooling system

Milling:

This process is used to remove the extra material at the place of bearing cap

Boring:

Boring operation is done on crank & cam bore which is a semi-finish operation

Thresh washer:

A shell is fixed in the crank shaft area in order to avoid the wear & tear during the crank rotation

Boring:

Linear bore & counter bore is made of about 4.378dia & depth of about 186 to 191 inches

Cylinder bore honing: This operation is carried out for making the perfect dimension at the surface of cylinder bore

Final inspection:

Final inspection is made to find any defects in crank case

Torque plate fixing:

A torque plate is fixed in crank case Rough honing:

To correct the geometry of the cylinder bore (i.e. to avoid the taper bore)

To create the oil package this avoids the friction in piston movement

Finish honing:

It is the finishing operation of rough honing process

Finishing operation:

In this operation fixing of rear plate, side water line, venge plug, quarter inch bolt are made

After this operation crank case is sent through the engine assembly.

Stage by stage assembly:

Stage 1:

Freezing of cam bushes about 00c in the liquid nitrogen. Fitment of cam shaft bearings takes place.

Fitment of cam shaft operation is performed. Stage 2:

Fitment of tappets and additional gallery plugs. Checking of cam shaft free rotation. Fitment of idler spindle bolt and piston cooling nozzles.

Removing of bearing caps and appropriate bearing shells are fixed and then crank shaft is connected.

Stage 3:

Connecting cylinder head studs in crank case. Checking of oil hole position in pilot bush. Fitment of timing back plate at the side of the crank case.

Fitment of additional gallery plug.Stage 4:

Lapping of Oil Relief Valve bore takes place. Fitment of oil relief valve, cam gear.

Stage 5:

Fitment of oil pump takes place. Fitment of oil filters in order to filter the oil. Checking of free rotation of cam shaft and oil pump.

Stage 6:

Fixing of fly wheel case and fly wheel takes place at the side of crank case.

Fitment of FWH screws. Fitment of oil filter, integrated filter takes place.

Stage 7:

Fitment of oil seal housing takes place. Checking of free rotation of fly wheel. Mounting of fly wheel takes place.

Stage 8:

Cleanliness of liner bore takes place. Fitment of piston as per the grade. Staggering of piston rings and connecting rod is screwed in piston and then connected to the crank case.

Punching of piston no. takes place. Fitment of crank case ferrule with `O` rings takes place.

Tighten of cam gear set screw and idler gear.

Fitment of cylinder head gasket and cylinder head.Stage 9:

Fitting of split pin, delivery pipe, suction filter, and timing pointer takes place.

Fitment of sump and punching of engine no. takes place.

Fitment of rocker `O` rings, pushrods, valve caps. Fitment of rocker assembly, inlet manifold and tappet clearance takes place.

Stage 10:

Fitment of air compressor takes place. FIP drive assembly is fixed. Fitment of A/C / drive hsg. Lubrication pipe. Fitments of fuel injection pump, check INJECTION timing and timing case dummy cover.

Ensuring tightness of air inlet pipe and lubrication pipe.

Stage 11:

Fitting of valve cover takes place. Fitment of injectors as per specifications is done. Fitment of injector clamp with nuts and leak off pipe.

Stage 12: Fitment of oil cooler, hoses as per specifications.

Stage 13:

Fitment of damper set screw takes place. Locking of damper set screw washer takes place.

Stage 14:

Fixing of cylinder head rear cover takes place. Fitment of power steering dummy plate and belt tensioner assembly.

Fitment of starter motor and alternator takes place.Stage 15:

Fitment of injector pipes as per specifications. Fitments of fuel filter as per specification.

Stage 16:

Fitment of exhaust manifold takes place. Fitment of breather pipe, water drain plug, oil plug, turbo dummy plug.

Stage 17:

Fitment of water pump takes place. Fitment of fan adaptor and fan as per specifications.

Stage 18:

Fitment of turbo charger as per specifications. Fitment of air compressor only for E II. Fitment of turbo and air compressor air pipes & hoses, oil supply pipes, oil drain pipe & hoses.

Fitment of water pipes & hoses for air compressor. Fitment of water pipes & hoses for water pump takes

place. Fitment of additional pulley, viscous damper and

torque tightness takes place.

Fitment of fan belt takes place.

Now this heat engine is send for Engine testing.

Engine Test bed

The assembled engine is tested for various like ,

Idealing condition Loaded condition Firing order Leakages Lubrication Smoke test

AXLE ARM

HOLES MAKING: Holes making at the top and the bottom of the axle arm. Then this arm is send to the next process.

Drill and ream: In this process drilling and reaming is done for

2 holes and drilling is done for other 4 flange holes to 12.5mm diameter. For steering arm tapering is done.

Milling: Milling is done for steering arm i.e. facing operation is done in the steering arm. The tool used is t-max milling cutter.

Milling: In this operation also milling process continues. This operation is done for the other side of the axle arm.

Finished milling: In this process the axle arm undergoes finished milling operation. So, that the axle arm get a smooth surface finish without any roughness.

Ejector drilling: In this operation ejector drilling is done in the axle arm. This is done at the one side of the axle arm.

Chamfering: After the ejector drilling chamfering operation is done to remove the sharpened edge of the axle arm.

Grooving: In this operation the axle arm is grooved at the finished surface. This is done for the purpose of the oil supply to the axle arm.

CHASSIS ASSEMBLY: The following components are used for assembling the chassis. They are

1. Frame

2. Front spring

3. Front axle

4. Rear spring

5. Rear axle I

6. Rear axle II

7. Axle shaft

8. Axle ratio

9. Front shock absorber

10. Steering gear

11. Fuel tank

12. Engine

13. Fip

14. Starter motor

15. Air compressor

16. Alternator

17. Gear box

18. Propeller shaft

19. Radiator

20. Charged air cooler

21. F.E.S

22. Batteries

23. Air cleaner

24. Rear shock absorber

Process involved in chassis assembly:

Stage I: Front axle dressing :

Fitting of springs and clamp bolt head facing inside

Fitting of front axle dressing castor plate

Checking of F.S. bolts fitment and tighten

Stage II: Rear axle dressing:

Ensure same make springs and clamp bolt head position facing inside

Seating of spring dimple Fitting of “U” bolt with conical washer and nut

Stage III: Front and Rear axle coupling:

Fitting of shackle coupling and shackle pin Cotter bolt fitment and tightness Grease nipple fitment and tightness

Stage IV: For multi axle chassis:

Assembling of bell crank lever with spacers and lip seal Dressing of dummy rear axle Coupling of front, rear& dummy rear axle Dimple seating of rear axle Grease nipple adapter was placed and then grease

nipple was placed Fitment and tightness of cotter bolts

Stage V: Cab mounting brackets and op brackets:

Fitment of op brackets and clutch pedal assy Fitting of stay rod brackets on frame side member Tightening of op brackets& cab mounting brackets to

torque 75/90ft lbs after ensuring c o shaft freenessStage VI: Chain Conveyor Stage:

Fitting of boosters and booster hoses with T piece Fitment of rear buffer pads Front shock absorber was fixed and connected to the

top and bottom brackets Fitting of power stg.box

Stage VII: Fitting of steering support structure

Fitment and tightness of UJ cotter belts E2 sub assembly was fitted Silencer sub assembly was fitted Fitting of fuel tank and drag link

Stage VIII:

Fitment of unloader valve and serviceable air filters Fitting and tightening of air hoses and E2 valve

segment with clipping Fitment of air hoses-rear air hoses segment with

clipping& tightening Fitment of air hoses-front chamber pipe segment with

clipping& tightening Fitment of air hoses-air compressor pipe segment with

clipping& tightening Fitment of fuel hoses-tank to frame with clipping&

tightening Fuel filter assembly with hoses was fitted Fitment of fuel hoses-inside pipes with adaptor &L

bracket with clipping& tightening Chassis number punching on frame Renewal plate punching &riveting on plate

Stage IX: Engine & gear box:

Engine mounting-as per spec.& proper mounting with front cross member

Fitment of metacone mounting bolts Tightness of engine bed bolts Fuel overflow hoses fitment and clipping Fitment of Speedo cables as required

Stage X: propeller shaft:

Fitment of front, rear, center propeller shaft and tightness to torque75/80ft.ibs

Fitment of center bearing bolts and tightness to torque30/35ft.ibs

Clutch rod assembly was fitted and connected to gear box

Stage XI: Radiator sub assembly:

Tightness of radiator mounting bolts and confirms the radiator without fouling after sub assembly

Fit CAC pipes and hoses to the CAC Inlet & outlet Connect the radiator to the bracket on the frame with

stay rod to pintle Hooke cross member Fitting of exhaust pipes at manifold joint and silencer

mouth Fitment of tyres and tightening of wheel nuts to

torque475/525ft.ibsStage XII: Lubrication stage:

Filling up of gear box oil, engine oil, steering oil as per required

Grease lubrication at all points Fitment of fuel tank indicator

Stage XIII: F.E.S. mountings and other fittings (Final stage):

Fitting& tightness of F.E.S.-as per spec Fitment and tightness of gear shift lever Fitment of accelerator, clutch pedal assembly Fitting of driver seat and flick valve Fitment& tightness of bumper and battery carrier Filling of correct quality of diesel in fuel tank as

required Fitment of steering wheel and tightness of steering

wheel nuts & also the power stg. Reservoir.

Different models of road transport produced by ashok leyland

Passenger segment: Viking BS-I - city bus

Viking BS-II - city bus

Viking BS-III -city bus

Cheetah BS-I

Cheetah BS-II

Panther

12 M

Stag Mini

Stag CNG

222 CNG

Lynx

Double Decker

Vestibule

Airport Tarmac Coach

Trucks:

Tippers Trailers Multi-axle trucks Tractors