Ashok Leyland Report.doc 2d6qz

CONTENT LIST • • • • • • • • • •

COMPANY PROFILE OBJECTIVE OF STUDY ORGANISATIONAL PROFILE MISSION GEMBA A BRIEF OF DEPT. RESEARCH METHODOLOGY CONCLUSIONS RECOMMENDATIONS BIBLIOGRAPHY PROJECT

COMPANY PROFILE Ashok Leyland is the flagship of the Hinduja group and is the second largest manufacturer of commercial vehicles in India. The company was established as ASHOK MOTORS in 1948 and entered into collaboration with British Leyland in 1955 with current name as ASHOK

LEYLAND.

The

company

has

grown

as

a

reputed

manufacturer of quality automotive products ranging from light commercial

vehicles

to

heavy

duty

vehicles

and

engines

for

automotive, industrial and marine applications. The products of the company are of proven design for durability and reliability and are hence very popular both in Indian and overseas markets. In recent years , the product range is upgraded to the latest technological developments in the World, for which the company has technical

from IVECO ( FIAT

group ) , Italy for manufacture of IVECO Cargo range of vehicles ; HINO Motors Japan for manufacture of fuel efficient engines and ZF , for manufacture of synchromesh gear boxes. The company has its corporate office ed at Chennai. The marketing headquarters at Chennai and sales and services network and spare parts warehouses are spread throughout India with regional sales offices, area offices and service centers located in all major cities and towns in the country. The products are also exported to overseas customers. The marketing personnel maintain

constant

interaction

with

customer

for

application

development and for continuous improvement of the product. The service function is carried out by qualified personnel, whose skills are continuously upgraded through training, to meet the servicing requirement of newer or improved products. The design function is carried out by product development division operating through 3 centers viz. product development Encore for engineering services engine R&D; technical center , vellivoyalchowadi for design

of vehicles and aggregates , prototype development, vehicle and component testing , R& D engines, Hour for design and development of engines.

MANUFACTURING PLANTS:Ashok Leyland presently has six manufacturing plant in India. 1. Encore plant ( mother plant) near Chennai 2. Hosur- 1

3. Hosur-2

( along with a press shop near Bangaluru)

4. Bhandara ( assembly plant) 5. Alwar ( assembly plant) One new plant is coming which is in Pant nagar (Uttaranchal). The total covered space at these six plant exceeds 4,50,000 sqm and together employ over 11,000 personnel. Two new plants are also being established outside our country are:1.

Srilanka &

2.

Dubai (UAE)

ORGANISATION PROFILE The head office of ASHOK LEYLAND is in Chennai, India and the company is owned by the Hinduja group. Mr. Parmanand D. Hinduja was the founder of Hinduja group.

Mr. R. J. Shahaney

Chairman

Mr. R. Seshasayee

Managing director

Mr. Vinod k. Dasari

Chief operating officer

Mr. R.R.G. Mennon

Executive director- product development

Mr. Rajinder Malhan

Executive director- International operations Executive director –Projects planning

Mr. A. K. Jain Chief finance officer Mr. K. Sridharan

Chief programmer mentor

Mr. M. Natraj

Executive Director & Company Secretary

Mr. A. R. Chandra Sekharan Mr. Anup Bhat

Executive Director- Strategic sourcing

Mr. J. N. Amrolia

Executive Director- Construction & Allied Businesses

Certification and Awards obtained

ISO 9002: 1987

1993

Ennore & Hosur unit -1

ISO 9001: 1994

1994

Ennore, Hosur unit1 & 2, Bhandara, Alwar & Corporate function

QS 9000: 1998

1998

Ennore, Hosur unit1& 2/PS, Bhandara, Alwar & Corporate function

ISO 9001: 2000

2003

ISO 14001: 1996

2001

Ennore, Hosur unit1& 2, Bhandara, Alwar & Corporate function Ennore

ISO 14001: 1996

2002

Ennore , Hosur unit1 & 2 & PS

ISO 14001: 1996

2003

BS 7799-2: 2002

2005

ISO/ TS- 16949-2002

2006

Ennore , Hosur unit -1 & 2 & PS , Alwar & Bhandara Information security management system for Ennore data center Ennore, Hosur unit-1 & 2/ PS, Bhandara, Alwar & Corporate function

PRODUCTS From 18-seater mini-buses used by schools and corporate to 82seater double-decker buses, from 7.5 tone to 49 tone in haulage vehicles, from numerous special vehicle applications to diesel engines

for

industrial,

marine

and

genset

applications,

Ashok

Leyland offers a wide range of products. Through timely innovations, the Company has created new product and application segments, thereby expanding the market. From eggs to steel, from flowers to cars... what doesn’t move on Ashok Leyland vehicles? Ashok Leyland have made and sold products like roadways buses, CNG buses, defense trucks, double-decker buses, vestibule buses, luxury buses, rear engine buses, school buses tipper, and dumper, vehicle for fire-brigade. Mostly AL produces the chassis of vehicles which gives flexibility for the customer that he can make the body of his own choice and requirement. Some of the products are made with body by the company. The bus running at Delhi – Lahore route is also made by AL. Apart from these AL makes the engines also, which are being used for gensets /generator, marine and industrial applications. AL makes three kinds of engines-AL engine, HINO-engine, and IVECO engine. Mostly HINO-engines are being used. The products are listed below: School bus – stag (ICV)  Bus (MDV)- Viking cheetah, Viking super, falcon  Double-decker  Vestibule bus  Rear-engine bus-panther, cruiser, enviro  Luxury bus – luxura, foton

 CNG bus – Viking , Viking super, lynx,4.2&4.9  Multi-axle vehicle

 Haulage-comet, comet gold, bison, tusker super  Tipper  Dumper  Tractor- comet, tusker turbo, beaver, hippo, rhino, 4018,4921  LCV/ICV-cargo 759,cargo 909 100.12  Water tender-16KL  Fire fighter- comet gold 4x2, RIV 4x4, CFT 6x6  Defence- stallion 4x4,YAK 4x4, HMV 6x6,RAT 6x6,LRV 4x4, TFF 4x2

ASHOK LEYLAND ALWAR Alwar is a strategic town in Rajasthan midway between Delhi and Jaipur is located with national capital region. As a part of expansion programme alwar unit was added to the family of ASHOK LEYLAND & started its operation in 1982 & has completed its 25 years successfully. It is basically an assembly plant where the chassis is assembled. Ashok Leyland, Alwar is world’s largest CNG Vehicle producing plant; CNG is used as an alternate fuel to diesel and is very less polluting. The pollution of CNG vehicle is less than ever Euro-4 vehicle which is known for its lesser pollution vehicle. The total covered area of Alwar plant is 352 acres and the fencing is done in around 161 acres of area. The plant comprises of 8 shops called shop-1, shop-2 & shop-5. the plant has three gates one is main gate, one for entering the goods carrier, third for the products going out of the plant for sale. There is an istrative office one P & A department block, a medical centre, a canteen, a newspaper reading room library, a training centre & system department, regional sale office yard & construction is going on for new stores.

WORK SHOP:There are four shops in the plant:SHOP-1:- chassis assembly takes place in a line by odd assembly method & the PDI (Pre Delivery Inspection) is carried painting of chassis is done. SHOP-2:- chassis assembly takes place on conveyor line in 20 stages. SHOP-4:- It is used as store and RSO re-furbishing work. SHOP-7:- PDI & GR & D work is carried out.

VISION The vision of Ashok Leyland is to be among the top Indian corporation acknowledged nationally and internationally for: Excellence in quality of its product  Excellence in customer focus and service.

MISSION Be a leader in the business of commercial vehicles excelling in technology quality value to customer fully ed by customer service of the highest order & meeting nationally and international environment and safety standards.

EMPLOYEES We consider our employees as our most valuable assets and are committed to provide full encouragement and to them to enhance their potential and contribution to the company businesses.

Quality policy Ashok Leyland is committed to achieve customer satisfaction by anticipating and delivering superior value to the customer in relation to their own business through the products and services offered by the company and to comply with statutory requirement. Towards this the

quality

policy

improvements

in

of the

Ashok

Leyland

processes

that

is

to

make

constitute

continuous the

quality

management system to make them more robust ant to enhance their effectiveness and efficiency in achieving stated objective leading to: Superior products manufactured by the company as also services offered by the company.  Maximum use of employee’s potential to contribute to quality and environment, by progressive up gradation of their knowledge and skills as appropriate to their functions.  Seamless involvement from vendors and dealers in the mission of the company to address customer changing needs and protection of the environment.  It is mandatory on the part of every employee of Ashok Leyland to understand, implement and maintain the quality policy of the company and to implement the procedures incorporated in this manual and other associated quality system documents issued by the manufacturing units and

corporate functional divisions on the basis of guidelines in this manual.

Environmental policy Any type of activity that is performed or any type of product that is manufactured had an effect on the surrounding or environment. At Ashok Leyland are committed to preserving the environmental through

a

comprehensive

environmental

policy

and

productive

approach in planning and executing our manufacturing and service activities. We are concerned about the earth our children will inherit that’s why we make sure our vehicles consume less fuel and pollute less. This concern is reflected in the manufacturing systems, the various processes energy conservation measure and conscious greening indicate of the company. A system is employed to control or minimize the adverse impact on the environment is environmental management system (EMS). Objective of Ashok Leyland Environmental policy are: To adhere to all applicable environment legislation and regulations  To adopt pollution preventive techniques in design and manufacturing of our products.  To conserve all such resources such as power, water, oil, gas, compressed air etc. & optimizes their usage through scientific methods.  To provide a clean working environment to our employees, contractors and neighbors.  Commit to comply with all relevant legal and other requirements.

 Continuously strive to minimize waste generation by all possible ways and to reuse and recycle the same through a time bound action plan  Things done to protect the environment and achieve the goal of the policy: Conserving natural resources like wood , coal , petroleum products  Avoiding wastage water at plant area  Switching off the idle engine, motors, pump & lights  Avoiding spilling oil , grease, paints on the floor  Do not through oil into drain  By planting many trees inside the company area  Recently planting plants on 5 June 2008(world environment day)

5-S HOUSE KEEPING 1. SEIRI (Clearing Up)

2. SECTION (Arraying) Arrange necessary items in good order so that they can be easily picked for use. A place for everything & everything in its place. 3. SEISO (Cleaning) Clean the workplace completely so that there is no dust on the floor machines and equipments. 4. SEIKETSU (Standardising Cleanliness) Maintain high standards of housekeeping and workplace organization at all times. 5. SHITSUKE (Training Discipline) Train people to always follow good housekeeping disciplines.

Safety and Health Policy Intension & commitment of the top management Ashok Leyland affirms that all its employees irrespective of the rank need to be safe guarded against any person injuries or damage to the

properties

during

working

period.

That

the

management

recognises the principle that accident prevention contributes in the long run progress and development of the organisation.

Ashok Leyland is committed to: Implementing all practical safety measures like safe working and environmental condition.  Carrying out a systematic critical appraisal of all potential hazards

involving

personal,

plant

services

and

operating

methods.  Following strictly safety rules and regulations incorporated in the factories act and rules.  Maintaining safe

and healthy working environment at all

working places conductive to the success of the management safety programs in the long run.  Implementing

safe

and

health

education

programmes

for

employee with specific emphasis on creating safety and health awareness.  Welcoming useful and constructive suggestions and ideas in regard to safety and health.

MISSION GEMBA ENHANCING EMPLOYEES PERFORMANCE VISION:-

FOR

WORLD

CLASS

GLOBALISED

Achieving leadership in the domestic commercial vehicle markets and a significant presence in the world markets and a significant presence in the world market by 2014 through transport solutions by enhancing the employ for their excellent work to promote them to do their best for the goal of organization. It’s a playful part of the company. It is totally based on the potential of the employee how can they do more, higher productivity can be generated and how efficiently their jobs do. If any employee renders his service for a new invention or a way by which the production, quality standards or any other standards can grow rapidly. Then the employee is awarded by senior officers or respective head of mission gemba. The main emphasis is on the increase of the potential of the employee. Motivate them through learning’s; self respect, honesty, hard work, etc... Have to become the essential part of an employee working in the organization It creates a positive psychological effect in the mind of employee. If he

perform

just

different

job,

respective

with

a

aspect

of

development of the company, he is being awarded and the same employee

works

with a difference in the company with

more

advantageous style. It

gives

a

friendly

and

competitive

environment

which

employee and the organization to achieve their ambitions.

helps

GEMBA is a Japanese word which means “SHOP FLOOR’’. It provides quality assurance, fastest delivery and least cost to customers by  Offering appropriate products and services.  Adopting lean manufacturing systems & practices through employee empowerment and participation.  Bench marking products, process and people against best in the industry In

processing

of

this

plan

everyday

all

permanent

workers,

engineers, managers amount up on the GEMBA floor and discuss their problems and solutions with each other. Every day for their improvement suggestion every guy is awarded marks according to the performance and after a period the highest scorer is awarded the GEMBA mission award.

A BRIEF OF DEPARTMENTS 1. PERSONNEL & ISTRATION DEPARTMENT Personal department has a very significant role in any organization. Here it is headed by Mr. Ramesh Yadav. This department has to perform a number of functions: Providing manpower as per production plan  Calling

application,

interviews,

short

application

listing

blank,

applicants,

letters, ing formalities  Issue of circulars / notices  Transfer, promotion , relieving letters

conducting

sending

tests/

appointment

 Arranging induction program  Disciplinary actions as per standing orders, ID act, conciliation proceeding  To arrange & attend meeting with union, conciliation meeting in labour department  To attend & follow up all court cases relating to P& A.  Grievance procedure – attending every grievances to srt it out at initial stage  Maintaining a vigil on movement of union/workmen  Maintaining a high morale of employees  Lessoning with government department concerning P& A  Correspondence with corporate personnel, insurance & other department.

STRATION:Purchase of soaps every month &distributed to workmen  Arranging measurement of uniform & distribution  Issue of tea mugs on quarterly basis  For executives processing of major medical claim, LTA, minor medical ETC  Mail dispatch through franking machine/ courier  Horticulture activity  Transport  Communication system  Engagement of house keeping contractor & all related activity

CORRESPONDANCE: Monthly report to corporate personnel, insurance accident reports to factories inspector and ESI department  Quarterly report to EMP exchange  Half yearly report o factory inspector  Renewal of license- factories, DD units

 Correspondence with corporate personnel on policy matters any clarification  Correspondence for approval with MM 

Correspondence for approval – diwali sweets, gifts

MEDICAL CENTRE: Up keeping the medical centre  Providing medicines  Tetvec injections/ medicines to all employees -6 month basis  Doctor appointment & relating correspondence

VEHICLES: Up keeping jeep , ambulance, fire tenders, arranging repairs, providing transport to all

CANTEEN: A watch on activities on canteen on daily basis, arranging repairs , equipments, canteen contractor, ensuring hygienic condition in canteen attending to complaints

SECURITY: A watch on security  Correspondence with security agency  Renewal of security contract- al relating action like ADVT, Inviting quotation, interviewers, spot inspection  Correspondence on security lapses , theft cases

HRD/ TRAINING: EMS work ( environment management system)

 Identifying training needs  Selecting training programme  Notice for training programme  Nominating participants  Attendance , feed back, evaluation of all training programme  Analyzing all data regarding activity like Bench Marketing, targets customer satisfaction reports, graphs.

2. PRODUCTION DEPARTMENT:This department handles all the plant work for production. This department is responsible for all tech production and its process going at assembly line and also the PDI (Pre Delivery Inspection). They deal with all the workers to get the work output from them for production. They decide which model is to be assembled according to the availability of material and demand of production.

3. QUALITY CONTROL DEPARTMENT Aiming the target of zero defects in their product this department has to play a very challenging role. Attainment of prestigious quality certificate such as QS 9000 as Ashok Leyland has the landmark of being the first auto industry in India to receive this honour. So to keep the real value responsibility of this department becomes tougher. So personnel of this department has to keep a sharp eye on every activity so that a minute kind of defect must not be allowed with their product. The QC department of Ashok Leyland, Alwar is running under wise guidance of Mr. Vinay Bhargava along with cooperation of Mr. Rajendra Yadav & Vinay Gupta.

Currently nine personnel are deployed under this department and QC department work is distributed among three sections: first one is GR&D, LINE and the last one is PDI. This department is responsible for the quality of products and parts whatever they sell or purchase. The quality checking is done in three processes which are given as follows:  Incoming material inspection  In-process inspection  Final inspection There is a GR & D (Goods receipt and dispatch) section which receives good and QC department inspect them and ensure the quality as per the recommended standards and then send them to store. For in-process inspection they use one chassis-card in which the worker check whether all things has been done which he had to do and then do signature in the card. This is known as self-certification. When the chassis become off-track to the assembly line then the chassis goes for a road-test. The defects and shortcoming in the chassis are noted such as noise, smoke, driving control etc. Then an inspection of chassis takes place at PDI and then all the defects are noted and are rectified. After that the chassis is ed to sales department by QC department.

 PDI (PRE DELIVERY INSPECTION):It under comes the quality department but it has much utility that it has an important role in the production. The vehicle coming from assembly line is not perfect in quality. It has many defects. So the chassis is inspected, faults are arrested in this section and all the defects and faults are noted. The chassis comes into PDI section after road-testing. Then all the defects and faults found in the chassis are rectified using necessary tools and items. Then the chassis is painted in the paint booth and if there is any dent on the chassis FES, then it is

removed and finally ed to sales department. The chassis ed from PDI is fault free and perfect in quality. Painting of the chassis is also done under this department.

GR&D (Goods Receive and Dispatch) This department is provided or giving their services when the goods are received in the plant as a material from outside and when it dispatch outside the plant. This basically gives their service for quality and amount assuring.

 UNIT PLANNING DEPARTMENT:This department basically does the planning work. They are given the project of some new units to be prepared in the plant for which they plan the appropriate place installation of the new unit the approximate duration of completion of project cost estimation and benefits of the installation of new unit. Presently they are taking care of new rear axle assembly conveyor line project being installed in shop-2 paint booth for body painting of futon bus in shop-5.

 PURCHASE DEPARTMENT:-

Raw material is very important for the production. All the raw material is purchased by purchase department from various dealers and companies. They decide which material should from which company. They also look at the cost of material to be purchased and the transportation charges. It is better if the material is coming from a place near to the plant because the transportation cost will be reduced. They also decided the firm to sell the scrap items of iron, wood etc. The tender will be given to whoever will pay more. They also hire the contractors from the market by tendering to manage much work in plants like material unloading, transportation construction.

 FINANCE DEPARTMENT:This department takes care of all financial things of the plant. It keeps record of all the salaries and all allowances of the employees, the money spent on purchasing the things for the plant, the money earned by the sale of products and other financial activities. It prepares a monthly and annual budget of the plant. It also monitors the attendance of the employees by an electronic card punching attendance system. All the employees are provided with an electronic card which is punched in the card punching machine at the time of entering the plant and at the time of leaving the plan. The time of punching will be noted by the machine and thus the department gets the data.

 SALES AND MARKETING DEPARTMENT:Products are made in the plant and they need to be sold to the customers.

This

department

takes

care

of

all

the

marketing

activities. After the product is ed from QC department, sales

and marketing activities. After the product is ed from QC department, sales and marketing department keeps all the products at R.S.O. (Regional Sales Office). With safety the vehicle is kept in the R.S.O. after fitting the heat guards, warning triangles, RUPD (Rear Under Protection Device) and Canopy as per the government rule. Then at demand and requirement the products are sent to the dealers. They look at the demand of product in the market and the customer’s about the product. They also provide the training for servicing of the product. They

send

their

report

that

in

what

amount

has

demand

to

production department so that they can decide the amount of production that they can.

 PPC DEPARTMENT:Production planning and control department is known as PPC department. This department control GR & D section and storerooms. They receive the goods coming from the factories. Then according to the vouchers, counting of parts is done. They prepare a daily report of goods received and send it to Finance department for further procedure. They allot part number for the parts and parts arranged according to the part number in the store-room. They keep all the records of store-room. Monthly counting of parts is also done.

CONCLUSIONS The bird eye view of my project is that in this competitive market human resources are the major assets of an organization. Therefore, ASHOK LEYLAND Alwar, India really focuses to find out the effective sources of recruitment & selection process. The researcher has done enough research on sources of recruitment & selection process of the company. The researcher has come up with certain recommendations that are to be adopted, which on implementation would be beneficial for the company in long run. There are certain inferences what was found through the project in the company and are given below-



ASHOK LEYLAND Alwar is using both sources of recruitment i.e. internal and external sources.



ASHOK agencies

LEYLAND as

a

Alwar,

method

of

India

prefers

external

to

sources

use of

placement recruitment.

Company also recruits candidates through employee reference as an internal source.



ASHOK LEYLAND Alwar, India employees

on

daily

recruits

and weekly basis

the as

temporary well

as

occasionally because when company feels shortage of manpower in the lower level management, at that junction it recruits the candidates on daily basis

where as

shortage of

manpower in

middle level

management at that

point

of

time

recruitment

and selection is done but this situation comes occasionally.  Theoretically, there are eight standard steps of selection process but

company

follows

one

to

five

steps

for

selecting

the

candidates, for example temporary employees are selected with in one to two steps where as permanent

employees and

executive are selected with in three to five steps.



After selection of the candidates they are on a probation period of six months and after six months if their performance matches with the job description, they are appointed on the payroll of the company.



There are some internal and external factors which affect the recruitment and selection process and the factors which affect most are place of posting and compensation structure.



Apprentice is recruited from the organization whose temporary employees completed 6 month period.

LIMITATIONS OF THE STUDY 

This project is limited to one plant of Ashok Leyland Alwar, which is based in Alwar (Rajasthan).

 Some

data

was

confidential

and not disclosed

company’s policy.  Time limitation was the major factor for the study.

as

per

the

RECOMMENDATIONS On the basis of the research work there are several points, which came as a conclusion and according to that there are some points which are pointed out as recommendations, and if company follows these points then company can effectively recruit and select the candidates and increase the retention of the employees. These points are given as follows:1. The

Company

at

present

is

mostly

utilizing

the

source

of

recruitment by employee referrals and placement agencies. If the company goes for other effective sources of recruitment like job portals

and

ments,

it

can

get

some

effective

and

efficient candidates for recruitment and selection. 2. Company

should

decrease

the

complexity

of

the

selection

procedure for lower level employees while hiring the candidates for judging their competencies. 3. For selecting the candidates, company should go for some new technical and creative tests as a compulsory test apart from the aptitude and trade test for the employees. 4. At present the probation period in ASHOK LEYLAND, ALWAR is up to six months. It is advisable for the company that people at the different post should be given different probation period.

BIBLIOGRAPHY I got all the information regarding the study of Recruitment & Selection with written proofs from the following references.

Books:



HUMAN RESOURCE AND PERSONNEL MANAGEMENT by K.Aswathappa



HUMAN RESOURCE MANAGEMENT by Gary Dessler



HRM & IR by P Subba Rao

Manuals:  HRD MANUAL

Websites:



www.hrfactor.com



www.hrguide.com



www.hrtrends.com

 www.ashokleyland.com

PROJECT TITLE: Study of the production of goods Trucks and Buses.

INTRODUCTION: The project is related to the improvement of the production rate of the Goods Truck & Buses. Since truck & Buses assembly is recently started in Alw ar plant of ASHOK LEYLAND LTD, therefore some improvement for reducing assembly time &increase in productivity & also making easier assembly process inevitable. It includes suggestion & taking them under consideration for new layout & new manufacturing system.

INTRODUCTION TO PRODUCTION (Trucks & Buses): Assembly stages are given below: ● Framing ● Lay Dow n ● Bracketing Stages ● Piping Stages ● Engine Mounting 1 ● Engine Mounting 2 ● Lubrication ● Off track 1 ●Off track 2 ● Road Testing ● Pre Delivery Inspection(PDI)

FRAMING This is the first stage of the w hole assembly line. As the name suggesting at this stage frame of chassis is given the shape in form of ladder. This ladder shape form is given with help of tw o side and several cross . Number of cross member varies from model to model. All cross along with brackets, which hold and other components that will assemble later on are made connected to side member, which comes previously drilled form. So all cross member along with brackets made fixed at their respective position with help of bolts and nuts. Flitchs are also inserted to side member which provides extra strength to frame. General brackets which assembled to frame are to radiator, engine bracket, spring brackets. The size and structure of each bracket varies from model to model. Material for all frames is mild steel and length of cross member remains constant that is about 850 mm. After building frame, it is checked for bend, which may be produced while assembling cross to side member. It is made to inspect frame assembly line and rectification also made on this stage. For conforming w hether bend is present or not in frame stretchable thread is use and if there is end of specification of 0.5mm per meters then frame having this much bend would be allowable. Direction of bend present in both side is in the same direction then maximum of tw o is considered. And if the bend present in two side are in opposite direction then their summation is considered. And if bend present is in wavy form then two summation would be considered and maximum of these summation would be considered. So this is general method used for inspecting amount of bend present in frame. Specifications of some of frame models that have been built in ASHOK LEYLAND ALWAR are given below. FRAMELENGTH WHEEL BASE NO. OF CROSS MODEL (in mm) (in mm) 210 CH HINO EI

9678

210

7

222 VIK HINO EI

10100

210

7

222 CNG IVECO

10541

222

222 W/S A/SHIN

10541

222

8 7

LAY DOWN The lay down stage is the very stage of the framing stage. It comprises three distinct stages and the working of these stages varies model after model. Generally the work carried out at this stage Consists of assembly front and rear axle on chassis along with springs. Generally chassis are made to available with three kind of suspension system. These are mechanical suspension, Weller suspension, air/ webller suspension. Ordinary chassis are equipped w ith mechanical kind of suspension, as CNG chassis are equipped with Weller kind of suspension as CNG chassis have to bear heavy load of 12 cylinder of CNG, and last kind of suspension are employed on luxury chassis as this suspension is know n for its absolute shock free comfort. The procedure for mounting of mechanical kind of suspension is followed: enger models, like 203 cheetah enger chassis (6 wheeler) have processing stages, are as follows: 1. Axle dressing 2. Axle coupling 3. Torque stand So a brief description regarding process for enger chassis carried out at this stage is mentioned below.

AXLE Dressing:In this stage front and rear axles are assembled with leaf spring. The front leaf spring are assembled on front axle with I bolt and nut having inserted packing plates and shocker plates on which shockers are mounted. On the other side the rear leaf spring is assembled with the help 9f Ubolt. The brake boosters are also assembled on rear axle at this stage while on the front axle brake chambers are already assembled previously.

Axle Coupling:At the coupling stage the front and rear axles assembled w ith leaf spring are coupled w ith frame. The coupling is done with the help of shackle pin, which inserts in bracket and hole of the springs. The shackle pin has a very min tolerance and that special type of key pin is made with taper arrangements so proper alignment is required to fix that pin in leaf spring with brackets of frame.

Torque stand:At the torque stand tightening of all the nuts that have been bolted on previous two stages are done as on previous stages components have been just assembled, lightly on frame. After tightening nuts the strength of their tightness is checked with help of impact wrench. Of all type of rear suspension used on with rear axle vehicle the non reactive suspension has been chosen ow ing to its simplicity and safe riding Characteristics. Theterm non-reactive means that under all static and dynamic conditions the suspension is self-compensating. Unlike the balance beam, this is not self-compensating under all condition. The other advantages offered by this suspension are;

1.

It allow s the load on spring of one axle tube shared by the springs of other when an uneven road surface is encountered and results in minimal vertical movement of frame. On the of the load being alw ays shared equally by the axles road damage is considerably reduced.

2.

In normal twin rear axles vehicles while braking there is transfer of weight from front axle to back axle of the rear axle and thus can cause the wheels on forward rear axle to lave the road surface or at very least in loose tyre grip on road the result is loss in braking efficiency of vehicle But in nonreactive suspension the forw ard rear axle does not raise on braking preventing loss in brakin efficiency.

3. This suspension reduces the shock loads with resultant life extension chassis components. So this simple arrangement provides lot of advantages.The arrangement includes trailing springs anchored at front end with load equalization b\w the axles through ball crank levers and connecting rod.

FRAME DRESSING:At this stage tie rod is made to assemble on frame which is carrying tw o moveable parts called shackles to which front end of both rear springs would made to connect to brackets , and at axle coupling stage both rear axles come without having rear springs opposite to case of ordinary in which they comes along with rear springs. So firstly both rear springs are to made connected to tie rod and frame. So this is work that is carried out during lay dow n stage of multivalent vehicle such as 2214. Below is specification of components assembled at this stage: MODEL FRONT REAR REAR NO. OF IN REAR AXLE CAP AXLE AXLE LEAVES CAP RATIO IN F.A. 210 CHE 5460 10200 5.833:1 12 15 222 CNG 5460 10200 5.8333:1 111112 12 222 VIK 5460 10200 5.833:1 12 12 2214 MA 6000 19000 6.167:1 12 13 (9500*2) 222WA 5460 10200 5.8333:1 12 10

BRAKETING STAGE:This is next staged hat lies in assembly operation. The components assembled here are steering box, fuel tank, brackets for air tanks, dual brake valve, clutch pedal and carrier for spare w heel. Steering bar is mounted on chassis with arm, which is further connected to drag link & connection of drag links is made with fitment arm. By rotating steering wheel drop arm moves in required direction. In addition to mounting of above components wheel alingnment is also done on its stage. The purpose behind this is to sure that stub axle are exactly parallel to each other this is done by measuring b\w fronts & back portion of stub axle. MODEL

STEERING

210 VIKING POWER 222 POWER (IVECO,HINO) 2214 HINO POWER

RATIO

34.5:1

ANGLEOFST WHEEL G. DEG. DIA 73 73

533.5 533.5

71

533

PIPING STAGE:As name suggesting w ork carried out on this stage consists of making pipe arrangement for bake system of chassis. At this stage whole ckt. Of brake sys. Is laid dow n on chassis with help of metallic pipes. The brake sys. Of all models of ASHOK LEYLAND VECHICLE has being designed by SUNDRA CLAYTON LIT. of Chennai, and name given to such arrangements called DUAL BRAKE SYSTEM. This dual brake sys. a split sys. of air brake to actuate front and rear foundation brake separately, there by insuring partial braking for vehicle

Working System:As the system starts charging the preferential arrangement in SPV allow air in to service reservoir (primary/secondary) As the pressure reaches above opening pressure of auxiliaries in the sys. the auxiliaries line start charging. As long as the sys. Pressure is below he opening pressure of the auxiliaries, the hand brake is inoperative and the spring brakes are applied condition. As soon as the compressor start’s pumping air in to the sys. & the sys. Pressure is below the opening pressure of auxiliaries, the low pressure indicator switch continue to give warning. The warning from the low pressure indicator switch stop’s when the sys. Pressure reaches above opening pressure of the auxiliaries & with lever of graduated hand release valve in BRAKE OFF position. In this position the spring brake in rear are fully released. So when the dual brake valve pedal is pressed, compressed air from the primary reservoirs fed into the service port (11) of he spring brake actuators through dual brake valve primary & applies brake in rear. Simultaneously compressed air in the secondary reservoir is fed into the brake chamber through the dual brake valve secondary & applies the brakes in fronts, foundation brakes are actuated by the slack adjusters connected to the brake chamber & springs brake actuators in the fronts & rear brake the brake chamber & springs brake actuators in the fronts & rear brake respectively. In case of releasing the load from pedal air from service port (11) of brake actuators through dual brake valve primary & applies brake in rear. Simultaneously compressed air in the secondary reservoir is fed in to the brake chamber through the dual brake valve secondary & applies the brakes in fronts. Foundation brakes are actuated by the slack adjuster connected to the brake chamber & spring brake actuators in the front & rear brake respectively. In case of releasing the load from pedal air from service port(11) of springs brake actuators is exhausted by dual brake valve. During

same time air from the brake chamber is exhausted through the dual brake valve thus releasing brake in front. So this is about working of DUAL BRAKE SYSTEM of chassis having single axle in case of multi axle drive working is quite similar ht only ht only difference is due to addition of some components. These components are only assembled incase of multi axle drive a little detail about these components along w ith components that are assembled in single axle chassis, which also assembled in multi axle, is give below.

RELAY VALVE:In air pressure braking system employing long piping running between brake valve and brake chamber relay valves are used the signified by brake valves. The relay is connected to reservoir and air delivered to and release from brake chamber is ed through relay valve and only a small amount of air used to actuate relay valve is delivered and exhausted from brake valve. This gives quick braking response and also permits the same pressure to brake chamber as delivered by brake valve.

QUICK RELEASE VALVE:The component ensures faster exhaust of air pressure from brake chambers.

AIR FILTER:The component prevents dirt from reaching pipe line and valve in brake system. When air filter jammed due to dust then during suction of air, vacuum is created in air filter. There is a vacuum valve on the front penal of FES which is connected with air filter. Now due to jam in air filter, the spring inside the vacuum valve goes dow n, this gives indication to driver to clean the air filter.

BRAKE CHAMBER:The function of brake chamber is to convert energy of compressed air in to mechanical force and motion necessary to operate brake.

DUAL BRAKE VALVE:This valve gradually charges and exhausts air from brake chambers and spring brake actuators. Dual brake valve has two brake valves assembled in tandem. When brake is applied the plunger moves the primary piston downwards closing the exhaust age and subsequently opening primary inlet valve thus itting compressed air in delivery line connected to spring brake actuators in rear and applies the brake. When brake is released the inlet valves in the primary and secondary closes inlet age and opens the exhaust age by the secondary piston end subsequently opens the inlet valve of secondary thus itting compressed air in delivery line connected to brake chambers in rear and applies the brake. When brake is released the inlet valves in the primary and secondary closes inlet age and opens the exhaust age allow ing the compressed air from brake chambers and spring brake actuators to atmosphere.

GRADUATED HAND RELEASE VALVE:This valve charges and exhausts compressed air gradually form spring brake actuators for releasing and applying parking brake.

SPRING BRAKE ACTUATORS:THIS COMPONENT products necessary braking force at the foundation brake in service & hand brake application . This unit has diaphragm type brake chamber operation service brake connected port(11) & a spring brake operating the parking/hand brae connected port 12. When air pressure is applied to service port11 diaphragms flexes & operates the push rod which in turn moves slack adjuster to operate foundation brake. The spring brake portion when hand brake valve is operated, air pressure from spring brake portion is exhausted to atmosphere &heavy coil spring pushes the push rod through diaphragm sand brakes are applied.

SILENCERAll vehicles of ASHOK LEYLAND Ltd. are double silencer which reduces noise pollution at higher extent. It is all about brief description about working & functions of components assembled in vehicles. So at this stage lay down of all this components connecting through pipes is laid dow n along with connection of components by using air hoses & metallic pipes certain

Other components are assembled on this stage such as oil Bundy pipes all this which senses pressure of oil in engine & pressure of air in tw o tanks are connected tr. Hydraulic pipes which is connected to Hyd. Reservoir coming from stg. Box also leakage of whole arrangement is checked.

ENGINE MOUNTING 1 The next that lies during assembly operation is engine mounting 1 work carried out during this stage include following fitments of components .

FITMENT OF PROPELLOR V SHAFT:Previously a dressed propeller shaft that is dressed offline is mounted on chassis. Tw o propeller shafts (P.P.S.) refitted case on heavy vehicle & in case enger three PPS are fitted. So we take general case of two PPS. Two PPS are fitted b/w gear box & rear axle s by center bearing at center. The front shafts have a fixed t near gear box & rear end is ed on center bearing with a splinted stub shafts to take up rear propeller shafts. The rear shafts consists of fixed ts at rear end a slip t at free end for a longer end trouble free life these ts are to be lubricated periodically.

ENGINE MOUNTING:As the name given to this stage because of figment of this components. Previously dressed engine whose dressing is done off line w ith could plate, pressure plate & some other accessory made available to online & at this stage it is mounted. After fitting engine on chassis no. of connection of different components to engine is made connection such as asir cleaner which provide supply of air to engine if modal is of enger then air cleaner is directly mounted to engine if it of heavy then air cleaner is the separate unit exists which is assembled to engine by a pipe going to intake manifold of engine. Second connection is of tail pipe coming out through exhaust manifold & a head of this a silencer is mounted a head of which an exhaust pipe is fitted. Other connection is of fuel hose from diesel tank to feed pump that already mounted on engine, return fuel hose fro governor to fuel tank. This component that assembles here on chassis is radiator to engine, is which is also previously dressed off line connection of radiator to engine, is made through hose that are of radiator. One hose goes to engine it serves as inlet to engine second hose comes

from engine to radiator which act outlet for coolant & third hose that comes from diesel tank also act inlet hose of one way type outlet hose come through a thermostat valve which opens at definite temp. so until this temp. is achieved coolant cant go through engine. The basic function of thermostat valve is to engine to attain its working temp. as early as possible. And last component fitted is steering column to steering box. Steering column is connected to steering box through knuckle t in case of CNG many other components are assembled on chassis at this stage components like first stage regulator, second stage regulator are mounted on chassis .The function on these components is to reduce pressure of CNG which is filled in cylinders at a pressure of these components is to reduce pressure of CNG which filled in cylinder at a pressure of 200 bar to 9 bar So first stage regulator pressure reduces so drastically results in decrease in temperature which may result in freezing of CNG so to avoid this tw o pipes are made connected to this components which carries hot water from engine & circulates around it so that the above case may happen.

ENGINE MOUNTING 2 This is a next stage lie during assembly line. In case of assemble of ordinary chassis this stage is not much us. This stage comes in to its full operation in case of CNG chassis assembly. In case of assembly of ordinary chassis work carried out is composed of bumper, mounting of Head lights along with indicator lights so not tool much work is carried out. In case of CNG work carried out consists of various small tasks these includes connection of 3 WAY SOLENOID SWITCH Along with connection of hot water hoses to first stage regulator, connection of first stage regulator to second stage regulator, Along with this ing of spring brake actuators to the slack adjustor. Connection for hydraulic system is made i. e. one hose is connected from hydraulic rear oil to steering box &second hose is connected to hyd. Pump. Other outlet of hyd. Pump is made to connect with steering an one hose from steering goes into the hyd. Pump so w ith this arrangement hyd. Oil keeps circulate from hyd. Reservoir to steering with help of hyd. Pump. Along with this mounting of bumper & head and indicators light is done. A steering column is connected to steering box through universal t. The most arduous task performed here dismounting CNG cylinders on the chassis .12 cylinder each are having capacity of about 9 it. Is mounted on chassis in from of to channels each carrying 6 cylinders. At the outlet of each cylinder a valve is connected which act as a safety cum delivery

valve. The purpose of this valve is to provide safety case of leakage of CNG from cylinder. In case of leakage the safety valve would be open & through ventilation arrangement gas would disperse in to atmosphere. Gas piping arrangement for supply of CNG from all the hoses are made up of CDS and are very costly about 300/- per ft. so ing the transducer supply goes into first stage regulator. Also arrangement for ventilation is made at this stage hoses from the safety portion of valve are connected to tow hoses one for each side consisting of 6 cylinders and these tow hoses are left open for further connection where there would be further connected to tow main pipe w hich opens in air at rear side of chassis. As CNG is lighter then air it would readily diffuse in air as comparison to LPG which is heavier than air and in case of leakage it accumulates near to area of dispersion so in this case CNG in safer fuel then LPG.

LUBRICATION:As name suggesting the kind of work done during this stage is filling of oil to the various components of chassis and application pf grease to grease nipples so that operation of all these parts may take place smoothly with least friction so top ensure their long life. The work carried out on this stage mainly consists of oil and application no grease to components chassis. And wheels mounting on both front and rear axles are also done on this stage. Different type of oil is filled in number of components engine oil is filled in engine, gear oil in gear box, rear axle, hydraulic oil in steering box and addition of filling of DIESEL in fuel tank is also done about 20 Lt of diesel is filled in fuel tank and filling of water in radiator is also done. And application of grease to all grease nipple is done grease is applied to grease nipple until it starts to come out from other part of nipple. Tightening of all wheel bolt which are mounted on both front and rear axles is done keeping the torque of 400 lb. ft. In radiator, The ratio to coolant & waters in for enger vehicle-3:7 For Goods vehicle 1:1 Specification of oil changes from model to model and also from season to season. Quantity of oil also varies from model to model.

OFFTRACK 1 This is next stage that lies after lubrication stage in sequence of assembly line. At this stage wooden trame on which driver seat has been mounted is made to mount of chassis. Wooden str. Is made to mount in case of ordinary chassis but in case of chassis for heavies a steel str. Takes place of wooden str. Called FES (front-end Structure). Generally it can be said as cabin with no roof but having all features w hich have to be made available around driver such as dashboard having all displays, horn, steering wheel, head light, indicator light, acc. Pedal, brake pedal, clutch pedal, wiper motor. This str. is made to mount on chassis which one is needed. In addition of mounting of str. tw o batteries of 12 volt each is made to mount on chassis and +ve of one battery is made to connect with –ve of second battery thus providing series connection and –ve terminal of first battery is earth connected thus avoiding the danger of lcaage and +ve of second battery is made to connect w ith starter motor. And in addition of this a pedal is made to link with throttled valve. And incase of CNG filling of gas to all 12 cylinder is done. So this much amount of work is done at this stage.

OFFTRACK 2 This is last stage that lies during assembly operation. The chassis is made to run for very fist time. The work carried out at this stage involves connection of all electrical equipment. In addition to above task another operation which are preformed at this stage are mounting of steering w heel to steering column, mounting of dash board having all displays which will be further connected to respective components. Also max. cut is given to chassis at this stage. The purpose behind this is to set maximum limit to w hich a vehicle can take turn. The chassis is given so such limits by adjusting max cut screw mounted on front axle by adjusting the distance between outer edge of chassis and leaf spring of front axle. This is set at 505 inch. In the case of pow er steering another cut is also given in addition to max cut and this is called hydraulic max cut. The purpose behind this cut is to introduce safety factor. In case of hydraulic max cut the additional setting is done by keeping a distance of 3 mm between axle beam and front axle whether in former case i.e. in mech. Max cut axle beam and max cut screw touch each other.

And in last chassis is made to start for first time. All kind of leakage is checked along with proper functioning of each road testing.

ROAD TESTING So it is testing time for chassis. After coming from assembly line chassis is first time subjected to run on road. A testing of about 15 Km is given to chassis and during this 15km functioning of all components comes under observation. And after completing drive road tester made ROADTEST INSPECTION REPORT in which he motions defects that has been occurred during drive. The general area where defects are found to develop arête chances of oil leaks in engine, gear box, rear axle, steering box, pow er steering, diesel leaks, radiator leakage, propeller shaft leakage. And in addition to oil leakage functioning of brake system of chassis is observed. Observation regarding whether brake drum are over heating, hand brake functioning produced in various components are examined whether any axle noise, water pump noise, timing gear noise are observed overheating of engine and remark regarding pick up is also mentioned in inspection report.

PRE DELIVERYINSPECTION (PDI) As name suggesting function of this department is to rectify all defects in chassis, which may be left online and have been developed after road testing. In addition of rectifying other task involved filling of coolant in radiator by replacing water. Trouble shooting for some din d of defects w hich are found in chassis are done as for if engine is not starting then possible reason may be one or more of follow ing (insufficient gas pressure in CNG chassis, starter motor not working, insufficient air flow to carburetor and many more.) So after finding the fault the cause for fault is find out and rectified by workers of this department. In addition of rectifying all defects present in chassis specified work of this department is follow ing:1. Start engine and build air pressure to 8.25 Kgf/cm. 2. Check leak from pipe ts and valve with soap and rectify if any. 3. Tight all drain plug 4. Check ignition timing and adjust if required 5. Remove about 13 Lt. of water from radiator and fill coolant of specified quantity. 6. Cover dashboard with polythene. So this is general w ork carried out by PDI department both QC and PRODUCTION department.