Professional Documents
Culture Documents
Ashok Leyland
Ashok Leyland
Ashok Leyland
BASED ON
IN-PLANT TRAINING
IN
ENNORE, CHENNAI-57
BY
SAIPARMESHRAJ.S &PRAVEEN.S
SRM UNIVERSITY
B.Tech MECHANICAL ENGINEERING
FROM: 12-07-2016
TO: 16-07-2016
1
INTRODUCTION:
This report is based on knowledge that I gained on the Inplant training I undertook in your well-organized and interesting company.
I have written the report upon the various shops in the same order as I
visited. I have recorded as much as information and knowledge that I
collected in this visit clearly here. I hope you will find it satisfying.
DAY - 2: FRAME ASSEMBLY (FA) & CHASSIS ASSEMBLY
(CA)
Day 2 started with an interesting assembly unit. The moment we
got into the shop we were able to see the completely assembled truck
5
revving up for its test drive. We were navigated to the frame assembly
so that we could get an idea of how from down to the earth the very
aspiring truck is assembled. So we first dashed into the frame
assembly unit.
FRAME ASSEMBLY:
This unit has around 9 stages, each provided
a special function to play. Lets see all the stages one by one,
I.
II.
III.
FSM LOADING:
The acronym FSM leads to a definition
Finite State Machine. They are building cells of a
frame. They are loaded on the conveyor belt with
wooden logs for mounting for easy work. This
consists of two separate metal pieces clamped
with holding devices like square plates for further
mountings. After they are set on the conveyor it is
sent to the next stage.
CROSS MEMBER FITMENT:
Cross members are those joining members
between two FSMs. About three cross members
are fitted here. They are provided to create three
segments which are engine and gearbox setup,
front axle and rear axles. Further they are
provided with proper clamps for mounting the
steering and propeller shaft. Their bolts are
properly screwed and sent to the next stage.
CROSS MEMBER FITMENT:
Here too the same fitting is done, it is taken
down in stages to distribute the work load.
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IV.
V.
VI.
VII.
VIII.
IX.
FRAME UNLOADING:
FRAME UNLOADING:
Here the assembled frame is unloaded from
the conveyor and made ready to move it to the
chassis assembly section. This work is also done
in two stages based on the work load.
7
CHASSIS ASSEMBLY:
This section of assembly includes the adding up of
working parts of a truck in various stages. This assembly area
has around 16 stages. After each stage we can see the truck
being developed stage by stage. Lets see those assembly
level stages one after the other in order now.
i.
FRAME LOADING:
Here nothing but the assembled frame which
was the end product of the section frame
assembly is loaded on the conveyor belt of the
chassis assembly section. This activity is usually
performed by using cranes.
ii.
iv.
AXLE TORQUING:
This stage does the job of torqueing i.e
proper adjustments of the axles with the
frame by rotating the component through
small or large angles. This activity is
required for the smooth performance of
the axle in flow with the whole vehicle.
v.
SILENCER MOUNTING:
No machine is 100% efficient. So it is the
case of engines too. The useless gases produced
inside the engine are expelled out using the
exhaust. So this calls for the installation of
silencer in all vehicles which applies for trucks
too. The silencers are attached with a filter set up
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vi.
CHASSIS TURNOVER:
The mountings of various components on
the assembled frame till now was done in
upside down way. So the whole midassembled piece should be turned over for
the placement of further products. This sis
done using a chained pulley with a cloth
like material forming a belt around the
frame. It is lifted and the chain on the pulley
are actuated helping to turn the whole piece
downside up.
vii.
viii.
ENGINE MOUNTING:
Now it was the time for fixing the heart of
the truck. The engine is pre-assembled with the
gearbox and brought to mount on the space
provided between the cross beam members. The
engine assembly was quite interesting to see and
it had many intricate connections to make, so it
called for more manpower. The front axle
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ix.
x.
OIL FILLING:
Here the various tanks provided inside the
truck are filled with respective fluids and fuels.
In this stage various connections of these tanks
are also clearly established.
xi.
DRIVER UNIT:
Now the frame with all the necessary
components are ready. So now we need a proper
place for the driver to comfortably sit and operate
the truck. The whole driver unit is again
preassembled in a different shop and is brought
for direct installation. This installation took much
time and labor. All cables were set for more
electrical connections to be made in the
upcoming segments.
xii.
ELECTRICALS:
` This is the place where all the important
electrical connections are established. All the
various cables which were left out in different
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WHEEL MOUNTING:
This segment is for the installation of
wheels on both the axles. Only one wheel each is
given for the front axle whereas two wheels each
are given for the each side of the rear axle. On
observation we found out that commonly used
tyres are MRF, Vikrant,etc,
xiv.
WHEEL TORQUING:
This segment is purely meant for the
proper installation of the prefitted wheels on the
axle. This torqueing operation is done manually
with the help a long rod. The wheels are first
rotated through small or large angles and fixed
effectively. This process is necessary for the
proper functioning of wheels without derailment.
xv.
VEHICLE STARTING:
In this segment a trained driver climbs into
the truck to start the engine and give life to the
truck. The vehicle once started is then let in ON
state till it is test driven.
xvi.
OFF-TRACK:
This is the real testing of the truck on the
roads. Trained drivers take the incharge and rev in
the streets of Ennore to test and also exhibit the
Ashok leylands masterpiece.
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DAY-3: SHOP VI
This shop does activities like cylinder blocks, cam
shafts and cylinder heads. Moreover it produces cylinder blocks for two
kinds of engines, namely H and Neptune(N). Neptune engine cylinder
blocks are given a color code of blue and H blocks red. The moment
we stepped into the shop we were able to see the Neptune blocks being
operated. The whole setup was sort of fascinating since it had very
interactive employees and a great deal of techs.
H-CYLINDER BLOCK PROCESS:
Here there are majorly 3 Work Setting Stations (WSS).
From each WSS the cylinder blocks either start to get machined or
reach after undergoing various processes. There are two major work
stations here, they are named as WSS-4 and WSS-3. First lets see the
process flow of WSS-4. The name of each process is self-explanatory.
WSS
4
DRYING
& AIR
BLOWING
LINER
LINER
BORE
GRADIN
G
BORE
WASHING
TAPPET
REAMING
HONIN
G
13
14
BEARING
CAP DISSASSEMBLY
HIGH
PRESSURE
INJECTION
FLOOD
WASHING
IP
FACE
WELSCH
PLUG
PRES
S
LINER
BORE
OILING
MANUAL
WELSC
H
PLUG
PRES
S
OC FACE
WELSCH
PLUG
PRESS
GENERAL
WASHING
FOUNDRY
INSPECTION
ZONE
CAM
BUSH
PRESS
WATERWAYS
LEAK
TESTING
OIL PUMP
PERFORMANCE
CHECK
BORIN
G
LINER
COROUSS
AL
FINISHE
D
BLOCKS
LINE
R
PRES
S
PROTECTI
VE
COAT
APPLYING
K WSS-3 BORE
CRAN
DEBURRING
SEMIFINISH
OIL PUMP
BOREBUS
H
LINER
PROJECTION
AND
CHECKING
BLOCK
NUMBERING
FINISH
LINE
BORING
THRUST
FACING
NUMBER
MARKING
ON
BLOCK
& B
CAP
BEARING
CAP
OIL
GALLERY
ASSEMBLY
LEAK
TEST
BOSF
BLOCK
S
BOSF
BLOCK
FROM
STORE
S
LOADING
HIGH
PRESSUR
E
WASHIN
G
SPECIAL FEATURES:
1) CNC machines with automatic guided vehicle
for loading and unloading.
2) Centralized coolant & chip handling system.
Few intricate details of processes taking place in Injection
flood wash process are:
a) Idle station
b) Injection flood wash
c) High pressure deburring
d) Top butting and spray wash
e) Workpiece O/G butting and spray wash
f) Idle station
g) Turn over
h) Idle station.
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N BLOCK
LOADING
SUMP FACE
OPERATION
BEARING
CAPS DISSASSEMBLY
INJECTION
FLOOD
WASHING
PRESSURE
TESTING &
FINISHED
BLOCK
BEARING CAP
ASSEMBLY,
TIGHTEN
& NUMBER
MARKING
SEMI-FINISH
MACHINING
OPERATION
PRESS
WELSCH
PLUGS
LINE
BORING
INSERT
LINER TO
BORES
PROTECTIVE
OIL COAT
WATERWAYS
LEAK TEST
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DAY-4: SHOP-I
This segment of the factory deals with the gearbox
components production, assembly and testing of the assembled gearbox.
Lets see the process flow of each component of the gearbox.
HOBBIN
G
SHAPING
HEAT
TREATMEN
T
TOOTH
CHAMFERIN
G
WASHING
BORE &
TEETH
FACE
GRINDIN
G
WASHING
GRINDING
FINISHE
D
BLANK
ROUG
H
BLANK
HOBBING
TOOTH
CHAMFERIN
G
18
WASHIN
G
BORE
HEAT
GRINDING
TREATMENT
TEETH
GRINDIN
G
WASHIN
G
FINISH
BLANK
ROUGH
BLANK
MACHINING
DEBURRING
FINISH
BLANK
LAY SHAFT:
ROUGH
BLANK
FINIS
H
BLAN
K
HOBBING
WASHING
HEAT
TREATMEN
T
TEETH
BORE
OD
GRINDING
GRINDING
GRINDING
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MAIN SHAFT:
ROUGH
SHAPING
BLANK
THREAD
GRINDING &
FINISIH
SUPER
FINSIH
HOBBING
WASHING
OD
GRINDING
HEAT
TREATMENT
INPUT SHAFT:
ROUGH
SHAPING
BLANK
TEETH
GRINDING
BORE
GRINDING
& FINISH
HOBBING
OD
WASHING
GRINDING
HEAT
TREATME
NT
HOBBING
WASHING
SYNCHRO PARTS:
ROUGH
BLANK
BROACHING
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FINISH
GRINDING
BLANK
HEAT
TREATMEN
T
A few axle components that Ashok Leyland buys for the sake of
producing axles include:
Axle beam
Brake chamber
Front brake drum
Axle tube nut
Rear brake drum
Slack adjuster
Socket
Track rod
Track rod lever
Front axle king pin
TRFR bearing
Front hub
Rear axle distance piece
Rear hub
Ring for oil seal
Rear wheel bolt
Axle arm
Axle shaft
Oil flinger
Rear axle oil seal
Half axle.
FRONT
AXLE
BEAM
FRONT
BRAKE
DRUM
ASSEMBLED
FRONT
AXLE
BOOSTERS &
SUPPLEMENTAR
Y
ATTACHMENTS
TRFR
BEARING
FRONT
AXLE
HUB
ASSEMBLED
REAR AXLE
REAR
BRAKE
DRUM
TRFR
BEARING
SUPPLEMENTARY
ATTACHMENTS
REAR
AXLE
HUB
CONCLUSION:
This In-Plant Training was indeed a mere heavenly
experience. All huge trucks revving upon the roads in and out the plant,
often movement of load moving cars, sounds of large parts of truck
being produced, assembled and tested, helpful employees and strict
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SFSHFJGKHL,;JO;K/L
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AC
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ACD
22
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