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 virtue
Of mankind - this is a
choice which is possible
for all of us; and surely it
is
a 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 come
together.
• It is also the quality of human interactions in the workplace
- between co-workers, with customers and business partners.

Launched in June 2005 as a

company-wide initiative, Mission
Gemba’s objective is to provide
Information, develop skills and
Empower employees to reach
World-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 pump
Tapping:
 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 freeness
Stage 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.ibs
Stage 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