ABSTRACT This is a report on in-plant training carried out at ashok Leyland limited, ennore plant during 19-04-2011 to 26-042011. This report covers the important manufacturing process carried out at the industry. This report includes the aspects of production carried out at the sections like shop II, shop III, shop IV and shop VI. At the frame assembly section, the frame goes through various stages in which different components were attached to metal frame. In total there were 9 stages through which the frame passes through to become the skeletal function body of mobile function body of the automobile which can be a bus, track, or other such goods carrier. At the shop II various components of engine were produced.At the engine assembly section the various components being manufactured in shop II were assembled to form the engine and the assembled put to test for any correction required. At the shop IV, the assembly of rear and front axles were carried out.
ACKNOWLEDGEMENT First and foremost, we thank the management of ashok Leyland for following us to carry out our in plant training in their esteemed concern. We also thank various employees of the concern who spared their time answering our questions in spite of their busy schedule. Last but not the least we thank the almighty for keeping us in good health and for giving us this wonderful opportunity. First and foremost, we thank the management of ashok Leyland for following us to carry out our in plant training in their esteemed concern. We also thank various employees of the concern who spared their time answering our questions in spite of their busy schedule. Last but not the least we thank the almighty for keeping us in good health and for giving us this wonderful opportunity.
INTRODUCTION Ashok Leyland is an Indian automobile manufacturing company based in Chennai, India. Founded in 1948, and it is the second largest commercial vehicle manufacturers of commercial vehicles, such as trucks and buses, as well as emergency and military vehicles. Operating six plants, Ashok Leyland also makes spare parts and engines for industrial and marine applications. It sells about 60,000 vehicles and about 7,000 engines annually. It is the second largest commercial vehicle company in India in the medium and heavy commercial vehicle (M&HCV) segment with a market share of 28% (2007 – 08). With passenger transportation options ranging from 19 seaters to 80 seaters, Ashok Leyland is a market leader in the bus segment. The company claims to carry over 60 million passengers a day, more people than the entire Indian rail network. In the trucks segment Ashok Leyland primarily concentrates on the 16 ton to 25 ton range of trucks. However Ashok Leyland has presence in the entire truck range starting from 7.5 tons to 49 tons. With a joint venture with Nissan Motors of Japan the company made its presence in the Light Commercial Vehicle (LCV) segment (<7.5 tons).
Ashok Leyland's UK subsidiary Optare has shut down its bus factory in Blackburn, Lancashire.[2] This subsidiary's traditional home in Leeds has also been vacated in favour of a purpose built plant at Sherburn-in-Elmet.
MACHINE SHOP III: DATE OF TRAINING: 20-05-2014 FRAME ASSEMBLY The chassis of the vehicles’s first step starts from here at this shop-3. The frames of the vehicles are fixed together to be sent to the chassis assembly. The skids are mounted on the conveyor belt and frame is placed on the skids. And frame MTG on which engine is mounted is fixed across the two frames. On the rear end of the frame BKTS both sides are aligned with taper pin. Fit and tight FSR and BKTS on both sides with dummy bolts. Tilt both the FSMS to 90 degree by turning tackle and insert clamps. Tight and apply torque to engine MTG flinches and M12 with bolts. Correspondingly in every stage each workers tight appropriate bolt to the frame before taken to chassis assembly make it a complete frame.
STAGE 1: Load the FSM on the conveyor and fix the front bracket, V clamp, Skid and engine assembly brackets STAGE 3: Here the parts are bolted using M12 bolts and centre bearing cross member and rear spring cross member is fitted STAGE 4: Here the pintle hook cross member is fitted along with bumper extension racket STAGE 6: The rear spring cross member is bolted here using M14 bolts.
STAGE 7: Tightening of all the members is done here. STAGE 8: Elbow adapters and tow brackets are fixed in this stage. STAGE 9: Here air blow is done to ensure burr free frames.
MACHINE SHOP IV: DATE OF TRAINING: 21-05-2014 FRONT AXLE ASSEMBLY
STAGE 1: Axle beam is loaded on the conveyor belt. STAGE 2: Number is punched on the axle beam.
STAGE 3: Axle arm is fitted on the beam for steering.
STAGE 4: Steering rod is fitted. It is right end of the axle according to Indian STDs. STAGE 5: Tracking rod is fitted. It is used for the alignment of the wheel. It helps the left side of the tyre to turn along with the right side wheel. STAGE 6: Brake carriers with brake linings are fitted to the FR axle beam and taken to chassis assembled.
MACHINE SHOP IV: DATE OF TRAINING: 22-05-2014 REAR AXLE ASSEMBLY STAGE 1: Banjo casing from outside is unloaded and fixed on the conveyor and axle shaft is removed.
STAGE 2: Brake lining and 10 bolt and washer are fixed on the brake carrier with spring washer. Dust cover is also fitted.
STAGE 3: Brake nut and bolt are tighten and fitted 75 to 50 torques. STAGE 4: Ring for oil seal is fitted on the hub shim is fitted 3-6tau for the clearance flange cover is fitted with 4 bolts. STAGE 5: Inner oil seal is fitted on ring for inner oil seal. Inner wheel bearing is fitted. STAGE 6: Distance piece is fixed to align the inner and outer wheel bearing in the same axis. STAGE 7: Dry set, where the wheel hub is fixed roughly to verify whether to increase or decrease the shim. STAGE 8: WET SET Where grease is packed inside the wheel hub. STAGE 9: Axle tube nut is fixed with counter pin and bolt, 190 tau tightness. The given, studs are fixed in the hub to fixed to the shaft. Grease nipple is fixed on the wheel hub.
STAGE 10: Axle studs are tightened to 50-60 taus. Drum is fixed 8mm bolt is fitted.
STAGE 11: Axle shaft is fitted using 8 spring washer and nut on the stud.
STAGE 12: Complete assembly of rear axle is unloaded and taken to chassis assembly
MACHINE SHOP VI: DATE OF TRAINING: 23-05-2014 CYLINDER BLOCK In this shop the cylinder block is made and this is done through a series of steps by CNC machines these include Drying Tappet reaming Honing Linear bore wasing
Linear bore grading Bearing cap disassembly High pressure injection flood washing Foundry inspection zone Cam bush pressing Manual wrench pluck press IP,F/E & R/E, OC face wash plug press Oil pump performance check General washing Linear bore oiling Linear carousal & linear selection Linear press Linear projection checking Block numbering Protective coat applying
MACHINE SHOP II: DATE OF TRAINING: 24-05-2014 ENGINE ASSEMBLY
STAGE 1: CAM BEARING Crank case SWR/plate/EII NO is brought to the engine assembly, here cam bearings are fixed to the crank case of the engine. STAGE 2: CAM SHAFT Cam shaft types E0/EI/EII NO are fixed in appropriate place in the crankcase. STAGE 3: CRANK SHAFT Crank shaft, make BM/GB is fixed at base of crank case like passing thru hole. STAGE 4: M-14 STUDS are fixed at the holes on the crankcase. STAGE 5: In this stage 1st and 6th piston is kept at the top dead centre and timing gears are fixed to side of the engine for the firing order. STAGE 6: CAM GEAR Cam gears are fixed on the crankcase to operate the cam shafts in order to operate the valves. STAGE 7: FLYWHEEL housing is fixed on the crankcase of the engine. STAGE 8: The flywheel is placed on the housing and 90torques is applied to it. The flywheel housing consists of seal housing, flange and flywheel. STAGE 9: OIL PUMP Oil pump is fixed on the top of the crankcase to circulate the oil to the various parts of the engine.
STAGE 10: PISTON The readily made piston is fixed inside bore of the crankcase and connected to the crankshaft. Before that, piston rings of three types, two compression rings and an oil ring are fixed on the piston. STAGE 11: CONROD BOLT Conrod bolt is fixed to connect the piston with the crank shaft. STAGE 12: IDILING GEAR It’s fixed on the spindle which controls the r otations of cam gear, crank gear and compressor gear. STAGE 13: CYLINDER HEAD Cylinder head is fixed to the top of the crankcase to which rocker arm with valves are fixed. STAGE 14: OIL SUMP Oil pump is fixed at the bottom of the crankcase with adhesive (RTV) paste. STAGE 15: ROCKER Rocker assembly is fixed to the cylinder head. STAGE 16: AIR COMPRESSOR AIR COMPRESSOR is fixed to the crank case. STAGE 17: FUEL INJECTION PUMP Fuel pump is fixed to LTC/EII/EI types of engines. STAGE 18: VALVE COVER STAGE 19: OIL COOLER STAGE 20: INJECTOR PIPE AND INLET MANI FOLD is fitted. STAGE 21: SIDE COVER STAGE 22: WATER PUMP STAGE 23: STARTER MOTOR STAGE 24: EXHAUST MANIFOLD
STAGE 25: TURBO CHARGER STAGE 26: EII FTMENTS STAGE 27: Fully assembled engine is taken to the testing Area to be tested for is performance.
CONCLUSION: It’s been privilege to do in plant training in one of the India’s largest automobile producer ASHOK LEYLAND. It has helped in many ways to improve the knowledge about the actual work done in the industries and to have hands on experience.
