Ashok Leyland

Inplant training report

From 20/5/2014 24/5/2014




From,
Shreyash singh
Manipal Institute Of Technology, Manipal

















ABSTRACT

This is a report on in-plant training carried out at ashok
Leyland limited, ennore plant during 19-04-2011 to 26-04-
2011. 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%
(200708). 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 vehicless 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
Its fixed on the spindle which controls the rotations 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:

Its been privilege to do in plant training in one
of the Indias 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.