REPORT

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.
6

IV.

SPRING BRACKETS FITMENT:

These are spring brackets provided to mount
the axles suspension that is the leaf spring setup.
The leaf springs will be pre-attached to the axle
and they are directly mounted upon these
brackets later in chassis assembly section.

V.
VI.

SPRING BRACKETS FITMENT:

SPRING BRACKETS FITMENT:
In both the above stages the same work is
handled but in stages to reduce burden.

VII.

CAB MTG BKT FITMENT & SPEC

MARKING:
This stage does a specified function. It
provides clamps for fixing the air tanks. They are
provided in 3 nos and it is subjected to
requirement. Here they are properly labelled
after they are properly fitted with the C shaped
clamps. The whole assembled frame is now
labelled with colored chalks. Now the frame is
completely done with assembling.

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.

FRONT AXLE MOUNTING:

Initially before mounting the front axle on the
frame, various supplementary components required
for the efficient working of truck are added. Those
components include air tanks, dryer and
distribution unit, reverse valve and all these parts
are properly hosed and lined in such a way that
they dont affect the placement of other major
components, all the pipes and hoses are taken to the
frame edges and strapped on with the frame. Now
the front axle mounting job is performed. Here it
was surprising to see that the assembled axle which
we saw in the shop-4 comes here pre-fitted with
suspensions i.e, the leaf springs. We

observed that those springs were joined to the

axles using a heavy U clamp.
iii.

REAR AXLE MOUNTING:

As in the case of front axle mounting what
we saw was the mounting of axle with frame is
not direct, instead the leaf spring are attached to
the spring brackets clamped on the frame. In
rear axle assembly after this kind of indirect axle
mounting it is also again mounted on with the
frame directly through a wishbone shaped two
cylindrical rods which can move inside another
hollow cylinder. By this way the rear axle gets
another way of suspension and more importantly
it gets attached to the frame directly, so higher
stability.

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
9

to reduce the emission rate of harmful gases and

also plays an important role in sound of the truck.

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.

FUEL TANK MOUNTING:

This stage is nothing but where the fuel tanks
and batteries are attached to the truck frame.
Necessary clamps are provided for the
mounting of fuel tank. A bar like structure is
also provided for the installation of batteries.
On observation we found out that the
batteries used over there are commonly
AMARON and Exide Express.

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
10

ix.

attachments were also established as soon as the

engine assembly was over.
RADIATOR MOUNTING:
This is the time for the installation of
supplementary components of the heart. The
radiator is required in all aspects for the very good
performance of the vehicle. It was also
preassembled and was made ready to be directly
installed.

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
11

sections of the assembly line are all properly

given attachments. This work is mainly handled
by trained electrical workers.
xiii.

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.
12

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

F/E & R/E

WELSCH
PLUG
PRESS

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

Now lets see about WSS-3 process flow:

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.
16

NEPTUNE BLOCK PROCESS FLOW:

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

17

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.

MAIN SHAFT GEARS:

ROUG
H
BLANK

HOBBIN
G

SHAPING

HEAT
TREATMEN
T

TOOTH
CHAMFERIN
G

WASHING

BORE &

TEETH

FACE
GRINDIN
G

WASHING

GRINDING

FINISHE
D
BLANK

LAY SHAFT GEARS:

ROUG
H
BLANK

HOBBING

TOOTH
CHAMFERIN
G

18

WASHIN
G

BORE

HEAT

GRINDING

TREATMENT

TEETH
GRINDIN
G

WASHIN
G

FINISH
BLANK

GEAR BOX CASING:

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

19

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

20

FINISH
GRINDING
BLANK

HEAT
TREATMEN
T

The so called synchro parts include:

Ring
Slee
ve
Hub
Cone
DAY 1: SHOP 4
On my day-1 I visited the shop-4. Here I found out that
this shop is soulfully allocated only for the assembly of front and rear
axles of various vehicles with respect to the customers needs. It was
interesting to find that Ashok Leyland has managed to develop shop-4 in
an extravaganza way such that it manages to store the various axle parts
and assemble them in the same roof. Front and rear axles are assembled in
two different not far off places here and is made ready for dispatch.

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

Front axle distance piece

2

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.

It was surprising to note that all these components are completely

supplied by Mahindra another Indian origin giant. It was impressive
to see both Indian companies growing hand in hand encouraging each
other. The whole activity going on in this shop can be explained using
three categories. They are,
1) AXLE STORE:
This is place where the load trucks deliver the axle
components. These components are further sorted out
and sent to respective front and rear axle store where
they are secondarily stored for assembly use. The
whole area is systemized and taken care to feed in all
the infos about each component in a separate database.
It takes only a few employee count to handle the store.
2) FRONT AXLE ASSEMBLY:

Here the assembly of front axle takes

place. The front axle is not a driving axle, it just receives the
power from the rear axle and uses it to circle down the front
3

wheels. The front axle assembly takes place in following

stages. Front axle assemblys basic process flow is as
follows,

FRONT
AXLE
BEAM

FRONT
BRAKE
DRUM

ASSEMBLED
FRONT
AXLE

BOOSTERS &
SUPPLEMENTAR
Y
ATTACHMENTS

TRFR
BEARING

FRONT
AXLE
HUB

Supplementary attachments include small yet uncompromising for axles

performance are distance pieces, oil seals, slack adjusters, socket, king
pin.
3) REAR AXLE ASSEMBLY:
Here the assembly of whole rear axle takes place
likewise what we saw in front axle assembly. All the
components are similar but here the rear axle is the drive
axle. So the live axle beam differs from the normal axle
beam in such a way that it houses a small doom structure
which performs the task of receiving the output power from
the shaft of engine and delivers it to the wheels of the rear.
4

Whereas another axle called dummy is also assembled

here which comes into play in cases of long haul trailing
trucks. These axles are alike front axle and at times possess
boosters too. The rear axle assembly process flow is as
follows,
REAR AXLE
BEAM
(LIVE &
DUMMY)

ASSEMBLED
REAR AXLE

REAR
BRAKE
DRUM

TRFR
BEARING

SUPPLEMENTARY
ATTACHMENTS

REAR
AXLE
HUB

The significant difference between front and rear axle in trucks

is that the rear axle is the driving axle and hence houses energy
transmitting systems, which also compels front axle on the other side
to possess boosters to energize further the energy transmitted from
rear wheels to the front wheels.

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

securities. The knowledge that we gained is bountiful and we actually

saw in front of us the mere application of what we study out there in
our college campus. We are truly indebted to G.Karthikeyan who got us
this wonderful opportunity.

21

SFSHFJGKHL,;JO;K/L
SXSXS
X

CC
AC
AC
ACD
22

CD
CDC

23