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PRODUCTION PROCESS OF ASHOK LEYLAND

ABSTRACT: Theme of the paper is to deal with the production process and operation involved in the commercial vehicle manufacturing company ASHOK LEYLAND. At the end of reading you get the idea regarding the manufacturing or production process, operations, supply chain management undertaking in the respected vehicle manufacturing company.

PRODUCTION PROCESS IN ASHOK LEYLAND

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INTRODUCTION:
Ashok Leyland is a commercial vehicle manufacturing company based in Chennai, India. Founded in 1948, the company is one of India's leading 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 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. The joint venture announced with Nissan Motors of Japan would improve its presence in the Light Commercial Vehicle (LCV) segment (<7.5 tons). In 1968, production of the Leyland Titan ceased in Britain, but was restarted by Ashok Leyland in India. The Titan PD3 chassis was modified, and a five speed heavy duty constant-mesh gearbox utilized, together with the Ashok Leyland version of the O.680 engine. The Ashok Leyland Titan was very successful, and continued in production for many years.

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ACHEIVEMENTS OF ASHOK LEYLAND:1966 1967 1968 1979 1980 Introduce full air brakes. Launched double-decker bus. Offered power steering in commercial vehicles. Introduced multi-axle trucks. Introduced the international concept of integral bus with air suspension. Introduced vestibule bus. Won self-certification status for defense supplies. Received ISO 9002. India's first CNG powered bus joined the BEST fleet. Received ISO 14001 certification for all manufacturing units. Launched hybrid electric vehicle.

1982 1992 1993 1997 2001 2001

MANUFACTURING PLANTS OF ASHOK LEYLAND:

Ashok Leyland has seven manufacturing plants:
1) Ennore 2) Hosur: Unit 1 3) Hosur: Unit 2
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4) Hosur: Unit 2A 5) Alwar 6) Bhandara 7) Pantnagar

Ashok Leyland products.

1:-Buses Leaders in the Indian bus market, offering unique models such as CNG, Double Decker and Vestibule bus.

3:- Engines:Diesel engines for Industrial, Genset and Marine applications, in collaboration with technology leaders.

2:-Trucks:Pioneers in multi axle trucks and tractor-trailers.

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Largest provider of logistic vehicles to the Indian army.

4:- Defense & Special: -

Mission
Achieving Customer Delight Excellence in technology and engineering Continuous Improvement and Learning Teamwork, training, transparency, people - based management and internal of our employees. customer satisfaction. Protection of working environment that promotes safety and health

Vision
To become Customers first choice, by focusing organizational energy on understanding and delivering on their need for state-of-the-art technology, cost and quality benchmarks, and overall relationship, which they expect from a world class supplier.
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USERS OF ASHOK LEYLAND PRODUCTS:

INDUSTRIAL USER: mining industry and other industries etc. PUBLIC USER: GOVERNMENT USER: Public user includes individual or passenger transport.

Industrial user includes transporter, Logistics Company, coal an

Government user includes state and central transport like DTC UPSRTC and other.

DEFENSE USER:

Defense user includes Indian army trucks, tanks and transpo buses.

PROCESS FLOW CHART OF ASHOK LEYLAND

purchase of raw material

components machined

rough milling

drilling

finish milling

washing

boring

end milling

assembly of bearing caps

PRODUCTION PROCESS IN ASHOK LEYLAND

finish products

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CRANKSHAFT:

CRANKSHAFT is attached with a gear and is fixed to the bottom of the cylinder block by bearing caps.

CAMSHAFT: CAMSHAFT is attached with a timing gear and is fixed in the required space provided in the cylinder block.0

INPUT AND OUTPUT PROCESS

INPUTS: Collecting information about the parts of truck and buses, which Ashok Leyland is going to produce. Production system of Ashok Leyland. Production Strategy of Ashok Leyland (Strategy for HCV and LCV is different.) PROCESS PLANNING: Ashok Leyland selects the process for production.
PRODUCTION PROCESS IN ASHOK LEYLAND

Study of new product which Ashok Leyland is going to produce and study of process. Study of Machinery, which is used to produce the product.

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OUTPUTS: Final product is prepared(Product is with new technology) Hybrid features of new product. *Hybrid engine. *Hybrid model. OPERATIONAL MANAGEMENT

Ashok Leyland is trying to improve efficiency and production quality, reduce costs and increase customer satisfaction.

Among the means company is adopting just-in-time inventories system.

Strategic
that valuable people, part

Sourcing:
including of an

Technology Upgradation:
The Company has a strong focus on technology upgradation in order to meet the growing demand for newer & better models.

Strategic sourcing recognizes innovative suppliers, are a organization and focuses on reducing waste or non-valueadded costs.

The upgradation

technology initiative

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the Company expects to produce more fuel efficient vehicles with robust designs which are globally best in their class.

are carried out under stringent simulated landscapes. conditions that replicate the most treacherous

Innovations:

Ashok

Leyland product development successes have come from a To offer keen sense of anticipation and attentiveness. The company initiated research into alternative fuels well before legislative debate had even begun in the country.

World-class Technology:
world-class technology that is relevant and affordable to the Indian customer is the philosophy that drives R&D at Ashok Leyland.

Value to the Customer:

The address immediate safety R&D and priorities are to pro-actively environmental issues, harness and adopt technologies that provide value to the customer in an atmosphere enabling creativity and innovation.

Best practices: The new

lines, apart from being stateof-the-art machines incorporate automated management consumption. The Execution Manufacturing System (MES) in and terms tools, of also global coolant system

many

industry best practices. The

significantly reduces coolant

Test Tracks: but Company

R&D is not confined within walls. It extends to the test tracks as well. Rigorous tests
PRODUCTION PROCESS IN ASHOK LEYLAND

allows for online monitoring

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of all operational parameters such as breakdowns, tool change and power consumption - both current status and history.

and crankshafts lines. Robots are used for handling hot axle arms and axle beams.

Compact and versatile:

A significant addition to capacities, the new lines are extremely Transformation becomes movement crucial of versatile. training in men such from

Automation:
automation to

New minimize

benchmarks have been set in activities that cause human fatigue or pose hazards and achieve speed. Gantry Systems are used for axlebeam, axle arm, camshafts

accustomed work situations to a whole new set-up.

PRODUCT SUPPLY CHAIN

It has been found that the automobile giant Ashok Leyland ltd, chennai has got one of the very successful
PRODUCTION PROCESS IN ASHOK LEYLAND

supplier class

development supply chain

program as part of its worldmanagement.

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Manufacturer Customer

Dealer

CMD identifies the vendors, rates the vendors based on feedback received from Supplier Quality Assurance Cell, sends drawings / specifications, calls for quotes with detailed break-up of operation-wise costs, and negotiates the price at which the parts will be supplied. Ashok Leyland considers its vendors as partners in

progress and believes in establishing mutually beneficial relationships. Ashok Leyland provides necessary technical assistance in the form of Project and Production Engineering, to maintain quality levels. In addition, where required, Ashok Leyland also helps vendors financially.

DRAWBACK:

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As Ashok Leyland is giving its best to its customer but then also there are some drawbacks: The domestic sales of the company are not up to the mark. Ashok Leyland has not got a foothold in the luxury trucks segment in its domestic market. Ashok Leyland have low cost advantage over its competitors, once the competitors find out the low cost production methodology then there will no competitive advantage. CNG buses of Ashok Leyland are also not playing well on the roads, some or other break down creating problem for them.

Some of the automobile company is going to launch HMV to give competition to Ashok Leyland and till now Ashok Leyland not got any alternative to comptite with it.

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FEATURES OF THE COMPANY:

As we know through this project that Ashok Leyland is also one of the leading automobile manufacturers in the world and it also came to know that:-

Provide World technology:-

class

Provide Value to the customer:The immediate R&D priorities are to pro-actively address safety and environmental issues, harness and adopt technologies that provide value to the customer in an atmosphere enabling creativity and innovation. Powering those who "engineer tomorrows" with an enabling infrastructure has been top priority for the company.

To offer world-class technology that is relevant and affordable to the Indian customer is the philosophy that drives R&D at Ashok Leyland. Over the years, this philosophy has been translated time and again into products that seamlessly integrate international technology with local needs. "The role of R&D is central in fulfilling the companywide commitment to total customer satisfaction" states Mr. R. Seshasayee, Managing Director, and adds that the increased infrastructural and financial support expresses the company's determination to become self-reliant in R&D.

Keep innovating there product:Ashok Leyland product development successes have come from a keen sense of anticipation and attentiveness. The company initiated research into alternative fuels well before legislative debate

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had even begun in the country. The result was the implementation of CNG technology ahead of the rest

promising a breath of fresh air for polluted cities. *********

PRODUCTION PROCESS IN ASHOK LEYLAND