ACKNOWLEDGEMENT

This Internship has been a very good experience for me in

the way that it has given a chance to understand the real
world outside the classroom. I have learnt a lot about the
manufacturing environment and also developed my
interpersonal skills which has given a boost of self-
confidence.
Firstly, I would like to express my deep sense of gratitude
to Mr.Danshekar for giving me an opportunity to take an
internship at an outside industry. I would also like to
thank Mr.Anantha Krishna Upadyaya and Mr.Wasique
Rahaman for their guidance and supervision which has
made it possible for me to learn many things and make a
report which comprises of good theoretical and practical
knowledge I gained during this starting stage of the
internship.
I would also like to thank other employees of
AUTOMOTIVE AXLE LTD. for their extended co-
operation.
 Table of Contents
Chapter 1 : Company Overview

1.1 History
1.2 Visio

1.3 Major Customers

1.4 AAL Partners

1.5 Environment, health and safety

Chapter 2 : Quality Process

Chapter 3: Corporate Social Responsibility

3.1 Learning at AAL

3.2 Strategic HR initiatives

3.3 Career Opportunities

CHAPTER 4: Hub Reduction Axels

4.1 Features and Benefits

CHAPTER 5: Breaks
5.1 Disc Breaks
5.2 Drum Breaks

CHAPTER 6: Gear Manufacturing

 CHAPTER 1
Company Overview

Established in 1981, Automotive Axles Limited (AAL) is a joint venture of Kalyani Group
and Meritor Inc., USA. With manufacturing facilities located at Mysore (Karnataka), the
company is currently the largest independent manufacturer of Rear Drive Axle Assemblies
in India. The company has also expanded its footprints in North India with its plants at
Pantnagar and Jamshedpur.

Established : April 21, 1981

Equity Share

i. Meritor : 35.52%

ii. Kalyani : 35.52%

iii. Public : 28.96%

Land Size : 202,343.5 Sqm

Location : Mysore, India

 Total Employees : 2000+

Manufacturing Plants : Mysore, Pantnagar, Jamshedpur

Over the past 30 years, it has successfully been manufacturing reliable & long-life Medium
& Heavy duty Drive axles, Front Steer axles, Non-Drive axles, Axles for Defence & Off-
Highway applications and Drum & Disc Brakes. Recently it has forayed into manufacturing
axels.
Over the years, AAL has developed an impressive domestic OEM clientele that includes
Ashok Leyland, Tata Motors, Asia Motor Works, Daimler India, Volvo India, SML Isuzu
Ltd., Volvo Eicher Commercial Vehicles, Vehicle Factory-Jabalpur, BEML, MAN Trucks
Pvt. Ltd., Mahindra Trucks & Buses, CAT, Escorts, TIL and Sonalika. AAL also exports
axle parts to USA, France, Italy, China, Brazil and Australia.

1.1 History
Milestone Achieved
To be a world class quality manufacturer of axles, providing innovative solutions to
customer at competitive price, that enhance mobility, safety & environment and retain
leadership.
1.2 Vision

1.3 Major Customers :Trusted By Partners

1.4 AAL PARTNERS

Meritor HVS (India) Ltd

Meritor HVS (India) Limited (MHVSIL) is a joint venture company promoted by Meritor
Heavy Vehicle Systems LLC, Troy, U.S.A., (51% shareholding) and the Kalyani Group,
Pune (49% shareholding). MHVSIL is located in Mysore, Karnataka. MHVSIL is engaged
in design, development and marketing of drive axles, non-drive steer axles, military &
specialty axles, drum brake and air disc brake assemblies for commercial vehicles. MHVSIL
is equipped with design validation capabilities and has been customizing various products of
Meritor design to suit various rigorous application requirements in India.

Bangalore Technical Center (BTC)

The BTC is a wholly owned subsidiary of Meritor Inc. The state-of-the-art facility focuses
on product engineering, product benchmarking, prototyping, validation & testing,
aftermarket engineering and metallurgy & metrology services. The BTC is involved in
product innovations jointly with other Meritor global technical centers across the globe. The
BTC has submitted approximately 20 patent applications, and 50 percent of these
applications have been awarded to patents in china North America and Europe.

The technical capability covers all stages of product design and development from concept
to validation for axles and brakes of commercial vehicles. Using a multitude of CAD & FEA
tools and skills under one roof, the BTC offers support to Meritor’s other technical centers
globally. The BTC’s capabilities also help Meritor meet the needs of global customers
operating on different CAD platforms. It also houses supplier development and global
purchasing, supporting Meritor’s global locations. This center is certified under ISO/TS
16949-2009 quality systems and follows global project planning processes for project
execution. In terms of headcount, the BTC is one of the largest of all Meritor global technical
centers. Current strength is around 120 engineers – most of them are qualified in specific
fields.

Policies
Policies adhered to
 Nomination and Remuneration Policy.
 Policy on Trading of Shares by Insider.
 Policy on Related Party Transaction.
 Policy for Prevention, Prohibition & Redressal of Sexual Harassment.
 Policy on Corporate Social Responsibility.
 Policy on Whistle Blower Mechanism.

1.5 Environment, Health and Safety

Concern for environment
• Conserving all resources such as power, water, OIL, gas etc. by optimizing their usage and
prevention of pollution by adopting sustainable technologies.
• Minimizing waste generation by promoting reduce, recover, reuse and recycle methods.

• Complying with all relevant legal and other requirements.

• Creating awareness through involvement & training among employees regarding their role
in sustaining EMS.

• Periodically reviewing and evaluating environmental management system performance for

continual improvement by framing objectives and targets.

Environmental Policy and Certificate:

 Chapter 2
Quality Process
Customer Satisfaction:
Supply state of the art Products/Services to Customers that meet their expectations for
Quality, Technology, Time, and Responsiveness.

Quality:
Continually improve Effectiveness and Efficiency of Quality Management Systems to
maintain a distinguishable competitive Edge as viewed by Customers.
Human Resources Development:
Establish and Implement leading edge Human Resource Systems and Practices to meet the
business objective through Training, Empowerment, and Motivation in achieving Total
Employee Involvement.

Competition:
Perform Competitors strategies by developing Customer Loyalty with differentiated
products, superior service and competitive Pricing.

Financial Performance:
Exceed our financial and growth objectives through aggressive implementation of our
Business Plan.

Environment & Safety:

Establish and implement suitable environment and safety practices/ systems to fulfill our
social objectives.

Quality Policy and TS Certificates:

 Chapter 3
Corporate Social Responsibility (CSR)
Our Social Responsibility
In our Company, CSR has evolved over decades on minimal scale with the simple objective
of “improving the community at vicinity of the company”. Now, we wish to scale-up our CSR
activities through the initiatives aimed at improving the lot for needy, deprived and
marginalized sections of the society including economically deprived children, women and
senior citizens as well as the overall welfare of the community and make a difference in living
standards so that they can be an integral part of the mainstream of growth and development.

Drive Axles
Providing Enhanced Mobility

At Automotive Axles Limited, we’re dedicated to rear axle solutions that enhance mobility
to give our customers the leading edge. With more than 30 years of axle manufacturing
experience for Indian applications, we’ve become India’s largest independent manufacturer
of commercial truck axles for a broad range of vehicle applications. And, our rear axles are
at the heart of this heritage.

We’ve mastered the combination of precision engineering, component durability, and

lightweight options – all to bring your operation enhanced movement. We can provide a
complete solution for all your needs in form of drive axles, brakes and suspension interfaces.
When your operation needs a drive axle product to move you past the competition, you can
rely on Automotive drive axles to deliver. We can provide a complete solution for all your
needs in form of drive axles, brakes and suspension interfaces.

Products

 Drive Axles
 Front Steer Axles
 Defence Axles
 Off-Highway Axles
 Non-Drive Axles
 Drum Brake
 Disc Brake
Life @ AAL

Work Cultures at AAL

AAL believes that its human capital is the most valuable asset, nurturing and investing in
high performing team helps to meet customer’s changing needs and remain competitive.
Hence it always promotes, build leadership pipeline and develop strong talent pool for
excellence. At AAL, everyone contributes to our success and can take advantage of growth
opportunities to enhance their career. Our talent management processes help us identify
develop and promote high caliber individuals to support the organization’s future leadership
needs.

We empower our teams of talented, diverse individuals to make sound business decisions
that drive the company's success. In return, we provide them with numerous opportunities
for personal and professional growth with the growing organization at multiple locations in
India.

3.1 Learning at AAL

Training Facilities

At AAL, learning is a continuous process. AAL has an In-house training facility on CNC,
Welding, Fork lift training with internal seasoned trainers.

Training is imperative for the all-round growth and development of our employees. The
training modules are prepared & rolled out with an appropriate blend of technical &
behavioral program.
3.2 Strategic HR Initiatives at AAL

Building Leadership Pipeline:

AAL is constantly striving to build leadership pipeline through its SDP (Succession and
Development Planning) and training program. The key objective of SDP process is to identify
successors for leadership positions, highlight talent across the organization and identify
career development opportunities for our employees. We have successfully rolled out SDP
process during FY13 for our management staff to build and strengthen the leadership
pipeline.

Carried out 360 degree feedback survey for 32 leaders as part of their leadership
development program on “lead self and lead others forum” followed by IDPs (Individual
Development Actions). The aim is to develop future leaders which will enable them to reach
the goals set by the organization and align them with the ultimate organizational strategies.

Invest in High Performing Team:

The Company is consistently driving pay-for-performance culture by facilitating robust

awareness and implementation of performance management system with 80% weightage on
performance and 20% weightage on leadership behavior.

Company is focused to strengthen employee engagement to achieve higher levels of

performance by improving culture survey scores as well as positive employee relations and
driving HR Initiatives such as employee engagement, rewards and recognition,
communication and succession development planning. Company is also driving to build a
diverse and inclusive culture through improvement in retention, moves/promotions, job
rotations, resource re-deployment and recruitment.

3.3 Careers Opportunities at AAL

Automotive Axles believes in nurturing its employees and provides significant global
opportunities. To meet our growth requirements and enhance our team significantly, we
continuously require competent professional with proven track record for placement at our
plants at Mysore, Pantnagar & Jamshedpur.

We are an equal opportunity employer and make a commitment to attract, retain, develop
and promote the most qualified candidates regardless of race, gender, religion, sexual
orientation etc., We offer attractive remuneration, stimulating work environment and
excellent career growth opportunities.

At AAL we are always looking for fresh thinkers who are passionate about their profession.
If you have what it takes to be part of our team of top performers, take a look at some of the
positions we have available in the on-line application section.
 Chapter 4

Hub reduction Axles

Based on the successful Meritor European planetary wheel-end reduction design that has
provided fleets with outstanding performance in harsh applications for more than a decade,
hub reduction axles offer a ratio range of 3.46 to 7.21 – allowing a match for virtually any
individual application.

Our MT-610 series (cast housing) axles are equipped with standard driver controlled
differential locks in the forward, rear gear, and interaxle differrential. To meet application
requirements and customer preference, cam and pneumatic disc brake designs are offered.
The wheel-end reduction is a proven high capacity planetary design.

For reduced parts complexity, lower installation costs, and maximum customer value,
complete axle modules may be specified to include brakes, hubs, drums, and other associated
wheel-end equipment. The axle housing accommodates all popular air and spring suspension
brackets which also may be specified as part of the module.

The MT610 is available as a solo and as a tandem axle, from 13 to 32 tons Gross Axle Weight
Rating.
4.1 Features and Benefits

Four-planet hub-reduction gearing design provides higher-capacity ratings, and optimized

driveline angles reduce harsh drivetrain vibrations, providing longer life.

Needle bearing design throughout interaxle differential provides spin-out protection and
eliminates the need for a lube pump.

Driver-controlled differential locks (DCDL) are standard in both the forward and rear axles
for increased traction when needed.

Wheel reduction is configured to suit your application requirements with three or four
planetary gears.

Reduced maintenance activity and environmental impact can both be achieved by using
Meritor-approved synthetic OILS. Drain intervals can be conducted as infrequently as
400,000 miles or three years.

The MT-610 series are designed for high ground clearance for off-highway applications.
 Chapter 5

BREAKS

5.1 Disc Brake

Automotive axles are the first to bring indigenously manufactured disc brake for Heavy
Vehicles in India and in doing so became the only braking system manufacturer that offers
a complete portfolio of brakes – Drums and Discs.

Designed to package with 22.5”/19.5” wheel size, the calipers are compatible with anti-lock
braking systems resulting in better vehicle control and stability. For simplified maintenance,
lining changes require only the removal of the lining retention bolt (no swing of caliper).

ELSA-225

Meritor’s Elsa 225 Air disc Brake for 22.5” wheel size is a tried, tested and proved product
for high speed applications. Rated to 28KNm of braking torque along with 18.5mm of usable
pad thickness, Elsa 225 is the ultimate in stopping power for commercial vehicles. It enhances
stopping power in an easy to maintain assembly.

It features pad wear sensor for optimum use of brake pads and a vented rotor for greater
heat dissipation and uniform brake performance under all conditions. The design which
originated in high speed environment of Europe has been completely localized for Indian
application and thus is an ideal product for high speed passenger and commercial vehicle
application

5.2 Drum Brake

Automotive Axles Limited is a leader in both size and capability for the commercial vehicle
industry, supplying more than 400,000 brake assemblies per year for trucks, trailers, buses
and coaches. Our brakes can be found on trailers, buses and coaches, and in such vocational
applications as emergency, linehaul, fire and defense. We enjoy a leading position with cost
of ownership optimized through the application of advanced predictive techniques and
innovative manufacturing processes.

We are driven by safety. We work daily to engineer safety into every brake system, detail
and control. Safety directs our innovation into every braking product we make, from drum
and air disc brakes, to hubs and drums & friction products.

15.5 Inch

Meritor’s 15.5” dia S-Cam Drum Brakes come in large variety of shoe widths (5” to 8”) and
liner grades for different braking/life requirements. Flexible mounting configuration eases
vehicle packaging while the fast shoe replacement design minimizes repair/service time. The
brakes are designed to suit a wide torque requirement band for broad range of applications.
With asbestos free liners Meritor brakes offer the best in durability, performance and safety.
 Chapter 6

Gear Manufacturing:

Gear Variant :AAL has capability to make Spiral Bevel, Straight Bevel, Hypoid and
Amboid type gears. Gears & Pinions are produced using Gleason make-5 Cut machines and
Face Hob machines. After cutting, it is heat treated in continuous carburizing furnace and
shot peened. Turbo Tester with SFT Measurement Capability is used for Noise Sensitive
Gear processing after lapping process. AAL also has Gleason make-114 Coniflex machines
to make bevel gears for making diff nest and Sealed quench furnace for carburizing.

Gear profile inspection gear set testing

Flexible Housing Line

AAL has a flexible Housing Line suitable for all kinds of axles used in LCV, MCV and HCV
vehicles. The production lines are quipped with continuous type shot blasting machines, double-
head semi-automatic seam welding machines and Robotic axle dome welding machines. Each
line has Friction welding for spindle and 100% testing for joint integrity. It also has VMCs and
HMCs for machining, Tunnel-type washing machines and flexible welding lines for customized
bracket welding.
Thank You