DEPARTMENT FUNCTIONS

The major functional areas of the unit and the major departments which oversee
those areas are catalogued as follows:

1. Personnel and Administration Department

2. Purchase & Material Planning Department
3. Production Department
4. Finance Department
5. Systems Department
6. Research & Development.

MACHINE SHOP-V

COMPONENTS MACHINED:

BEARING CAP FOR H-SERIES:

Operations done:

 Rough milling
 drilling
 arrow milling
 finish milling
 washing
 boring
 tapping
 end milling
 brushing of holes

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  assembly of bearing caps
 injection flood washing
 leak test water ways
 counter boring,reaming

ENGINE ASSEMBLY II & V

FIXING OF CRANKSHAFT AND BEARING CAPS:

CRANKSHAFT is attached with a gear and is fixed to the bottom of the

cylinder block by bearing caps.

FIXING OF CAMSHAFT
CAMSHAFT is attached with a timing gear and is fixed in the
required space provided in the cylinder block

 Fixing of flywheel housing

 Assembly of oil sump
 Fitting of oil stainer
 Fixing of fuel injection pump
 Fixing of connecting rod and piston
 Assembly of inlet manifold
 Fixing if started motor
 Fixing of connecting rod with crankshaft
 Fixing of timing gear case
 Compressor fitting
 Fitting of cylinder head and rocker arm assembly
 Fitting of cylinder head cover

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  Fitting of oil coolant
 Assembling of turbocharger or air fitter
 Fitting of atternator, fitting of belt.

MEDIUM DUTY VEHICLE(MDV)

CATEGORY:

Vehicles which transport load in the range of 16 to 35 tonnes

PRODUCTION IN MDV ASSEMBLY(H1 PLANT):44/day ,22/shift

STAGES OF ASSEMBLY :

Frame Assembly: 5stages

Chassis Assembly: 13 stages

FRAME ASSEMBLY:
STAGE 1: Mounting of side members and cross members

STAGE 2: Mounting of Front Spring-rear, Front Spring-rear, Rear spring-front,

Rear spring-middle, Rear spring-rear.

STAGE 3: Fitting of Engine mounting brackets and FES mounting brackets

STAGE 4: Side members fastening to torque limit, Steering box bracket, Side
Members reaming, Front tie channel mounting

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STAGE 5: Fitment of FES rear brackets, Shock absorber brackets and Torque
checking

PASSING STAGE: Checking and tilting

CHASSIS ASSEMBLY:
STAGE 6: Radiator mounting brackets, Air tank mounting , Air cleaner mounting
bracket, battery mounting bracket, grease nipple fitment, Bellcom lever mounting.

STAGE 7: DC valve mounting, Oil piping, Clutch oil piping, Quick release valve
mounting.

STAGE 8: Spring fitment, frame punching

STAGE 9: Silencer fitment, first axle mounting.

STAGE 10: Second axle mounting, slack adjustment

STAGE 11: Fuel piping, Air piping, Air filter mounting, Diesel filter mounting,
Steering box mounting

STAGE 12: Engine mounting, fuel tank mounting, Diesel filter mounting,
Steering box mounting

STAGE 13: Radiator fitment, Radiator supports tightening, Rear lamps

fitting,Turbocharger outlet pipe connection and Radiator hose connections

STAGE 14: Exhaust piping, Shock absorber fitment (front and rear), Battery
mounting and connection of circuits, battery casing fitment and second
propeller shaft mounting

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STAGE 15: Tyre mounting, Maxcut checking

STAGE 16: FES mounting, Electric fitments (male-female connecting process)

STAGE 17: Bumper fitment, FES wiring, Universal joint (UJ) fitment with
steering handle, ABC fitment and connecting

STAGE 18: Greasing of joints, nuts, etc., Off track arrangements

FES DRESSING:

 Fitting of seats, ABC pedals, steering handle and instrument box

 Electrical wiring
 Flink Valve Fitting.

PDI (PRE DELIVERY INSPECTION):

Testing of vehicle on real road conditions

The following are the various tests done to test the vehicle:

1. Speed test
2. Acceleration test
3. Vibration test
4. Torque tightening
5. Oil level and water level checking
6. Electrical components checking
7. Air leakage test

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 8. Grease level checking
9. Power steering hose routing and clamping
10. Road test

QUALITY CONTROL

QUALITY:

It is the degree to wish a set of inherent characteristics fulfills requirements. The

following are the various dimensions of quality.
 Performance
 Features
 Conformance
 Reliability
 Durability
 Service
 Response
 Aesthetics
 Reputation

TQM:

It is defined as both a philosophy and a set of guiding principles that represent the
foundation of a continuously improving organization. It is the application of
quantitative methods and human resources to improve all the processes with an
organization and exceed customer needs now and in the future.