Production Process Of Ashok Leyland 2u1ug

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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 enger 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 engers 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 t 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.

PRODUCTION PROCESS IN ASHOK LEYLAND

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ACHEIVEMENT’S OF ASHOK LEYLAND:1966

Introduce full air brakes.

1967

Launched double-decker bus.

1968

Offered power steering in commercial vehicles.

1979

Introduced multi-axle trucks.

1980

Introduced the international concept of integral bus with air suspension.

1982

Introduced vestibule bus.

1992

Won self-certification status for defense supplies.

1993

Received ISO 9002.

1997

India's first CNG powered bus ed the BEST fleet.

2001

Received ISO 14001 certification for all manufacturing units.

2001

Launched hybrid electric vehicle.

MANUFACTURING PLANTS OF ASHOK LEYLAND: Ashok Leyland has seven manufacturing plants: 1) Ennore 2) Hosur: Unit 1 3) Hosur: Unit 2 PRODUCTION PROCESS IN ASHOK LEYLAND

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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:-

2:-Trucks:-

Diesel engines for Industrial, Genset and Marine applications, in collaboration with technology leaders.

Pioneers in multi axle trucks and tractor-trailers.

PRODUCTION PROCESS IN ASHOK LEYLAND

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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

customer satisfaction.

Protection of working environment that promotes safety and health of our employees.

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. PRODUCTION PROCESS IN ASHOK LEYLAND

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S OF ASHOK LEYLAND PRODUCTS: INDUSTRIAL :

Industrial includes transporter, Logistics Company, coal an mining industry and other industries etc.

PUBLIC :

Public includes individual or enger transport.

GOVERNMENT :

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

DEFENSE :

Defense 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

PRODUCTION PROCESS IN ASHOK LEYLAND finish products

end milling

assembly of bearing caps

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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. • Study of new product which Ashok Leyland is going to produce and study of process.

PRODUCTION PROCESS IN ASHOK LEYLAND

• 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. *HybridMANAGEMENT model. OPERATIONAL 

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

Sourcing:

Technology

Strategic sourcing recognizes

Upgradation:

that

including

Company has a strong focus

innovative suppliers, are a

on technology upgradation in

valuable

an

order to meet the growing

organization and focuses on

demand for newer & better

reducing waste or non-value-

models.

people, part

of

added costs.



The upgradation

PRODUCTION PROCESS IN ASHOK LEYLAND

The

technology initiative

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the Company expects

are carried out under stringent

to produce more fuel

simulated

efficient vehicles with

replicate the most treacherous

robust designs which

landscapes.

are globally best in

Innovations:

their class.

Leyland product development

World-class

conditions

that

Ashok

successes have come from a offer

keen sense of anticipation and

world-class technology that is

attentiveness. The company

relevant and affordable to the

initiated

Indian

the

alternative fuels well before

philosophy that drives R&D

legislative debate had even

at Ashok Leyland.

begun in the country.

Value to the Customer:

Best practices: The new

The

lines, apart from being state-

Technology:

To

customer

immediate

is

R&D

research

into

priorities are to pro-actively

of-the-art

in



address

machines

and

tools,

safety

and

many

of also

environmental issues, harness

incorporate

global

and adopt technologies that

industry best practices. The

provide value to the customer

automated

coolant

in an atmosphere enabling

management

system

creativity and innovation.

significantly reduces coolant

Test Tracks: but Company

consumption.

R&D is not confined within

The

walls. It extends to the test

Execution

tracks as well. Rigorous tests

allows for online monitoring

PRODUCTION PROCESS IN ASHOK LEYLAND

Manufacturing System

(MES)

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of all operational parameters

and crankshafts lines. Robots

such as breakdowns, tool

are used for ‘handling’ hot

change

axle arms and axle beams.

and

power

consumption - both current

Compact and versatile:

status and history.

A

Automation:

New

significant

extremely

automation

“Transformation

minimize

to

capacities, the new lines are

benchmarks have been set in to

addition

versatile. training

activities that cause human

becomes

fatigue or pose hazards and

movement

achieve

accustomed work situations

speed.

Gantry

Systems are used for axle-

crucial of

in

such

men

from

to a whole new set-up”.

beam, axle arm, camshafts

PRODUCT SUPPLY CHAIN It has been found that the

supplier

automobile

program as part of its world-

giant

Ashok

development

Leyland ltd, chennai has got

class

one of the very successful

management.

PRODUCTION PROCESS IN ASHOK LEYLAND

supply

chain

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Manufacturer

Dealer

Customer

CMD identifies the vendors, rates the vendors based on 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 it’s 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.

PRODUCTION PROCESS IN ASHOK LEYLAND

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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:-

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 expresses the company's determination to become self-reliant in R&D.

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.

PRODUCTION PROCESS IN ASHOK LEYLAND

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

PRODUCTION PROCESS IN ASHOK LEYLAND

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