Professional Documents
Culture Documents
Introduction
Shop III
Frame Assembly
Sprockets Finishing
X-member production
Hub Finishing
Shop IV
Front Axle
Rear Axle
Chassis Assembly
Old Conveyer
New Conveyer
Shop II
Engine Assembly
Conclusion
Introduction:
Shop III
Frame Assembly:
Here the Frame Assembly is done. The chassis of the vehicle first step starts from here at this
shop-3. This assembly is divided into 9 stages. At first the sides frames are mounted for
both sides which are hold using the proper clamps. The frames of the vehicles are fixed
together to be sent to the chassis assembly. The skids are mounted on the conveyor belt and frame is
placed on the skids. And frame MTG on which engine is mounted is fixed across the two frames.
On the rear end of the frame BKTS both sides are aligned with taper pin. Fit and tight FSR and
BKTS on both sides with dummy bolts. Tilt both the FSMS to 90 degree by turning tackle and insert
clamps. Tight and apply torque to engine MTG flinches and M12 with bolts. Correspondingly in
every stage each worker tight appropriate bolt to the frame before taken to chassis assembly makes it
a complete frame.
At present two types are made in more numbers. One is for commercial vehicles which is 9meters
long. The other is for heavy vehicles which is 12meters long. This heavy vehicle frame and chassis
will be soon moved to Neptune shop which is planned to construct. For each type of frames separate
distinct connecting rods are used. Thus at the end of the 9 th stage the perfect frame will come to off
track. These frames will be now moved to the chassis assembly. These frames are important for the
chassis, so it is built with the strong bolts.
Sprockets finishing:
The material needed to make the sprockets is outsourced as a moulded part. Then it
has been taken in to milling, grinding, drilling, surface finish, etc. to get the finished
product of the sprockets. There are many sprockets in this usage Leaf spring sprocket,
engine mounting sprocket, etc.
X-member production:
X-member is the connection made to fix both the side members in the place. The x-
member is the combination of gusset plate and the cross member.
The gusset plate is made by cutting sheet of required size and punching of holes in it
by a hydraulic press then making the bend by another hydraulic press. Then the gusset
plate riveted with the cross member to make the x-member.
Hub Finishing:
The hub is also like the sprockets, it has been outsourced as a moulded part then it has
been finished by various processes to get the finished hub.
SHOP IV:
The shop IV comprises of assembly of front and rear axles. The axle casing and the
differential unit of the rear axle were outsourced. The leaf springs, brake drums are
assembled before being attached to the main frame of the vehicle.
The front axle is provided with less number of spring sections than the rear.
Stage 1: Axle beam is loaded on the conveyor belt.
Stage 4: Steering rod is fitted. It is right end of the axle according to Indian standards.
Stage 5: Tracking rod is fitted. It is used for the alignment of the wheel. It helps the left side of the
tyre to turn along with the right side wheel.
Stage 6: Brake carriers with brake linings are fitted to the front and rear axle beam and taken to
chassis assembled.
The rear axle will have more spring arrangements than the front axle.
Stage 2: Brake lining and 10 bolt and washer are fixed on the brake carrier with spring washer.
Dustcover is also fitted.
Stage 3: Brake nut and bolt are tighten and fitted 50 to 75 torque.
Stage 4: Ring for oil seal is fitted on the hub shim is fitted 3-6tau for the clearance flange cover is
fitted with 4 bolts.
Stage 5: Inner oil seal is fitted on ring for inner oil seal. Inner wheel bearing is fitted.
Stage 6: Distance piece is fixed to align the inner and outer wheel bearing in the same axis.
Stage 7: Dry set, where the wheel hub is fixed roughly to verify whether to increase or decrease the
height. Stage 8: Wet set where grease is packed inside the wheel hub.
Stage 9: Axle tube nut is fixed with counter pin and bolt, 190 thou tightness. The given, studs are
fixed in the hub to fixed to the shaft. Grease nipple is fixed on the wheel hub.
Stage 10: Axle studs are tightened. Drum is fixed 8mm bolt is fitted.
Stage 11: Axle shaft is fitted using 8 spring washer and nut on the stud.
Stage 12: Complete assembly of rear axle is unloaded and taken to chassis assembly.
Chassis Assembly:
The chassis assembly is the last part of a production plant. Here all the parts from
other shops are assembled to make a vehicle. In this Ashok Leyland plant there has
been two conveyers, a new one and an old one.
Old Conveyer:
The old conveyer is also the same process as like the new conveyer. But the new
conveyer has been technologically developed.
New conveyer:
This shop comprises of machining of various engine parts and assembly of marine
engines.
Marine Engine Assembly:
The engine which has high torque and rpm are used in marines. Rectification of
engines is also done here. They use the normal man driven machines. Both 4 and 6
cylinder engines are made.
In this shop the perfectly casted part of crankcase arrives from the casting plant situated somewhere
near the main plant. This casted crankcase constitutes the main part of the engine compartment. This
shop-2 consist of the heavy machines of HMT that helps in boring and drilling different sizes of
holes needed for the fitments of various engine spares. There are different process of manufacturing
is done here. Fabrication of Valves:
Stage-1: Facing and the centring (length) of the valves is done here.
Stage-5: Keyway milling (Gear Fixing, Oil pumping) are done here.
So the major works done here are Grinding, Wilding, Lathe works.
As most of the machines in this shop are very old model also they are not maintained
properly they will consume more power than usual. This will increase the cost of
operating machines.
Engine assembly:
Engine assembly is done by fitting the below components. Their functions we learnt
are also given below
Stage 7: Flywheel
Flywheel is the larger circular disc attached to the crank shaft to produce
uniform torque.
Stage 8: Oil pump
Oil pump is the part of engine lubricating system which provides oil to
the parts of engine by various actions.
Stage 9: Piston
Next is the fitting of the piston which is the energy converting agent
which converts chemical energy into mechanical energy. It is cylindrical
in shape which travels between top dead centre and bottom dead centre.
The profit of an organization entirely depends on the way the top chairs manage the
Resources the organization has. Whatever the other aspects may be, it was seen that
managing human resource was extremely difficult. The stability or the sustainability
of the Organization mostly depends on this factor.
On the other hand, it was prominently seen that thinking should precede doing. In
most cases It could be seen that there exists easier or better ways to do something. As
far as the above mentioned factor is considered, continuous knowledge mining
followed by experience in a cycle upholds the entire system in every aspect.