Content:

• Introd!7tion
• %ho* III

• 8rame Assem$ly

• %*ro7kets 8inishing

• -mem$er *rod!7tion

• /!$ 8inishing

• %ho* I6

• 8ront Ale

• )ear Ale

• hassis Assem$ly

• ld on;eyer 

•  e< on;eyer 

• %ho* II

• +arine Engine Assem$ly

• rank ase +a7hining

• Engine Assem$ly

• on7l!sion
Introd!7tion:
As!o# Leland is a 7ommer7ial ;ehi7le man!fa7t!ring 7om*any $ased in hennai, India#
8o!nded in 194, the 7om*any is one of IndiaBs leading man!fa7t!rers of 7ommer7ial
;ehi7les, s!7h as tr!7ks and $!ses, as <ell as emergen7y and military ;ehi7les# *erating si
 *lants, Ashok Leyland also makes s*are *arts and engines for ind!strial and marine
a**li7ations# It sells a$o!t (0,000 ;ehi7les and a$o!t C,000 engines ann!ally# It is the se7ond
largest 7ommer7ial ;ehi7le 7om*any in India in the medi!m and hea;y 7ommer7ial ;ehi7le
D+/6F segment <ith a market share of 2G D200CH0F# =ith *assenger trans*ortation
o*tions ranging from 19 seater to 0 seater, Ashok Leyland is a market leader in the $!s
segment# The 7om*any 7laims to 7arry o;er (0 million *assengers a day, more *eo*le than
the entire Indian rail net<ork# In the tr!7ks segment Ashok Leyland *rimarily 7on7entrates on
the 1( ton to 25 ton range of tr!7ks# /o<e;er Ashok Leyland has *resen7e in the entire tr!7k 
range starting from C#5 tons to 49 tons# The >oint ;ent!re anno!n7ed <ith  issan +otors of 
a*an <o!ld im*ro;e its *resen7e in the Light ommer7ial 6ehi7le DL6F segment DC#5
tonsF#
%ho* III
The %ho* III is a 7om$ination of 8rame assem$ly, %*ro7kets 8inishing, -mem$er
 *rod!7tion and the h!$ finishing#

$ra%e Asse%&l:
/ere the Frame Assembly is done# The 7hassis of the ;ehi7le first ste* starts from here at this sho*-3#
This assem$ly is di;ided into 9 stages# At first the sides frames are mo!nted for $oth sides
<hi7h are hold !sing the *ro*er 7lam*s# The frames ofthe;ehi7les are fiedtogetherto $e sent to the
7hassis assem$ly# The skids are mo!nted on the 7on;eyor $elt and frame is *la7ed on the skids# And frame
+T. on <hi7h engine is mo!nted is fied a7ross the t<o frames# n the rear end of the frame "T% $oth
sides are aligned <ith ta*er *in# 8it and tight 8%) and "T% on $oth sides <ith d!mmy $olts# Tilt $oth the
8%+% to 90 degree $y t!rning ta7kle and insert 7lam*s# Tight and a**ly torJ!e to engine +T. flin7hes and
+12 <ith $olts# orres*ondingly in e;ery stage ea7h <orker tight a**ro*riate $olt to the frame $efore taken to
7hassis assem$ly makes it a 7om*lete frame#

At *resent t<o ty*es are made in more n!m$ers# ne is for 7ommer7ial ;ehi7les <hi7h is 9meters long# The
other is for hea;y ;ehi7les <hi7h is 12meters long# This hea;y ;ehi7le frame and 7hassis <ill $e soon mo;ed
to e*t!ne sho* <hi7h is *lanned to 7onstr!7t# 8or ea7h ty*e of frames se*arate distin7t 7onne7ting rods are
!sed# Th!s at the end of the 9 th stage the *erfe7t frame <ill 7ome to off tra7k# These frames <ill $e no< mo;ed
to the 7hassis assem$ly# These frames are im*ortant for the 7hassis, so it is $!ilt <ith the strong $olts#

'pro(#ets )inis!ing:
The material needed to make the s*ro7kets is o!tso!r7ed as a mo!lded *art# Then it has $een
taken in to milling, grinding, drilling, s!rfa7e finish, et7# to get the finished *rod!7t of the
s*ro7kets# There are many s*ro7kets in this !sage Leaf s*ring s*ro7ket, engine mo!nting
s*ro7ket, et7#

*-%e%&er produ(tion:
-mem$er is the 7onne7tion made to fi $oth the side mem$ers in the *la7e# The -mem$er is
the 7om$ination of g!sset *late and the 7ross mem$er#

The g!sset *late is made $y 7!tting sheet of reJ!ired si@e and *!n7hing of holes in it $y a
hydra!li7 *ress then making the $end $y another hydra!li7 *ress# Then the g!sset *late
ri;eted <ith the 7ross mem$er to make the -mem$er#
+u& $inis!ing:
The h!$ is also like the s*ro7kets, it has $een o!tso!r7ed as a mo!lded *art then it has $een
finished $y ;ario!s *ro7esses to get the finished h!$#

%/P I6:
The sho* I6 7om*rises of assem$ly of front and rear ales# The ale 7asing and the
differential !nit of the rear ale <ere o!tso!r7ed# The leaf s*rings, $rake dr!ms are assem$led $efore
 $eing atta7hed to the main frame of the ;ehi7le#

$ront A,le asse%&l:

The front ale is *ro;ided <ith less n!m$er of s*ring se7tions than the rear#

%tage 1: Ale $eam is loaded on the 7on;eyor $elt#

%tage 2: !m$er is *!n7hed on the ale $eam#

%tage 3: Ale arm is fitted on the $eam for steering#

%tage 4: %teering rod is fitted# It is right end of the ale a77ording to Indian standards#

%tage 5: Tra7king rod is fitted# It is !sed for the alignment of the <heel# It hel*s the left side of the tyre to t!rn
along <ith the right side <heel#

%tage (: "rake 7arriers <ith $rake linings are fitted to the front and rear ale $eam and taken to 7hassis
assem$led#

Rear A,le Asse%&l:

 The rear ale <ill ha;e more s*ring arrangements than the front ale#

%tage 1: asing is fied on the 7on;eyor and ale shaft is remo;ed#

%tage 2: "rake lining and 10 $olt and <asher are fied on the $rake 7arrier <ith s*ring <asher# !st7o;er is
also fitted#

%tage 3: "rake n!t and $olt are tighten and fitted 50 to C5 torJ!e#

%tage 4: )ing for oil seal is fitted on the h!$ shim is fitted 3-(ta! for the 7learan7e flange 7o;er is fitted <ith 4
 $olts#

%tage 5: Inner oil seal is fitted on ring for inner oil seal# Inner <heel $earing is fitted#

%tage (: istan7e *ie7e is fied to align the inner and o!ter <heel $earing in the same ais#

%tage C: ry set, <here the <heel h!$ is fied ro!ghly to ;erify <hether to in7rease or de7rease the height#
%tage : =et set <here grease is *a7ked inside the <heel h!$#

%tage 9: Ale t!$e n!t is fied <ith 7o!nter *in and $olt, 190 tho! tightness# The gi;en, st!ds are fied in the
h!$ to fied to the shaft# .rease ni**le is fied on the <heel h!$#

%tage 10: Ale st!ds are tightened# r!m is fied mm $olt is fitted#

%tage 11: Ale shaft is fitted !sing  s*ring <asher and n!t on the st!d#

%tage 12: om*lete assem$ly of rear ale is !nloaded and taken to 7hassis assem$ly#

C!assis Asse%&l:
The 7hassis assem$ly is the last *art of a *rod!7tion *lant# /ere all the *arts from other sho*s
are assem$led to make a ;ehi7le# In this Ashok Leyland *lant there has $een t<o 7on;eyers, a
ne< one and an old one#

Old Coneer:
The old 7on;eyer is also the same *ro7ess as like the ne< 7on;eyer# "!t the ne< 7on;eyer
has $een te7hnologi7ally de;elo*ed#

New (oneer:
%tage 1: Air 7ham$er and air tank Dlay do<nF:
Initially air 7ham$er is fitted# The n!m$er of 7ham$ers de*ends on the n!m$er of
<heels# Air 7ham$er is res*onsi$le for the $raking system
%tage 2: 8ront ale mo!nting:
The ale <hi7h is fitted in front $ody of the ;ehi7le is front ale# It hold the front
<heels
%tage 3: )ear ale mo!nting:
The ale fitted $a7k is rear ale <hi7h holds rear <heels# These <heels are the a7t!al
dri;ing <heels#
%tage 4: %ilen7er mo!nting:
%ilen7er is the long *i*e <hi7h red!7es the noise 7reated $y the engine and
7ontri$!tes in eha!st system
%tage 5: hassis t!rno;er:
Then the frame is t!rned !*side do<n <hi7h is the normal *osition#
%tage (: 8!el tank mo!nting:
Then the tank <hi7h stores f!el is mo!nted on the right side# %ometimes a shield is
also *ro;ided o;er it#
%tage C: Engine mo!nting:
 Then the engine is fitted in the front of the 7hassis#
%tage : )adiator mo!nting:
 )adiator is the tem*erat!re e7hanging !nit of the 7ooling system# It is mo!nted no<#
%tage 9: il filling:
 Then the oil is filled !sing oil g!n# il is !s!ally greased#
%tage 10: Ele7tri7al:
In this stage the ele7tri7al <irings are done# A $attery is *ro;ided to s<it7h the head 
rear lam*s, horns, et7#
%tage 11: =heel mo!nting:
Then the <heels are mo!nted# In the t<in <heel set!* only one <heel is mo!nted
other one is mo!nted in the other sho*s# =e !se , +)8 et7 $rands of tyres
%tage 12: 6ehi7le starting:
8inally the ;ehi7le is started and deli;ered to the 7!stomer#

%ho* II
This sho* 7om*rises of ma7hining of ;ario!s engine *arts and assem$ly of marine engines#

Marine Engine Asse%&l:

The engine <hi7h has high torJ!e and r*m are !sed in marines# )e7tifi7ation of engines is
also done here# They !se the normal man dri;en ma7hines# "oth 4 and ( 7ylinder engines are
made#

Cran# Case Ma(!ining:

In this sho* the *erfe7tly 7asted *art of 7rank7ase arri;es from the 7asting *lant sit!ated some<here near the
main *lant# This 7asted 7rank7ase 7onstit!tes the main *art of the engine 7om*artment# This sho*-2 7onsist of 
the hea;y ma7hines of /+T that hel*s in $oring and drilling different si@es of holes needed for the fitments of 
;ario!s engine s*ares# There are different *ro7ess of man!fa7t!ring is done here# 8a$ri7ation of 6al;es:

%tage-1: 8a7ing and the 7entring DlengthF of the ;al;es is done here#

%tage-2: %traightening D"end remo;ingF is done#

%tage-3: )o!gh t!rning and finish t!rning are done#

%tage-4: Again the straightening is done here#

%tage-5: ey<ay milling D.ear 8iing, il *!m*ingF are done here#

%tage-(: A+ milling D;al;e inlet, ;al;e o!tletF are done#

%tage-C: .ear ho$$ing is done thro!gh gear ho$$ing ma7hine#

%tage-: .!n drilling is done Dthro!gh holeF#

%tage-9: o!nter $oring and ta**ing Dn!ts, front and rearF#

%tage-10: il hole drilling#

%tage-11: =ashing and n!m$er *!n7hing is done#

%tage-12: Inde hardening and tem*ering and hardening are done#

%tage-13: /arden testing Dmoderate hardeningF is tested here#

%tage-14: n7e again the straightening is done here#

%tage-15: "earing D>o!rnalF o!ter grindings are done#

%tage-1(: A+ grindings are done#

%tage-1C: ra7k 7he7king is done#

%tage-1: Ins*e7tion of ;al;es is done at the final#

The fly<heel ho!sing is tested and fitted at the engine 7ase#

%o the ma>or <orks done here are .rinding, =ilding, Lathe <orks#
 As most of the ma7hines in this sho* are ;ery old model also they are not maintained
 *ro*erly they <ill 7ons!me more *o<er than !s!al# This <ill in7rease the 7ost of o*erating
ma7hines#

Engine assem$ly:
Engine assem$ly is done $y fitting the $elo< 7om*onents# Their f!n7tions <e learnt are also
gi;en $elo<

%tage 1: am $earing

 After the arri;al of 7ylinder $lo7k 7am $earing is fitted# It is !sed for red!7ing
the fri7tion in the 7hain dri;ed 7am shaft
%tage 2: am shaft
am shaft is the 7ylinder rod <ith *ro>e7tions 7alled 7am lo$es# am lo$es are
res*onsi$le for o*ening the inlet and eha!st ;al;es *eriodi7ally#
%tage 3: rank shaft& 7rank assem$ly
 et is the assem$ly of 7rank shaft# rank shaft is the *o<er transmitting
agent to the fly<heel# It is fitted <ith 7onne7ting rod and the fly<heel#

%tage 4: %t!d D+-14F

Then the st!d $olt is fitted

%tage 5: Timing $elt D$a7k *lateF

"a7k *late is a metal *late <hi7h sits $ehind the 7am *!lleys# It is a $elt <hi7h
starts the ignition in time#

%tage (: am gear 

They atta7h to the 7am and allo< ad;an7ing or retarding the ignition timing#
Then ho!sing the 7ylinders is done#

%tage C: 8ly<heel
8ly<heel is the larger 7ir7!lar dis7 atta7hed to the 7rank shaft to *rod!7e
!niform torJ!e#
%tage : il *!m*
il *!m* is the *art of engine l!$ri7ating system <hi7h *ro;ides oil to the
 *arts of engine $y ;ario!s a7tions#

%tage 9: Piston
 et is the fitting of the *iston <hi7h is the energy 7on;erting agent <hi7h
7on;erts 7hemi7al energy into me7hani7al energy# It is 7ylindri7al in sha*e
<hi7h tra;els $et<een to* dead 7entre and $ottom dead 7entre#

%tage 10: onne7ting rod $olt

 Then the 7onne7ting rod is fied# It is the agent <hi7h dri;es the 7rank shaft#

%tage 11: Idler gear 

The gear <hi7h s<it7hes the idling 7ondition is idler gear 

%tage 12: ylinder head

Then the 7ylinder heads <ith the ;al;es are fitted#

%tage 13: %!m*

%!m* is the $ottommost *art of the engine <hi7h 7ontains the l!$ri7ating oil
<hi7h 7an $e taken !* $y 7onne7ting rodKs motion#

%tage 14: )o7ker Arm

)o7ker is the im*ortant arm <hi7h holds the inlet and eha!st ;al;es#

%tage 15: Air 7om*ressor 

It 7om*resses the air and let it into the inlet manifold

%tage 1(: 8!el in>e7tor *!m*

This *!m* in>e7ts the f!el from the tank to the engine#

%tage 1C: 6al;e 7o;er 

)o7ker 7o;ers are also 7alled ;al;e 7o;ers# It 7o;ers the ro7ker arm#

%tage 1: il 7ooler 

Then the oil 7ooler is fied# It 7ools the l!$ri7ating oil

%tage 19: In>e7tor *i*e

It is a do!$le <alled *i*e <hi7h in>e7ts the f!el in diesel engines

%tage 20: %ide 7o;er 

It 7o;ers the side of the engine

%tage 21: =ater *!m*

=ater *!m* is a 7om*onent <hi7h 7ir7!lates the 7ooling <ater into the
engine?s o!ter $ody
 %tage 22: %tarter motor 
%tarter motor is the engine starting agent <hi7h starts the engine <hen ignition
is on#

%tage 23: Eha!st manifold

The *i*e <hi7h 7onne7ts eha!st ;al;e and eha!st system

%tage 24: T!r$o 7harger 

T!r$o 7harger is a system <hi7h is fitted to the eha!st system of the engine
<hi7h *!m*s to 7om*ress the intake air to in7rease air in air-f!el mit!re
<hi7h in t!rn in7reases the effi7ien7y of the engine# 8inal fittings are the
7ylinder head *l!gs, radiators et7#

on7l!sion:
The *rofit of an organi@ation entirely de*ends on the <ay the
to* 7hairs manage the )eso!r7es the organi@ation has#
=hate;er the other as*e7ts may $e, it <as seen that managing
h!man reso!r7e <as etremely diffi7!lt# The sta$ility or the
s!staina$ility of the rgani@ation mostly de*ends on this
fa7tor#
n the other hand, it <as *rominently seen that thinking
sho!ld *re7ede doing# In most 7ases It 7o!ld $e seen that there
eists easier or $etter <ays to do something# As far as the
a$o;e mentioned fa7tor is 7onsidered, 7ontin!o!s kno<ledge
mining follo<ed $y e*erien7e in a 7y7le !*holds the entire
system in e;ery as*e7t#

 Earning and living a satisfactory life is the desire of all.