Production activities at ASHOK LEYLAND, Ennore

In Plant Training report

Submitted by,

This

is

to

certify

that

------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------ have successfully completed the inplant training at ASHOK LEYLAND LIMITED, ENNORE PLANT from 21.06.2011 to 25.06.2011.

ABSTRACT

This is a report on in-plant training carried out at Ashok Leyland Limited, Ennore plant during 7.12.2010 to 11.12.2010. This report covers the important manufacturing process carried out at the industry. This report includes the aspects of production carried out at the sections like Chassis Assembly section, Shop II , Shop III, Shop IV and Engine Assembly Section. At the Chassis Assembly Section, the Chassis goes on through various stages in which different components were attached to the Metal Frame. In total there were about 19 stages through which the frame passes through to become the skeletal functional body of the automobile which can be a bus, truck or other such goods carrier. At the Shop II, various components of the Engine were produced. At the Engine Assembly Section, the various components being manufactured in the Shop II were assembled to form the Engine and the assembled engine was put to test for any correction required. At the Shop III, Metal plates were assembled to form the complete frame. The frame passes through 10 steps in which various cross-railings and mounts were fitted to the frame to form the complete chassis. At Shop IV, the assembly of rear and front axles were carried out.

Chassis Assembly: STAGE 1&2: Already assembled FR Axle & Rear axles from machine shop-4 are fixed on the main frame that fabricated from the machine shop 3 of the vehicle. STAGE 3: The fixed frame assembly is placed on the conveyor belt, where brake chamber is fitted to it. STAGE 4: Steering gear box is fitted to the main frame. STAGE 5: Silencer tank is fixed to the main frame. STAGE 6: Then fuel tank is fitted in this stage of chassis assembly. STAGE 7: Engine mounted on the main frame of the chassis of the vehicle. STAGE 8: Radiator fixed in front of the engine. STAGE 9: Tires for all the wheels are fixed to the drums of the axles. STAGE 10: The vehicle is toed then and taken to the other unit to make it running conditions and test driven.

Machine Shop II:

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Here 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 consists 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

Engine Assembly:

STAGE 1: CAM BEARING Crank case SWR/plate/EII NO is brought to the engine assembly, here cam bearings are fixed to the crank case of the engine. STAGE 2: CAM SHAFT Cam shaft types E0/EI/EII NO are fixed in appropriate place in the crankcase. STAGE 3: CRANK SHAFT Crank shaft, make BM/GB is fixed at base of crank case like passing thru hole. STAGE 4: M-14 STUDS are fixed at the holes on the crankcase. STAGE 5: TIMING BRAKE PLATE In this stage 1st and 6th piston is kept at the top dead centre and timing gears are fixed to side of the engine for the firing order. STAGE 6: CAM GEAR Cam gears are fixed on the crankcase to operate the cam shafts in order to operate the valves. STAGE 7: FLYWHEEL housing is fixed on the crankcase of the engine. STAGE 8: The flywheel is placed on the housing and 90torques is applied to it. The flywheel housing consists of seal housing, flange and flywheel. STAGE 9: OIL PUMP Oil pump is fixed on the top of the crankcase to circulate the oil to the various parts of the engine.

STAGE 10: PISTON The readily made piston is fixed inside bore of the crankcase and connected to the crankshaft. Before that, piston rings of three types, two compression rings and an oil ring are fixed on the piston.

STAGE 11: CONROD BOLT Conrod bolt is fixed to connect the piston with the crank shaft. STAGE 12: IDILING GEAR: Its fixed on the spindle which controls the rotations of cam gear, crank gear and compressor gear. STAGE 13: CYLINDER HEAD: Cylinder head is fixed to the top of the crankcase to which rocker arm with valves are fixed. STAGE 14: OIL SUMP Oil pump is fixed at the bottom of the crankcase with adhesive (RTV) paste. STAGE 15: ROCKER Rocker assembly is fixed to the cylinder head. STAGE 16: AIR COMPRESSOR AIR COMPRESSOR is fixed to the crank case. STAGE 17: FUEL INJECTION PUMP Fuel pump is fixed to LTC/EII/EI types of engines. STAGE 18: VALVE COVER STAGE 19: OIL COOLER Due to friction between the engine parts the lubricants gets heated, so there is a need for oil cooler. STAGE 20: INJECTOR PIPE AND INLET MANI FOLD is fitted.

STAGE 21: SIDE COVER

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STAGE 22: WATER PUMP STAGE 23: STARTER MOTOR Starter Motor is made to mesh with flywheel STAGE 24: EXHAUST MANIFOLD STAGE 25: TURBO CHARGER STAGE 26: EII FTMENTS STAGE 27: Fully assembled is taken to the testing area to be tested for is performance.

Machine Shop III:

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The chassis of the vehicle first step starts from here at this shop-3. STAGE 1: The frames of the vehicles are fixed together to be sent to the chassis assembly. STAGE 2: The skids are mounted on the conveyor belt and frame is placed on the skids. STAGE 3: And frame MTG on which engine is mounted is fixed across the two frames. STAGE 4: On the rear end of the frame BKTS both sides are aligned with taper pin. STAGE 5: 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. STAGE 6: Tight and apply torque to engine MTG flinches and M12 with bolts. STAGE 7: Correspondingly in every stage each workers tight appropriate bolt to the frame before taken to chassis assembly make it a complete frame.

Machine Shop IV: This shop-4 is divided into two departments where the front and rear axles of the vehicles are assembled with leaf springs, brake drums before being attached to the main frame of the vehicle. Firstly Front axle assembly: STAGE 1: Axle beam is loaded on the conveyor belt. STAGE 2: Number is punched on the axle beam. STAGE 3: Axle arm is fitted on the beam for steering. STAGE 4: Steering rod is fitted. It is right end of the axle according to Indian STDs. 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 FR axle beam and taken to chassis assembled. REAR AXLE ASSEMBLY: STAGE 1: Banjo casing from outside is unloaded and fixed on the conveyor and axle shaft is removed. STAGE 2: Brake lining and 10 bolt and washer are fixed on the brake carrier with spring washer. Dust cover is also fitted. STAGE 3: Brake nut and bolt are tighten and fitted 75 to 50 torques. 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 shim. 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 tau 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 to 50-60 taus. 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.
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Conclusion: This inplant training have helped us gain an insight into the various aspects and stages involved in the manufacturing of a heavy automotive. We gained the technical know-how involved in the manufacturing and assembly of the engine and chassis. This knowledge would be of great help for us in the long run. ***************
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