St.

JOSEPH’S COLLEGE OF ENGINEERING

CHENNAI -119.

INPLANT TRAINING REPORT

Duration : 08/04/2019 – 11/04/2019

Department : B.E Mechanical Engineering
Batch : 2017 - 2021
Submitted by
NAVEEN KUMAR R 312317114117
JERISH RAJ S 312317114081
 AKNOWLEDGEMENT

This is a report on IN-PLANT TRAINING at ASHOK

LEYLAND during 8th april 2019 to 11th april 2019 by the
fourth semester B.E MECHANICAL ENGINEERING
students of ST. JOSEPH’S COLLEGE OF
ENGINEERING , CHENNAI.

we take this opportunity to express our hearty thanks to

the members of the organization who helped us a lot
during this period . We also sincerely thank our college
and management for arranging the inplant training.

NAVEEN KUMAR R
JERISH RAJ S
 CONTENTS

INTODUCTION
-Company Profile
-Products Produced
DEPARTMENTS
-Axle Assembly
-SMP
-Frame Assembly
-Chassis Assembly (LCV)
-Chassis Assembly MDV & RTP
-Chassis Assembly HGP
-LCV (PDI)
CONCLUSION
 INTRODUCTION

ASHOK LEYLAND:
Ashok Leyland is an Indian automobile
company headquartered in Chennai , India . It is owned
by Hinduja group, founded in 1948. It is the second
largest commercial vehicle manufacturer in India , fourth
largest manufacturer of busses in world and 10th largest
manufacturer of trucks globally . Operating nine plants ,
Ashok Leyland also makes spare parts and engines for
industrial and marine applications . It sold approximately
140000 vehicles (M&HCV) segment , with a market
share of 32.1 % (FY 2016) . With passengers and
transportation options ranging from 10 seaters to 74
seaters . (M&HCV – LCV), Ashok Leyland is a market
leader in bus segment . In the trucks segment ashok
Leyland primarily concentrates on the 16 – 25 ton range .
However Ashok Leyland has a presence in the entire
truck range from 7.5 to 49 tons.Ashok motors was
founded by Ragunadhan Saran in 1948. He is a freedom
fighter . After independence he was persuaded by India’s
first Prime Minister Nehru to invest in a modern
industrial venture so only it was started.
 DEPARTMENTS

AXLE ASSEMBLY

In the axle assembly department the axles of the

wheels are assembled .The parts for assembly comes from
different places and they are assembled here. The frame
of the axle the wheel drumms , break shoes , break
springs are fitted and the nuts are fitted fully
pneumatically.
It is further classified into two departments they are
1. Rear axle assembly
2. Front axle Assembly
REAR AXLE ASSEMBLY :
The rear axle assembly has many
stages they are as follows
Load rear axle casing on pedestals and remove wire
strips , axle shafts.

Assemble dust covers on break shoes and tighten

with bolts and nuts .

Apply torque on mounting nuts.

Assemble inner ring for oil seal.

Distance piece is fixed to align the outer and inner

wheel bearings in the same axis .

Fix the wheel drum

Punch the SI number on the rear axle

Unload rear axle from conveyor an take it to the

chassis assembly shop.
FRONT AXLE ASSEMBLY:
The front axle assembly has the following
stages

First the axle beam is loaded at the conveyor belt .

The number is punched on the axle beam.

Next the axle arm is fixed to the steering with pin

and cotter pin usong dummy bolts .

The tracking rod is fixed for the alignment of the

wheel.This helps the left side tyre to turn along with
the right side tyre.

Fix chamber and breajk shoe .

Fix the hub and lock setting using axle arm.

Fix the wheel drum to both the ends of axle arm.

Unload the axle from the conveyor and it is taken to

the chassis assembly.
 SMP

SMP denotes Side Member Pressureup . The side

member is the backbone of a vehicle. In the side member
all parts including axles , frames , holding parts are fixed
. They are fixed by using nuts and bolts . For fixing the
nuts and bolts holes are punched on the side member .
Initially the side member will be in the form of coils .
They are stretched and decoiled into a flat surface and
then the holes are punched on it .
The stages in the manufacturing of
side member are
 Decoiling and Piercing and FSM
Decambering Forming

Coil Storage WIP Storage

CNC Punching

After completion of all these processes the fully

completed side member can be obtained. The machines
used for this operation are heavy machines . The side
members manufactured here are exported to many
companies . The profile for the side members will be sent
in the form of holes with measurements in a plastic sheet .
The profile on the plastic sheet applied on press by
adjusting the punching tools . By punching the sheet the
profile is printed on the sheet .
Then the sheet is forged to the required shape .

The machines used for this process are

 1. 80T Hydraulic CNC Punching Machine
2. Cut to Length and Chamber Correction
Machine
3. 5000T Hydraulic Press

80 T HYDRAULIC PUNCHING MACHINE

Manufacturer : Soenen
Specifications:
1. Max hole dia : 39 mm
2. Min hole dia : 9 mm
3. Average cycle time : 240 sec
4. Sheet thickness : 4mm to 8mm
5. Sheet length : 5 mm to 11.6 mm

Functional Uniqueness:
1. Mistake proofing facility .
2. Single piece flow .
3. Cost effective .
4. Used for production of non tooled up models .
CUT TO LENGTH AND CHAMBER CORRECTION
MACHINE:

Manufacturer : Kohler
Specifications :
1. Decambering < 2mm
2. Thickness : 4mm to 8mm
3. Width : 250mm to 500mm
4. Length : 5m to 12m
5. Cycle time : 35s to 40s
Functional uniqueness :
 1. Decoiling straightens , length cutting &
camber correction
2. Can process from 4mm to 8 mm thick sheet
3. More flexible process
4. Camber correction achieved within 2mm
5. Can process material from BSK36 to BSK 55.
6. Entire process EEI friendly.

5000T HYDRAULIC PRESS:

Model : LTP5000
Manufacturer : Siempelkamp
Specifications :
1. Bed size : 1300mm *1300 mm
2. Total operating height : 1700
3. Shut height : 800mm
Capacity:
1. Length : 4.5m to 11.6m
2. Thickness : 4 to 8mm
3. Width : 250 to 450mm
Functional Uniqueness:
1. Fully automated press with dual siemen with
scada software .
2. A high speed press.
3. Effective interlocking in program
4. Light curtain for better safety.
5. Make holes in a single punch.
 FRAME LAYDOWN

The side member manufactured from the SMP

shop has been brought to the frame assembly shop and the
frame for the truck is made by fitting the holders for the
cylinders and holders for axle and engine

The stages in frame assembly are,

The frame before fitting anything is laid down and
the cabin bracket and engine bracket are fitted.
Cross member is loaded and fitted.

Bump stop bracket is fitted . cross members are

bolted and the centre bearing bracket is fitted.
Steering bracket is fitted and the steering box
bracket is fitted .
Fitment of cab mounting bracket and the front
shock absorber bracket.

Reaming and bolting of the brackets . reaming is the

process of surface finishing the already drilled holes.

The bolts are toque tightened with pneumatic screw

tighters .

Again the reaming process is done on the holes of

brackets.

The bolts in the holes are torque tightened .

Fitment of helper spring bracket and bumper bracket

. frame sreial number punching .
Lift axle fitment and relay drop arm fitment. Bogle
bracket fitment .

Bogle bracket tightening. Fuel tank bracket fitment .

battery carrier fitment.
 Air tank and silencer bracket fitment. The
completed piece is transferred to the chasis assembly
shop.

CHASSIS ASSEMBLY (LCV)

LCV denotes light commercial vehicles

 In the chassis assembly shop the axle from the
axle assembly shop and the engine from the engine
assembly plant and the cabin are fitted in the frame
coming from the frame .
In addition to it the air cylinders , fuel tank ,
radiators and the shafts all are fitted on the frame of the
LCV.
The stages in the assembly of the chassis of
LCV are as follows,
The frame from the frame assembly is laid down.

Steering box is fitted and bump stop is fitted and the

front cross sectional member is fitted.

Steering lever is assembled and steering link rod is

fitted. I shaft is fitted.

Front axle is located on the bracket and it is

fitted.and the bolts are tightened.

Rear axle is located on the frame bracket and it is

mounted on the frame bracket.
 PKB cables are routed . spare wheel carrier is
mounted. Axle U bolts are tightened.

Rear shock absorber is fitted. Engine front bracket is

fitted.

Brake pipe is assembled and the vaccum pipe are

assembled.
Front shock absorber assembly and the center
bearing bracket fitment .

CNG( Compressed Natural Gas ) cylinders are fitted

and the radiator splash guard are fitted.

Brake pipe is assembled and the vaccum pipe are

assembled.

Frame is turned over . rear axle U bolt tightening .

Tail wires are routed .fuel box is fitted.

Power steering pipe is fitted and torsion bar is

assembled.
Engine is mounted and the reverse gear sensors are
fitted .

Cabin is mounted and the bolts are torque tightened .

Vaccum hose is fitted and the radiator is mounted .

Battery cable is routed and the fuel tank is fitted on

the chassis. Coolant hose and power steering pipe
are connected.

Diesel is filled and the gear box cables are fitted.

Propeller shaft guard is fitted .

Air intake is assembled and the battery cable

connection are provided.

Cable fitment on the gear box is selected. Propeller

shaft guard is fitted.

Fitment of relay and bull bar . ECU is fitted.

Horn is connected . gear shift konb is assembled.

Tyres are fitted on the rear and front axles and the
spare tyres are fitted on the bracket.

Wheel nuts are tightened. Bumper is fitted and the

reflector tape are sticked.

Seats are mounted . A/C piping is done to the cabin

and the A/C gas is filled .

Power steering oil is filled and the remaining oils are

filled .
CHASSIS ASSEMBLY MDV & RTP
 MDV’s are medium sized vehicles where its
weight ranges from 16 ton to 25 ton. The chassis
assembly is similar to the chassis assembly of LCV .
As silmilar to LCV the frame comes the
frame assembly in which the different parts including
axles , engines , cylinders , tyres , radiators are fitted.
After completing all the fitments the vehicle
is subjected to RTP.
RTP denotes the road test preparation, which
is conducted at the end of assembly in order to check the
quality of vehicle before it is released for use of people.
The stages in the assembly of chassis of MDV
are ,
Frame assembly is loaded in the chassis assembly
section and the electrical hoses and brackets are
fitted .

Battery carrier is fitted. Air pipes and valves are

fitted .
Rear axle U bolt is torqued , front bolt I bolt is
torqued . Radiator bracket is fitted and the hoses are
connected .

Propeller shaft is fitted , brake chamber is fitted ,air

cleaner bracket is fitted . brake hoses are fitted .

Chassis is turned over . front brake hose is fitted .

air hose is routed .

Electrical cables are strapped. For earthing paint is

removed. Engine is mounted on bracket ,Propeller
shaft is connected.

 Power steering and clutch piping are fitted. And the

vin plate is fixed.

Silencer and exhaust hoses are fitted and exhaust

hoses are fitted .
Radiator is mounted , aompressor pipes are clamped
, radiator pipes arev fitted. ABS cables are routed.

Front and rear axle tyres are mounted. Spare tyres

are fitted and the nuts are torque tightened.
Bumper is fitted , wheel choke and tail lamp are
fitted , tow pin is fitted.

Gear connections are setted. Air leak is checked.

Power steering oils are filled.

Fuel is filled and engine oil is pumped . SLD motor

is fitted.

Cab is mounted , battery is fitted , air cleaner is

fitted, foot step is fitted and the wire connections are
given.

After completion of all these processes it is sent for

RTP.
 CHASSIS ASSEMBLY ( HGP)

The HGP vehicles are the large sized vehicles

produced by the Ashok Leyland. They are in the weight
range of 25 ton to 45 ton.
Initially in the assembly of chassis the frame
manufactured from side member is laid down and the
cylinders , engine, axles , air pressure chambers are fitted
on the bracket given on the frame of the HGP. The wheels
are fitted on the front and the rear axles. The fuel and the
oils for engine and coolant oils are filled .
 The stages in the assembly of the HGP are
given as follows ,
Frame assembly is laid down. Vin number is
punched. Valves and air tanks are fitted.

Steering box is fitted. Modular and loose hose are

fitted . Hoses are rooted and clamped.

Axle is mounted and radius rod is fitted. Shakles and

the lift axle are mounted.

Axle is mounted . Lift axle bolts are torqued and the

shakles are mounted .

Rear axle U bolts are torquened. Front axle I bolts

are torquened . Brake hose is connected.

Propeller shaft is fitted. Inter axle shaft fitment.

FUPD & RUPD are fitted. Antiroll bar and tail lamp
bracket are fitted.

Brake chamber is connected . Proprller shaft bolts

are tightened and rear axle pinch bolt is fitted.
Shock absorber and tow pin are fittedcd. Axle
breather hose is fitted and the frame is turned over.

Engine is mounted and the compressor pipes are

fitted. Propeller shaft and power steering hose are
fitted.

Silencer is fitted, compressor pipe and power

steering pipe are fitted. Fuel filter is fitted.

Fuel tank , hose and pipe are fitted and the cabin is
fitted.

Front , rear and lift axle tyres are mounted and the
air leak is checked.

Front , rear and lift axle tyre bolts are torquened .

gear shaft lever and knob are fitted.

Air leak checking , power steeing oil is filled and

bumper is fitted.

After completing all these process the vehicle is sent

for checking.
 LCV ( PDI )

PDI refers to Pre Delivery Inspection . It is the

final check carried out by the dealer on the vehicle before
they hand over it to us. As the part of process the
costumer should receive a certificate which gurantees
that inspection is carried out.
It is a complete examination of every aspect of
vehicle from exterior to interior mechanical parts and
electrics. A brief road test is also included. And if there
are any minor problems they will be fixed there and then.
Major problems are passed on to an appropriate specialist.
At the same time , the fluid levels will be checked
and the vehicles number plate s will be put on. The
electronic items in tne vehicle are checked . These all
tests are to ensure that when a customer is buying a
vehicle it should be problem free.
CONCLUSION

The ASHOK LEYLAND is a well reputed and

profit making vehicle manufacturing company with area
of 256 acres just in the Hosur branch where I have visited.
They are producing hundreds of vehicles in a day without
any problem. They are manufacturing vehicles for
military too.
Through this In-Plant training it was able to
fulfill the objective of my study. Detailed study on the
processes was made possible by giving emphasis on
practical side of theory. All together it was a good
experience to see the company and various assemblies of
parts and various functions of the company.