PROJECT ON PRODUCTION PROCESS OF
SUBMITTED TO:-
SUBMITTED BY:-
PROF. SHYAMANUJA DAS
NIKHIL PANDEY (45)
(PRODUCTION MANAGEMENT)
PRADEEP SINGH (52)
IILM(NEW DELHI )
SAURABH GARJOLA (69) SURJEET KUMAR (77) TARUN AHALAWAT (78) VIKRAM PRATAP SINGH (83)
CONTENTS y
INTODUCTION.
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CUSTOMER BASE AND SEGMENTATION.
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COMPETITION OF ASHOK LEYLAND WITH OTHER AUTOMOBILE SECTOR.
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PROCESS FLOW CHART OF ASHOK LEYLAND .
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INPUT AND OUTPUT PROCESS.
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DIAGRAM SHOWING THE LAYOUT AND FLOW OF MATERIAL
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.QUALITY ASSURANCE OF ASHOK LEYLAND.
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SUPPLY CHAIN MANAGEMENT AT ASHOK LEYLAND.
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DRAWBACK.
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LEARNING ACHIVED.
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 passenger transportation options ranging from 19 seaters to 80 seaters, Ashok Leyland is a market leader in the bus segment seg ment .The company claims cla ims to carry over 60 million passengers a da y, 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 joint venture announced with Nissan Motors of Japan would improve its presence in the Light Commercial Vehicle (LCV) segment (<7.5 tons).
The origin of Ashok Leyland can be traced to the urge for self-reliance, felt by independent India. Pandit Jawaharlal Nehru, India¶s first Prime Minister, persuaded Mr Raghunandan Saran, an industrialist, to enter automotive manufacture. The company was established in 1948 as Ashok Motors, to assemble Austin cars. The company¶s destiny and name changed soon with equity participation by British Leyland and Ashok Leyland commenced manufacture of commercial vehicles in 1955. Today the company is the flagship of the Hinduja Group, a British based and Indian originated transnational conglomerate. 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. Through tie-ups with global technology leaders, supplemented by in-house R&D infrastructure and capabilities, Ashok Leyland has maintained its technological leadership even as it offers the most comprehensive range of model configurations in its class. In the journey towards global standards of quality, Ashok Leyland reached a major milestone in 1993 when it became the first in India's automobile history to win the ISO 9002 certification. The more comprehensive ISO 9001 certification came in 1994, QS 9000 in 1998 and ISO 14001 certification for all vehicle manufacturing units in 2002. In 2006, Ashok Leyland became the first automobile company in India to receive the TS16949 Corporate Certification. The company has increased its rated capacity from 50,000 vehicles per annum to nearly 77,000 vehicles per annum. Also further investment plans including putting up two new plants in North india are fast Afoot.After expansion, the company shall attempt to dominate the medium- and heavy-duty commercial vehicles market in India.
Achievement¶s of Ashok Leyland:-
1966 :-Introduce full air brakes. 1967:- Launched double-decker bus. 1968:- Offered power steering in commercial co mmercial vehicles. 1979:- Introduced multi-axle trucks. 1980:- Introduced the international 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 joined the B EST fleet. 2001:- Received ISO 14001 certification certification for all manufacturing units. 2001:- Launched hybrid electr ic vehicle. Product of Ashok Leyland:-
1:-Buses Leaders in the Indian bus market, offering unique models such as CNG, Do uble Decker and Vestibule bus.
2:-Trucks:-Pioneers in multi axle trucks and tractor-trailers.
3:- Engines:-Diesel engines for Industrial, Genset and Marine applications, in co llaboration llaboration with technology leaders.
4:- Defense & Special:- Largest provider of log istic istic vehicles to the t he Indian army.
CUSTOMER BASE AND SEGMENTATION
Ashok Leyland, over five decades in in the transport solution solution industry,offering a world class range of trucks, buses, special application vehicals, and engines, touching millions across 40 countries world wide.Ashok Leyland has a good customer base most of the customer who comes to Ashok Leyland become a loyal loyal customer . Ashok Leyland is Brand name with the flagship of hinduja group. To sell is to know your customers. Ashok Leyland has built-up a data base of 130,000 customers. The information captures the business nuances of the customers and shows Ashok Leyland precisely where and how the customer would use trucks. The company today knows much more about its customers today than earlier. Ashok Leyland has has a large large customer base base for public public transport buses,commercial vehicles, defense and special vehicles for special purpose.it caters to different class of society which includes individual buyer,industrial buyer,government buyer and de fense also. Segmentation of Ashok Leyland can be done on the basis of o f it¶s user:Segmentation
Industrial user
Defense user Public user
Government user
INDUSTRIAL USER:- Industrial user includes transportor,logistics transportor,logistics company, coal co al and mining industry and other industries etc. PUBLIC USER:-Public user includes includes individual or passenger transport . GOVERNMENT USER:- Government user include state and central transport like DTC,UPSRTC and other. DEFENSE USER:- Defense user include include Indian army trucks, tanks and and transport buses.
COMPETITION OF ASHOK LEYLAND WITH OTHER AUTOMOBILE SECTOR
COMPETITION WITH TATA MOTORS:Ashok Leyland Ltd. will introduce 15 new truck models as India's biggest truck makers by sales seek to beat growing competition from Tata motors. The new truck models under its new UTruck platform by March 2011,The trucks will be between 16 tonners and 49 tonners. To Compite with Ashok Leyland Tata motors will also introduce three new heavy trucks in India by March from its Prima range of so-called world trucks.As,we had seen that Ashok Leyland low floor buses giving tide competition to Tata motors low low floor buses in Delhi. COMPETITION WITH EICHER:Eicher is also one of competitor of Ashok Leyland,Eicher began its business operation in 1959 with Tactor,but now Eicher had expanded it self with Truck¶s,Buses,Gear box,etc.Eicher is giving competition to Ashok Leyland with Truck¶s and Buses,Eicher small trucks are making there good market in India. COMPETITION WITH MAHINDRA:MAHINDRA:Mahindra had also also launched a truck in collaboration with Navistar Inc. USA on Indian roads known as Mahindra Navistar,which is going go ing to give tuff competition to Ashok Leyland. With a commanding strength of the about 12,000 employees the company is looking forwards to enhance the scope of its action. It is aiming at expanding its production operation overseas to make it a more globally accessible company. It is looking to acquire a small to medium sized commercial vehicle manufacturers in China and other developing nations, which have an established product line. An example would be the 2007 acquisition of the Czech based Avia¶s truck business rechristened Avia Ashok Leyland Motors.
PROCESS FLOW CHART OF ASHOK LEYLAND
Purchase of raw material
Components machined
Rough Roug h Milling
Drilling
Finish
Washing
Boring
Milling
End Milling
Assembly of
Milling
Bearing caps
Engine Assembly
Fixing of Cranshaft and Bearing Caps
Fixing of Camshaft
Fixing of Flywheel Housing
Assembly of
Fitting of
Oil Pump
Stainer
Final Product
Compressor Compresso r Fitting
Fitting Fitt ing of Oil Coolant
Fitting of Belt
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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 c ylinder block.
INPUT AND OUTPUT PROCESS INPUTS:y
Collecting information about the parts of truck and buses,which Ashok Leyland is going to produce.
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Production system of Ashok Leyland.
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Production Strategy of Ashok Leyland(Strategy Le yland(Strategy for HCV and LCV is different .)
PROCESS PLANNING:y
Ashok Leyland select the process for production.
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Study of new product which Ashok Leyland is going to produce and study of process.
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Study of Machinery, Machinery, which is used to produce the product.
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Ashok Leyland do lot of research f or their production process.
OUTPUTS:y
Final
product is prepared(Product is with new technology)
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Hybrid
features of new product. *Hybrid engine. *Hybrid model. *Hybrid technology.
DIAGRAM SHOWING THE LAYOUT AND FLOW OF MATERIAL There are 3 stages of o f Frame Assembling And 13 stages of o f Chassis Assembling. Assembling.
Stage 1 Mounting of side members, Mounting of cross members
Stage 2 Mounting of front spring Rear,rear spring middle.
Stage 3 Fitting of engine Mounting.
Passing stage Checking and Tilting
Stages 4 Side members fastening To torque limit. limit.
Stage 5 Fitment
of FES rear
brackets
Stage 8
Stage 7
Stage 6
Stage 5
Stage 4
Stage 3
Stage 2
FES DRESSING:-FITTING
Stage 9
Stage 10
Stage 11
Stage 12
Stage 1
OF SEATS,
Stage 13 ELECTRICAL WIRING,FLINK VALVE FITTING.
STAGE 1: Radiator mounting brackets, Air tank mount ing , Air cleaner mounting bracket, battery mounting bracket, grease nipple fitment, Bellcom lever mounting. STAGE 2: DC valve mounting, O il piping, Clutch oil piping, Quick release valve mounting. STAGE 3: Spring fitment, frame punching STAGE 4: Silencer fitment, first axle mounting. STAGE 5: Second axle mounting, slack adjustment
filter mounting, STAGE 6: Fuel piping, Air piping, Air filter mounting, D iesel filter Steering box mounting. STAGE 7: Engine mounting, fuel tank mounting, Diesel filter mounting, Steering box mounting. STAGE 8: Radiator fitment, Radiator supports tightening, Rear lamps fitting,Turbocharger outlet pipe connection and Rad iator hose connections. STAGE 9: Exhaust piping, Shock absorber fitment fitment (front and rear), Battery mounting and connection of o f circuits, battery casing fitment and second propeller shaft mounting. STAGE 10: Tyre mounting, Maxcut checking. STAGE 11: FES mounting, Electric fitments (male-female connect ing process).
wiring, Universal joint (UJ) fitment with STAGE 12: Bumper fitment, FES wiring, steering handle, ABC fitment and connecting. co nnecting. STAGE 13: Greasing of joints, nuts, etc., Off track arrangements.
QUALITY ASSURANCE OF ASHOK LEYLAND
Ashok Leyland believe that our impressive impressive strides strides in the marketplace stem stem in equal parts from our proactive approach and our customers' unstinting support, earned the only way Ashok Leyland know: by giving our customers the most most appropriate transport solutions solutions for each of their applications, and by backing them up with consultancy, finance, driver training and a responsive after-market network. network. Ashok Leyland are conscious of the fact that vehicles are more than just a means of transporting people and goods; Ashok Leyland understand that they have a deep and far-reaching impact on society, the national economy and the environment. Ashok Leyland have, therefore, always always endeavoured to engineer engineer products and systems that promote progress on all these fronts. fronts. Ashok Leyland firmly believe believe that this honest approach will make the Ashok Leyland marquee the symbol of the very best in transportation, today and tomorrow.Ashok Leyland care for there customer,they try to give best quality engineering as well as best quality service to there t here customer. The major characteristic through which Ashok Leyland give the best quality to there customer are:* Reliability * Maintainability * Safety * Strength * Performance * Features * Conformance * Durability * Service * Response *Aesthetics * Reputation
Ashok Leyland is committed to achieve customer satisfaction by anticipating and delivering superior value to the customer in relation to their own business, through the products and services offered by the company and comply with statutory requirements. The quality assurance of Ashok Leyland is to make continual co ntinual improvements in the processes that constitute the quality management system, to make them more robust and to enhance their effectiveness and efficiency in achieving stated objectives leading to (1). Superior products manufactured as also services offered by the company. (2). Maximum use of employees pot ential to contribute to quality and environment by progressive up gradation gradat ion of their knowledge and skills as appropriate to their functions.
(3). Seamless involvement from suppliers and dealers in the mission mission of o f the company to address customers changing needs a nd protection of the environment. For the Quality assurance Ashok Leyland completed journey towards global standards of quality, history to win the ISO 9002 certification. The more comprehensive ISO 9001 certification came in 1994, QS 9000 in 1998 and ISO 14001.
SUPPLY CHAIN MANAGEMENT AT ASHOK LEYLAND
It has been found that the Automobile Giant Ashok Leyland Ltd, Chennai, has got one of the very successful Supplier development Program as part of its World-Class Supply Chain Management. Mission Statement of the Company: "Our Vendors are our valued partners in our business development and we shall work with them in a spirit of mutual co-operation to meet our business objectives." * Vendor Development and Strategic Sourcing are handled by Corporate Materials Department (CMD). - CMD identifies the vendors, rates the vendors based on feedback 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. - In addition to CMD at Ennore, and the two Units at Hosur, there are Materials Management Departments (MMDs) for scheduling based on unit production plan.
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Vendor
Development
of
Strategic
Sources
- Strategic Sourcing is central to the integrated Materials Management function. Ashok Leyland's policy is to develop a vendor base committed to continuous improvement to meet quality, cost and delivery standards. - 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 vendo rs financially. SCM one of the important task to improve,because some time before,The company was facing the huge task of integrating its entire supply chain and at the same time it had to reduce its costs, inventory, and improve customer satisfaction. Rising raw material cost was a serious concern for the company. Therefore, Ashok Leyland decided to t o streamline its supply chain process and the t he company started its SCM project µOscars¶ to optimise its supply chain and rat ionalise its sources. The project µOscars Inbound¶ included supplier partnership, vendor base rationalisation, tiering of suppliers and cluster information, inventory optimisation through JIT and LCL, total cost management, logistics initiatives, e-sourcing and global sourcing.
DRAWBACK
As Ashok Leyland is giving it¶s best to it¶s customer but then also there are some drawback :y y y
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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 advantage over its competitors, once the competitors find 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. the m. Some of the automobile company are going to launch HMV to give competition to Ashok Leyland and till t ill now Ashok Leyland not got any alternative to comptite with it.
LEARNINGS ACHIVED Ashok Leyland has got the world world class engineering and To offer offer world-class technology techno logy that is relevant and affordable to the Indian customer is the philosophy that drives R&D at Ashok Leyland.The role of Ashok Leyland is central in fulfilling the company-wide commitment to total customer Satisfaction.Ashok Leyland has achieved ISO 9002 in 1993 and received ISO 14001 certification in 2001 and many others.There are many world class product of Ashok Leyland like Buses for Public transport Purpose,Trucks for commercial purpose,vehical for defense purpose and many Other wo rld class equipment.
As we know through this project that Ashok Leyland is also one of the leading automobile manufacturer in the world and it a lso came to know that:Provide World class technology: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 company-wide commitment to total customer satisfaction" states Mr. R. Seshasayee, Managing Director, and adds that the increased infrastructural and financial support expresses the company's determination to become selfreliant in R&D. Provide Value to the customer: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. 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 had even begun in the country. The result was the implementation of CNG technology ahead of the rest promising a breath of fresh air for polluted cities.
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