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PRODUCTION PROCESS OF ASHOK LEYLAND
ABSTRACT:
Theme of the paper is to deal with the production process and operation involved in
the commercial vehicle manufacturing company ASHOK LEYLAND. At the end of
reading you get the idea regarding the manufacturing or production process,
operations, supply chain management undertaking in the respected vehicle
manufacturing company.
PRODUCTION PROCESS IN ASHOK LEYLAND
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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 .The company claims to carry over 60 million passengers a day,
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).
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.
PRODUCTION PROCESS IN ASHOK LEYLAND
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ACHEIVEMENT’S OF ASHOK LEYLAND:-
1966 Introduce full air brakes.
1967 Launched double-decker bus.
1968 Offered power steering in commercial vehicles.
1979 Introduced multi-axle trucks.
1980 Introduced the 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 BEST fleet.
2001 Received ISO 14001 certification for all manufacturing units.
2001 Launched hybrid electric vehicle.
MANUFACTURING PLANTS OF ASHOK
LEYLAND:
Ashok Leyland has seven manufacturing plants:
1) Ennore
2) Hosur: Unit 1
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3) Hosur: Unit 2
4) Hosur: Unit 2A
5) Alwar
6) Bhandara
7) Pantnagar
Ashok Leyland products.
1:-Buses
Leaders in the Indian bus market, offering unique models such as CNG, Double 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 collaboration with technology leaders.
PRODUCTION PROCESS IN ASHOK LEYLAND
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4:- Defense & Special: -
Largest provider of logistic vehicles to the Indian army.
PRODUCTION PROCESS IN ASHOK LEYLAND
Mission
Achieving Customer Delight
Excellence in technology and engineering
Continuous Improvement and Learning
Teamwork, training, transparency, people - based management and
internal customer satisfaction.
Protection of working environment that promotes safety and health
of our employees.
Vision
To become Customers’ first choice, by focusing
organizational energy on understanding and delivering on their
need for state-of-the-art technology, cost and quality benchmarks,
and overall relationship, which they expect from a world class
supplier.
USERS OF ASHOK LEYLAND PRODUCTS:
INDUSTRIAL USER: Industrial user includes transporter, Logistics Company, coal and
mining industry and other industries etc.
PUBLIC USER: Public user includes individual or passenger transport.
GOVERNMENT USER: Government user includes state and central transport like DTC,
UPSRTC and other.
DEFENSE USER: Defense user includes Indian army trucks, tanks and transport
buses.
PROCESS FLOW CHART OF ASHOK LEYLAND
purchase of raw material
components machined
rough milling drilling finish milling
washing boring end milling assembly of bearing caps
fixing of flywheel housing
assembly of oil pump
fitting of steiner
compressor fitting
fitting of oil coolant
fitting of belt
finish products
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 block.0
INPUT AND OUTPUT PROCESS
INPUTS:-
Collecting information about the parts of truck and buses, which Ashok Leyland is going to produce.
Production system of Ashok Leyland. Production Strategy of Ashok Leyland (Strategy for HCV and LCV is
different.)
PROCESS PLANNING:-
Ashok Leyland selects the process for production. Study of new product which Ashok Leyland is going to produce and
study of process. Study of Machinery, which is used to produce the product. Ashok Leyland do lot of research for their production process.
OUTPUTS:-
Final product is prepared(Product is with new technology) Hybrid features of new product.
*Hybrid engine. *Hybrid model. *Hybrid technology.
OPERATIONAL MANAGEMENT
Ashok Leyland is trying to improve efficiency and
production quality, reduce costs and increase customer
satisfaction.
Among the means company is adopting just-in-time
inventories system.
Strategic Sourcing:
Strategic sourcing recognizes
that people, including
innovative suppliers, are a
valuable part of an
organization and focuses on
reducing waste or non-value-
added costs.
Technology
Upgradation: The
Company has a strong focus
on technology upgradation in
order to meet the growing
demand for newer & better
models.
The technology
upgradation initiative
the Company expects to
produce more fuel
efficient vehicles with
robust designs which
are globally best in their
class.
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.
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.
Test Tracks: but Company
R&D is not confined within
walls. It extends to the test
tracks as well. Rigorous tests
are carried out under stringent
simulated conditions that
replicate the most treacherous
landscapes.
Innovations: 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.
Best practices: The new
lines, apart from being state-
of-the-art in terms of
machines and tools, also
incorporate many global
industry best practices. The
automated coolant
management system
significantly reduces coolant
consumption.
The Manufacturing Execution
System (MES) allows for
online monitoring of all
operational parameters such as
breakdowns, tool change and
power consumption - both
current status and history.
Automation: New
benchmarks have been set in
automation to minimize
activities that cause human
fatigue or pose hazards and
achieve speed. Gantry
Systems are used for axle-
beam, axle arm, camshafts
and crankshafts lines. Robots
are used for ‘handling’ hot
axle arms and axle beams.
Compact and versatile:
A significant addition to
capacities, the new lines are
extremely versatile.
“Transformation training
becomes crucial in such
movement of men from
accustomed work situations to
a whole new set-up”.
PRODUCT SUPPLY CHAIN
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.
Manufacturer Dealer Customer
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.
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 financially.
DRAWBACK:
As Ashok Leyland is giving it’s best to its customer but then also there are some drawbacks:-
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 over its
competitors, once the competitors 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.
Some of the automobile company is going to launch
HMV to give competition to Ashok Leyland and till
now Ashok Leyland not got any alternative to
comptite with it.
FEATURES OF THE COMPANY:
As we know through this project that Ashok Leyland is also one of the leading automobile manufacturers in the world and it also 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 self-reliant 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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