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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 more people than the entire
a commercial vehicle Indian rail network. In the
manufacturing company trucks segment Ashok
based in Chennai, India. Leyland primarily
Founded in 1948, the concentrates on the 16 ton to
company is one of India's 25 ton range of trucks.
leading manufacturers of However Ashok Leyland has
commercial vehicles, such as presence in the entire truck
trucks and buses, as well as range starting from 7.5 tons
emergency and military to 49 tons. The joint venture
vehicles. Operating six announced with Nissan
plants, Ashok Leyland also Motors of Japan would
makes spare parts and improve its presence in the
engines for industrial and Light Commercial Vehicle
marine applications. It sells (LCV) segment (<7.5 tons).
about 60,000 vehicles and
In 1968, production
about 7,000 engines annually.
of the Leyland Titan ceased
It is the second largest
in Britain, but was restarted
commercial vehicle company
by Ashok Leyland in India.
in India in the medium and
The Titan PD3 chassis was
heavy commercial vehicle
modified, and a five speed
(M&HCV) segment. With
heavy duty constant-mesh
passenger transportation
gearbox utilized, together
options ranging from 19
with the Ashok Leyland
seaters to 80 seaters, Ashok
version of the O.680 engine.
Leyland is a market leader in
The Ashok Leyland Titan
the bus segment .The
was very successful, and
company claims to carry over
continued in production for
60 million passengers a day,
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
3) Hosur: Unit 2

PRODUCTION PROCESS IN ASHOK LEYLAND

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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.

3:- Engines:-

Diesel engines for Industrial,

Genset and Marine
applications, in collaboration
2:-Trucks:- with technology leaders.

Pioneers in multi axle trucks

and tractor-trailers.

PRODUCTION PROCESS IN ASHOK LEYLAND

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Largest provider of logistic

vehicles to the Indian army.

4:- Defense & Special: -

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 an
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 transpo
buses.
 PROCESS FLOW CHART OF ASHOK LEYLAND

purchase of raw material

components machined

rough milling drilling finish washing boring end milling assembly of

milling bearing caps

fixing of assembly of fitting of compressor fitting of fitting of belt

flywheel housing oil pump steiner fitting oil coolant

finish products
CRANKSHAFT: - CAMSHAFT: - CAMSHAFT
CRANKSHAFT is attached is attached with a timing gear
with a gear and is fixed to the
and is fixed in the required
bottom of the cylinder block
by bearing caps. 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: produce more fuel
Strategic sourcing recognizes efficient vehicles with
that people, including robust designs which
innovative suppliers, are a are globally best in their
valuable part of an class.
organization and focuses on World-class Technology:
reducing waste or non-value- To offer world-class
added costs. technology that is relevant and
Technology affordable to the Indian

Upgradation: The customer is the philosophy

Company has a strong focus that drives R&D at Ashok

on technology upgradation in Leyland.

order to meet the growing Value to the Customer:

demand for newer & better The immediate R&D priorities
models. are to pro-actively address
 The technology safety and environmental
upgradation initiative issues, harness and adopt
the Company expects to technologies that provide
value to the customer in an automated coolant
atmosphere enabling management system
creativity and innovation. significantly reduces coolant
Test Tracks: but Company consumption.
R&D is not confined within The Manufacturing Execution
walls. It extends to the test System (MES) allows for
tracks as well. Rigorous tests online monitoring of all
are carried out under stringent operational parameters such as
simulated conditions that breakdowns, tool change and
replicate the most treacherous power consumption - both
landscapes. current status and history.

Innovations: Ashok Automation: New

Leyland product development benchmarks have been set in
successes have come from a automation to minimize
keen sense of anticipation and activities that cause human
attentiveness. The company fatigue or pose hazards and
initiated research into achieve speed. Gantry
alternative fuels well before Systems are used for axle-
legislative debate had even beam, axle arm, camshafts
begun in the country. and crankshafts lines. Robots

Best practices: The new are used for ‘handling’ hot

lines, apart from being state- axle arms and axle beams.

of-the-art in terms of Compact and versatile:

machines and tools, also A significant addition to
incorporate many global capacities, the new lines are
industry best practices. The extremely versatile.
“Transformation training accustomed work situations to
becomes crucial in such a whole new set-up”.
movement of men from

PRODUCT SUPPLY CHAIN

It has been found that the supplier development program
automobile giant Ashok as part of its world-class
Leyland ltd, chennai has got supply chain management.
one of the very successful

Manufacturer Dealer
Customer

CMD identifies the vendors, negotiates the price at which

rates the vendors based on the parts will be supplied.
feedback received from
Ashok Leyland considers its
Supplier Quality Assurance
vendors as partners in
Cell, sends drawings /
progress and believes in
specifications, calls for quotes
establishing mutually
with detailed break-up of
beneficial relationships.
operation-wise costs, and
Ashok Leyland provides maintain quality levels. In
necessary technical assistance addition, where required,
in the form of Project and Ashok Leyland also helps
Production Engineering, to 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 To offer world-class

technology:- technology that is relevant and
affordable to the Indian
customer is the philosophy technologies that provide
that drives R&D at Ashok value to the customer in an
Leyland. Over the years, this atmosphere enabling
philosophy has been translated creativity and innovation.
time and again into products Powering those who "engineer
that seamlessly integrate tomorrows" with an enabling
international technology with infrastructure has been top
local needs. "The role of R&D priority for the company.
is central in fulfilling the
company-wide commitment to Keep innovating there
total customer satisfaction" product:-
states Mr. R. Seshasayee, Ashok Leyland product
Managing Director, and adds development successes have
that the increased come from a keen sense of
infrastructural and financial anticipation and attentiveness.
support expresses the The company initiated
company's determination to research into alternative fuels
become self-reliant in R&D. well before legislative debate
had even begun in the
Provide Value to the country. The result was the
customer:- implementation of CNG
The immediate R&D priorities technology ahead of the rest
are to pro-actively address promising a breath of fresh air
safety and environmental for polluted cities.
issues, harness and adopt
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