MADE BY VOLVO. IN INDIA.

The quality of Volvo trucks and our manufacturing systems is well exhibited among the scores of Volvo trucks in operation in India, among the toughest of conditions & applications.

The factory is located over 122 acres and includes main assembly, gearbox assembly, cab welding, superstructure mounting and welding, paint shop, shot blasting, a test track, a driver training center besides a technical training center. The factory meets ISO 9000 quality standards and ISO 14,000 certification for Environment standards There are close to 140 people working on the shop floor, with an average age of around 24 years. Systems and people are geared to the 5 S way of housekeeping and Kanban storing, visual controls and employee involvement. Today, the installed Capacity is 1000 Vehicles per annum and can be quickly stepped up to additional volumes. The factory has a 100% back-up power ensured by our very own Volvo Penta Engines.

The Volvo factory in Bangalore is equipped with Volvos global-quality standard norm, tools, systems, training programs, dedicated people and an unbeatable culture that drives towards one common goal Produce Volvo trucks of outstanding quality.

Beyond ISO
Volvo in Indias quality system is based on the ISO 9001 & EMS 14001 standards, but in fact goes beyond the requirements of the international standards. A few examples that reflect the quality work:
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All suppliers must meet Volvo Truck Corporations requirements. Suppliers are responsible for delivering components of the right quality and must abide by our quality systems. Today, some of the suppliers to Volvo in India not only match Volvos global quality standards but are also ranked among the best in the world. All trucks undergo diagnostic tests for all truck functions with the help of a special program Prosit executed through a computer. Every truck goes through a check on the Volvo test track at the factory. High-tech equipment is in use to ensure topclass production. An example is the laserguided alignment of the axles on trucks as well as trailers. Specially trained employees check up the entire vehicle to spot any quality issue before the truck leaves the factory. Product audit is a common process for all Volvo factories, thus also making it easy to benchmark them with each other. Tools and equipment in the factory are calibrated at defined intervals. No matter whom you meet in the factory, quality will be on top of his mind.

The Main Assembly

This line has is a 9 stage operation. Starting with riveting of frame rails till the end where we drive off the truck. Behind the assembly is a set of well defined assembly instructions and set of tools & equipments that are quality checked & has a defined calibration cycle.
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Each preceding stage & forward stage act like customer & supplier concept At the end of the line we have a Computerised process quality function check. Since in our trucks we have large electronics integration, the electro-mechanical functional checks are important. We have microprocessor for vehicle management, Engine management etc. The software & hardware are checked using the computer. Every truck is connected to a remote server in Sweden & all software programmes are checked Various functions of the truck like, all lighting, accelerator, brake , gear shift operations are checked through the computer In case of any fault the same can be traced using the computer The trucks once started will be test driven at the test track for about 40 to 50 Kms & once again all functions are checked before delivery to the customer

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Gearbox Assembly
Volvo in India is one of the only 2 units outside Sweden to assemble gear boxes. The assembly is carried out in a controlled environment. The gearbox assembly includes the latest machines supporting in the process of washing and degreasing of the parts. We fill the gearbox with recycled oil and test it for even the minutest of leakage. Also included is a driveline simulator where we undertake thorough checks on noise levels and gear engagements.

Cabs Paintshop & Welding

The Paint shop are world class facilities for painting of cabs, plastic parts, Trailers & chassis components. All Paint material & systems are conform to International Volvo specification. The focus of painting from the customer perceptive is protection from corrosion, Weathering, ultra violet resistance. The paint shop is fully pressurised enclosed shop for dust control. Our paint system provides special protection in all cavities & box sections in cab to ensure complete corrosion resistance. In the factory we include the shot blasting facility used for trailers and tipper bodies. Starting this year Volvo, Hoskote will commence welding of stamped panels for the cab. This breakdown in the cab aggregate will help increase the local content in the local operations and will add even greater flexibility. As a consequence of the welding process Volvo in India will now upgrade its paint shop to include multi-layer paint process.

Environment & Safety

Volvo in India approaches environment concerns on the basis of Volvos global environmental strategy. We focus on minimising resource consumption, waste besides ensuring that we achieve significant energy savings periodically. The Volvo industrial system has a strong focus to integrate our suppliers in line with our core values. The Volvo factory at Hoskote is ISO 9001 and EMS 14001 certified.

Some of the activities with regard to our concern for environment are:

Usage of advanced systems

No use/procurement of chemicals in Volvos Black list example:

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Closed loop systems in paint shop Tertiary treatment in waste water treatment Reverse Osmosis Effluent treatment Painting process in environmental control booths 100% treated waste water reutilised for gardening
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No use of Asbestos Refrigerant in Cab and building is non-CFC Halon free fire extinguishers Factory noise levels at boundaries are well within legal limits

Work across the factory follows all the safety precautions wherein we have carefully planned our movement. Operators are equipped with the necessary gloves, ear cover or special suits as in the case of shot blasting and paint shop. The oil we use to test leakages, as in the gearbox assembly or other purposes is recycled in the silos located nearby.

Volvo India Private Limited Yalachahalli, Tavarekere Post, Hosakote Taluk, Bangalore 562 122, India. Phone: 080-7965251 - 60, Fax: 080-7965280/81 Ahmedabad: Phone: 98240 53038 Bangalore: Phone: 080-2520700109 Fax: 080-25207010 Jaipur: Phone: 0141-2363248 / 2363471, Fax: 0141-5120420 Kolkata: Phone: 033-22810794, 22808241, Fax: 033-22871631 Mumbai: Phone: 022-28345020, 28344293, 28344266, Fax: 022-28344263 New Delhi: Phone: 011-23314223, 23314262, Fax: 011-23316702 Raipur: Phone: 0771-5033031, 5033050, Fax: 0771-5033030

www.volvo.co.in