INPLANT TRAINING AT

ASHOK LEYLAND
TRANING PERIOD:
19-04-2011 TO 26-
04-2011

MURRUGAPPA POLYTECHNIC
COLLEGE
• R. Kavitha anjali

• S. Lalitha

• K. Naveen kumar

• G. Parthiban

INPLANT TRAINING
SCHEDULE
19-04-2011 - ENGINE ASSEMBLY

20-04-2011 - MACHINE SHOP III

 21-04-2011 - MACHINE SHOP IV

23-04-2011 – CHASIS ASSEMBLY

26-04-2011 – MACHINE SHOP II

ABSTRACT
This is a report on in-plant training carried out at ashok
Leyland limited, ennore plant during 19-04-2011 to 26-04-
2011. This report covers the important manufacturing
process carried out at the industry. This report includes the
aspects of production carried out at the sections like chasis
assembly section, shop II, shop III, shop IV and engine
assembly section.

At the chasis assembly section, the chasis goes

through various stages in which different components were
attached to metal frame. In total there were 19 stages
through which the frame passes through to become the
skeletal function body of mobile function body of the
automobile which can be a bus, track, or other such goods
carrier.

At the shop II various components of engine were

produced.

At the engine assembly section the various

components being manufactured in shop II were assembled
to form the engine and the assembled put to test for any
correction required.

At the shop III, metal plates were assembled to form

the complete frame. The frame passes through 10 steps in
which various cross railings and mounts were fitted to
frame to form the complete chasis.

At the shop IV, the assembly of rear and front axles

were carried out.

Acknowledgement
First and foremost, we thank the management of ashok
Leyland for following us to carry out our in plant training in
their esteemed concern. We also thank various
employees of the concern who spared their time answering
our questions in spite of their busy schedule.

Last but not the least we thank the almighty for keeping us
in good health and for giving us this wonderful opportunity.
INTRODUCTION:
Ashok Leyland (NSE: ASHOKLEY, BSE: 500477) 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 a market
share of 28% (2007–08). With passenger transportation options
ranging from 19 sweaters to 80 sweaters, 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).

The origin of Ashok Leyland can

be traced to the urge for self-reliance, felt by independent
India. Pundit 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.Early
products included the Leyland Comet bus which was a
passanger body built on a truck chassis, sold in large numbers
to many operators, including Hyderabad Road Transport,
Ahmedabad Municipality, Travancore State Transport, Bombay
State Transport and Delhi Road Transport Authority. By 1963,
the Comet was operated by every State Transport Undertaking
in India, and over 8,000 were in service. The Comet was soon
joined in production by a version of the Leyland Tiger.

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.Over
the years, Ashok Leyland vehicles have built a reputation for
reliability and ruggedness. This was mainly due to the product
design legacy carried over from British Leyland.

And this is the report of In plant training done in this well

reputed organization for period of two weeks.

ENGINE ASSEMBLY:
DATE OF TRAINING: 19-04-2011

STAGE 1: CAM BEARING

Crank case SWR/plate/EII NO is brought to the engine
assembly, here cam bearings are fixed to the crank case of
the engine.

STAGE 2: CAM SHAFT

Cam shaft types E0/EI/EII NO are fixed in appropriate place

in the crankcase.

STAGE 3: CRANK SHAFT

Crank shaft, make BM/GB is fixed at base of crank case like

passing thru hole.

STAGE 4:

M-14 STUDS are fixed at the holes on the crankcase.

STAGE 5:

In this stage 1st and 6th piston is kept at the top dead
centre and timing gears are fixed to side of the engine for
the firing order.

STAGE 6: CAM GEAR

Cam gears are fixed on the crankcase to operate the cam

shafts in order to operate the valves.

STAGE 7:
FLYWHEEL housing is fixed on the crankcase of the engine.

STAGE 8:

The flywheel is placed on the housing and 90torques is

applied to it. The flywheel housing consists of seal housing,
flange and flywheel.

STAGE 9: OIL PUMP

Oil pump is fixed on the top of the crankcase to circulate

the oil to the various parts of the engine.

STAGE 10: PISTON

The readily made piston is fixed inside bore of the

crankcase and connected to the crankshaft. Before that,
piston rings of three types, two compression rings and an
oil ring are fixed on the piston.

STAGE 11: CONROD BOLT

Conrod bolt is fixed to connect the piston with the crank

shaft.

STAGE 12: IDILING GEAR

It’s fixed on the spindle which controls the rotations of cam

gear, crank gear and compressor gear.
STAGE 13: CYLINDER HEAD

Cylinder head is fixed to the top of the crankcase to which

rocker arm with valves are fixed.

STAGE 14: OIL SUMP

Oil pump is fixed at the bottom of the crankcase with

adhesive (RTV) paste.

STAGE 15: ROCKER

Rocker assembly is fixed to the cylinder head.

STAGE 16: AIR COMPRESSOR

AIR COMPRESSOR is fixed to the crank case.

STAGE 17: FUEL INJECTION PUMP

Fuel pump is fixed to LTC/EII/EI types of engines.

STAGE 18: VALVE COVER

STAGE 19: OIL COOLER

STAGE 20: INJECTOR PIPE AND INLET MANI FOLD is fitted.

STAGE 21: SIDE COVER

STAGE 22: WATER PUMP

STAGE 23: STARTER MOTOR

STAGE 24: EXHAUST MANIFOLD

STAGE 25: TURBO CHARGER

STAGE 26: EII FTMENTS

STAGE 27: Fully assembled engine is taken to the testing

area to be tested for is performance.

MACHINE SHOP III:

DATE OF TRAINING: 20-04-2011

The chassis of the vehicles’s first step starts from here at

this shop-3. The frames of the vehicles are fixed together to
be sent to the chassis assembly. The skids are mounted on
the conveyor belt and frame is placed on the skids. And
frame MTG on which engine is mounted is fixed across the
two frames. On the rear end of the frame BKTS both sides
are aligned with taper pin. Fit and tight FSR and BKTS on
both sides with dummy bolts. Tilt both the FSMS to 90
degree by turning tackle and insert clamps. Tight and apply
torque to engine MTG flinches and M12 with bolts.
Correspondingly in every stage each workers tight
appropriate bolt to the frame before taken to chassis
assembly make it a complete frame.
MACHINE SHOP IV:

DATE OF TRAINING: 21-04-2011

This shop-4 is divided into two departments where the front

and rear axles of the vehicles are assembled with leaf
springs, brake drums before being attached to the main
frame of the vehicle.

FRONT AXLE ASSEMBLY:

STAGE 1:

Axle beam is loaded on the conveyor belt.

STAGE 2:

Number is punched on the axle beam.

STAGE 3:

Axle arm is fitted on the beam for steering.

STAGE 4:

Steering rod is fitted. It is right end of the axle according to

Indian STDs.
STAGE 5:

Tracking rod is fitted. It is used for the alignment of the

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

STAGE 6:

Brake carriers with brake linings are fitted to the FR axle

beam and taken to chassis assembled.

REAR AXLE ASSEMBLY:

STAGE 1:

Banjo casing from outside is unloaded and fixed on the

conveyor and axle shaft is removed.

STAGE 2:

Brake lining and 10 bolt and washer are fixed on the brake
carrier with spring washer. Dust cover is also fitted.

STAGE 3:

Brake nut and bolt are tighten and fitted 75 to 50 torques.

STAGE 4:
Ring for oil seal is fitted on the hub shim is fitted 3-6tau for
the clearance flange cover is fitted with 4 bolts.

STAGE 5:

Inner oil seal is fitted on ring for inner oil seal. Inner wheel
bearing is fitted.

STAGE 6:

Distance piece is fixed to align the inner and outer wheel

bearing in the same axis.

STAGE 7:

Dry set, where the wheel hub is fixed roughly to verify

whether to increase or decrease the shim.

STAGE 8: WET SET

Where grease is packed inside the wheel hub.

STAGE 9:

Axle tube nut is fixed with counter pin and bolt, 190 tau
tightness. The given, studs are fixed in the hub to fixed to
the shaft. Grease nipple is fixed on the wheel hub.

STAGE 10:
Axle studs are tightened to 50-60 taus. Drum is fixed 8mm
bolt is fitted.

STAGE 11:

Axle shaft is fitted using 8 spring washer and nut on the

stud.

STAGE 12:

Complete assembly of rear axle is unloaded and taken to

chassis assembly.

CHASIS ASSEMBLY:

DATE OF TRAINING: 23-04-2011

STAGE 1&2:

Already assembled FR Axle & Rear axles from machine shop-4

are fixed on the main frame that fabricated from the machine shop
3 of the vehicle.

STAGE 3:

The fixed frame assembly is placed on the conveyor belt, where

brake chamber is fitted to it.

STAGE 4:

Steering gear box is fitted to the main frame.

STAGE 5:

Silencer tank is fixed to the main frame.

STAGE 6:

Then fuel tank is fitted in this stage of chassis assembly.

STAGE 7:

Engine mounted on the main frame of the chassis of the vehicle.

STAGE 8:

Radiator fixed in front of the engine.

STAGE 9:

Tyres for all the wheels are fixed to the drums of the axles.

STAGE 10:

The vehicle is toed then and taken to the other unit to make it
running conditions and test driven.

MACHINE SHOP II:

DATE OF TRAINING: 26-04-2011

Here in this shop the perfectly casted part of crankcase

arrives from the casting plant situated somewhere near the
main plant. This casted crankcase constitutes the main part
of the engine compartment. This shop-2 consist of the
heavy machines of HMT that helps in boring and drilling
different sizes of holes needed for the fitments of various
engine spares. There are different process of
manufacturing is done here.

CONCLUSION:
It’s been privilege to do in plant training in one
of the India’s largest automobile producer ASHOK LEYLAND.
It has helped in many ways to improve the knowledge
about the actual work done in the industries and to have
hands on experience.

Thus we the students of murrugappa polytechnic

college, Avadi have successfully attended and completed
the training at ASHOK LEYLAND LIMITED ENNORE PLANT
FROM 19.04.2011 TO 26.04.2011.