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Chapter No: 01

Introduction to Ghandhara Nissan Limited

1.1 About Ghandhara Nissan 1.2 About GNL Plant 1.3 Nissan Products 1.4 Production/Assembly Plant 1.5 Quality Control Department 1.6 Warehouse 1.7 Final Remarks

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{D-08-IN-314, D-08-IN-331, D-08-IN-337, D-08-IN-338, D-08-IN-339} 1.1 Introduction to Ghandhara Nissan Limited:

Ghandhara Nissan Limited (GNL) is a group Company of Bibojee Services (Pvt.) Limited. The Company was incorporated in 1981 as a Private Limited Company having the sale licensee for the distribution of Nissan vehicles in CBU condition in Pakistan, later in 1992 it was converted in to a Public Company listed in Karachi Stock Exchange.

GNL has Technical Assistance Agreement with Nissan Motor Co. Japan and joint Venture Agreement with Nissan Diesel Co. Japan for the progressive Assembly of Passenger Cars, Light Commercial Vehicles and Heavy Duty Vehicles. GNLs Car and Truck Plants are located at Port Qasim adjacent to each other.

It is the only Automobile Company in the country, assembling complete range of product i.e. passengers cars, light commercial vehicles and heavy-duty trucks and buses.

The company is committed to achieve high quality products, customers satisfaction, market leadership, contribution in the economic growth of Pakistan and comply with all regulatory and other requirements for making the environment user friendly.

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{D-08-IN-314, D-08-IN-331, D-08-IN-337, D-08-IN-338, D-08-IN-339} 1.2 About GNL Plant: The Assembly Plant of Ghandhara Nissan Diesel Limited situated at Bin Qasim, Karachi is most modern of its kind in Pakistan. The innovations carried out in-house from time to time, contributes to high standard of quality. Its capacity is flexible and can be doubled easily. It can produce 1200 vehicles annually on single shift basis. The Company is committed to meet the nations transportation needs by providing economical, user friendly and high quality commercial vehicles.

In this regard quality at all levels is strictly maintained by GNDL team of Engineers and Technicians, trained locally and abroad. Area of Plant: Total Plant Area Total Built up Area : : 32373 Square Meters 10450.389 Square Meters

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{D-08-IN-314, D-08-IN-331, D-08-IN-337, D-08-IN-338, D-08-IN-339} 1.3 Nissan Products: Nissan is the only Automobile Company in the country, assembling complete range of products i.e. passengers cars, light commercial vehicles and heavyduty trucks and buses. Vehicle Line-Up 1.3.1 Cars:

Nissan X-Trail

Nissan Patrol

Nissan Cefiro

Nissan Sunny

1.3.2 Bus:

SP210 TURBO Bus

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{D-08-IN-314, D-08-IN-331, D-08-IN-337, D-08-IN-338, D-08-IN-339} 1.3.3 Trucks:

PKD 411 HHRR {New} (Turbo charger 4X2Truck)

PKD 311 HHRQ (4X2Truck)

CDA 311 PHRP (Turbo charger 4X2Truck)

PKB 211 GHRN (4X2Truck)

PKC-311ETNP (Turbo charger 4x2Truck Tractor)

CWM-454MHRA (6X4 Truck Tractor)

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{D-08-IN-314, D-08-IN-331, D-08-IN-337, D-08-IN-338, D-08-IN-339} 1.4 Production/Assembly Plant: Following production sections are being operated at GNDL Assembly Plant: Chassis Drilling Axle Assembly Shop Engine Test Shop Paint Shop Tube Bending Shop Frame Riveting Engine Assembly Shop Cab Metal Shop Trimming Shop Chassis Assy Line

A bird Eye-View of the Assembly plant is shown in the figure below.

Figure: Assembly Plant Layout

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1.4.1 Frame Drilling and Riveting: In this area frame is prepared, which is main component of the chassis. The work on the frames is carried out in following: 1st Stage: Drilling 30mm 2nd Stage: Drilling 30mm Flange Drilling 3th Stage: Web Drilling 4th Stage: Grinding Area: Here the frames are grinded, and all the burs of the holes arise due to drilling are cleaned/ removed. Also the number on the frame of the chassis is engraved through an engraving machine. 5th Stage: At this stage the frames are forwarded to the paint shop or painting. After painting and dried up, the frames are than send to the stage 6. 6th Stage: After painting, the frames are here permanently joined through riveting. Here the long members (i-e left and right frame) are joined together with the help of cross members by the application of welding and riveting.

Figure: Frame Riveting Shop

After drilling and riveting the frames are assembled as per drawing.

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1.4.2 Axle Assembly Shop: This shop is the one of the complex shop in the Chassis Assembly line. Axles are assembled here and sent to the main assembly line fro further possessing/operation. The work here is divided in the following six stages: 1st Stage: First all the components/parts required in the assembling process known as C.K.D parts (Complete Knock Down) are unboxed and than wash out to remove all the impurities present in the form of dust, rust, etc. These parts are: Hub and Drum Axle Shaft Front Beam Tube 2nd Stage: Hum and Drum is Assembled 3rd Stage: Bearing greasing and Lubrication 4th Stage: Differential in assembled over tube (Rear Axle) 5th Stage: Main assembling process starts at this stage. The different types of works performed here are: Brake Assembly (Left and Rights) Outer bearing and adjustment nut Inner bearing Pre-Load Adjustment (PLA) Hub/Drum mounting Brake Assembly Clearance Other adjustments and Brake settings (as specified in standards) Ready for paint. Standard: 0.3mm to 0.4mm clearance between brake shoe and drum) 6th Stage: Number Punch Knuckle Assembly (R/L) o King pin o Front Pulley/Thrust Bearing o Greasing Toe in-out adjustment (up to 46 ) Brake Assembly Inner bearing on knuckle assy (R/L) Hub and Drum (R/L) Different Adjustments Ready for Paint.
Figure: Axle Assembly Shop

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1.4.3 Engine Assembly and Testing Shop: Engine shop is the most important sub assembly shop to the main assembly line. Engines of the required specification for any vehicle are assembled in the engine shop. Most of the components of the engine are C.K.D (i-e received from Japan). In the assembling of the engine, first crankshaft and camshaft is attached with cylinder block, and then cylinder head is attached. After these things piston is attached to the crankshaft with help of the connecting rods, then housing is done, after which fly wheel is attached. Now the engine starts to get shape, as fuel injection pump and starter motor is attached with the engine, then compressor is attached. Now the engine assembling is almost completed and then the engine test is carried out before dropping the engine on the chasses. Some of the main components of engine used in the assembly process are: Cylinder Head Cylinder Block Crankshaft Camshaft Flywheel Piston Flywheel Housing Exhaust Manifold Intake Manifold Turbocharger Timing Case Rocker Arm Engine Gasket Kits Valve Cover Oil Cleaner Oil Sensor Air Intake Air Filter

Figure: Engine Assembling Shop

Figure: Engine Testing Shop

The engine test is done in specially designed environment providing fuel and air directly form the cylinder. Very rarely they get problems here but if the gets any, they quickly tries to satisfy or remove the problem. The engine is sent to the chasses assembling line, where it is drop on the chasses.

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1.4.4 Cab Metal Shop: In this area the body of the cabin is prepared. All the panels of the body are taken from the C.K.D; here all these are only assembled through different welding processes (i-e Spot welding and arc welding). Here the mostly commonly used welding process is spot welding process. This is the most effective welding process because it never develops any flaws. The welding process is facilitated or made easier through the use of jigs and fixtures. These jigs and fixtures are different for different models. Also at Ghandhara Nissan Limited they now used jigs and fixtures which can be adjustable for two or even at most for three models as well. When the assembling of the cab is completed than is move to paint shop, for painting, after which some other processing is done over cab, as scheduled or required.

1.4.5 Paint Shop: Then the body is taken into the paint booth for paint, Presently Electronically Deposit Paint (EDP) technology is being utilized at Ghandhara Nissan Limited, which makes UD brand trucks one of the favorite choices of its customers in Pakistan. Presently the paint shop in GNL Truck Plant is not utilized; therefore the cabs are move to the GNL Car Plant for painting. Before E.D paint, polymer is applied on the cab body surface, so that it can absorb the paint properly without developing a thick layer of paint on the cab body. Due to secrecy of this Technology, we were not allowed to visit and see the E.D Paint Process. There employee told us verbally about the process and also entertain our queries about the E.D.P Technology. After painting, the cabs are again transported to the GNL Truck Plant for further operations.
Figure: Paint Shop

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1.4.6 Trimming Shop: After Painting the Cab is sent to the trim line for further operations. As trimming is the process or act of adding decoration, therefore in trimming process the interior and exterior decorative work is done. It consists of fitting door, windows, seats and some electrical work.

Figure: Dash Board Installation

Figure: Trimming Line

The different types of work performed at trim line are: o o o o o o o o o Door preparation Exterior preparation Head lining preparation Harness installation Blower/Ventilator Air ducting Pedal assembly Steering column Dash board installation o o o o o o o o o Front panel assembly Bonnet assembly Floor mate Seat installation Wind shelled installation External mirror Under body assembly Cab tilt mechanism Engine room installation

1.4.7 Tube Bending Shop: In this shop pipes of different sizes and shapes are cut and bend as required on the assembly line. This shop is the most simplest in the whole chassis assembly line. Jigs are mostly used in this shop, which is used in bending operation of the pipes. These pipes are used for various applications especially to handle the movement of the fluid in the brake and fuel system.
Figure: Tube Bending Shop

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1.4.8 Main Assembly Line/Chassis Assy Line: This is the main assembly line in which all the above mentioned subassemblies of different components are combined. The work here is divided into the following stages: 1st Stage: Shackle assy Front leaf spring assy (R/L) Rear leaf spring assy (R/L) Power steering assy Horn assy Shock absorber Gear leaf bracket (R/L) Stabilizer A.C (Front and Rear) Outer kigger Turnion Assy Tilt bracket assy
Figure: Main Assembly Line

2 Stage: Front axle assy Rear axle assy Battery assy Linkage rod Pitman arm 3rd Stage: Air reservoir tank assy Brake booster assy Front brake tubing assy Rear brake tubing assy Chassis harness assy Fuel pipe assy 4th Stage: Engine transmission assy Muffler assy Exhaust tube assy Hydraulic oil tube assy Hydraulic oil cooler assy 5th Stage: Cab mounting Battery cable and self connection Bumper adjustments Steering shaft adjustments

nd

Tires front and rear (both R/L) Spare wheel carrier assy Fuel tank assy Rear dead axle assy

Brake valve assy (Front/Rear) Air brake pipe assy Clutch assy Magnetic valve assy (Exhaust Brake) Harness relay assy

Gear level rod assy Engine stopper motor assy Engine drop on chassis Radiator assy Clutch adjustments

Accelerator cable adjustments Propeller shaft Hand brake cable Air filter

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{D-08-IN-314, D-08-IN-331, D-08-IN-337, D-08-IN-338, D-08-IN-339} 6th Stage: Clutch adjustments Brake adjustments Diesel filling (fuelling) Hydraulic oil for power steering To check the leakage To check Brake oil leakage To check Dash board meter To check Indicator (R/L) To check Head lights To check Oil light To check Gear light To check RPM

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1.5 Quality Control and Quality Assurance Department: Quality control is a process by which entities review the quality of all factors involved in production. This approach places an emphasis on three aspects: Elements such as controls, job management, defined and well managed processes, performance and integrity criteria, and identification of records. Competence such as knowledge, skills, experience, and qualifications Soft elements such as personnel integrity, confidence, organizational culture, motivation, team spirit, and quality relationships. The quality of the outputs is at risk if any of these three aspects is deficient in any way. Quality assurance, or QA for short is the systematic monitoring and evaluation of the various aspects of a project, service or facility to maximize the probability that minimum standards of quality are being attained by the production process. QA cannot absolutely guarantee the production of quality products. Two principles included in QA are: Fit for purpose - the product should be suitable for the intended purpose; And Right first time - mistakes should be eliminated. QA includes regulation of the quality of raw materials, assemblies, products and components, services related to production, and management, production and inspection processes. Quality Control emphasizes testing of products to uncover defects, and reporting to management who make the decision to allow or deny the release where as Quality Assurance attempts to improve and stabilize production, and associated processes, to avoid, or at least minimize, issues that led to the defects in the first place. The GNDL quality control and quality assurance teams are fully aware of all these and therefore they work with confidence in their respective areas. They not only focused to find defective products but also work to reduce the production of defective products. The GNDL quality control department main task is to inspect and check all the products which they directly order form there vendors and also C.K.D products as well. The quality control department is responsible to carry out the
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inspection in the assembly plant (i-e all the sub-assembly shops and main assembly line), final inspection, Pre-delivery inspection (PDI) and also to maintain the quality of products in the warehouse.

1.5.1 Inspection During the Assembly Process: During the assembling process in the sub-assembly shops and main assembly line make it obvious to achieve high quality products. The persons responsible for this inspection really make efforts to minimize the production of non-conforming items. They have designed quality check sheets which help them to inspect processes stage wise and also without neglecting something during the process. The path which the quality control persons follow during the sub-assembly shops and assembly line inspection, final inspection and PDI is shown in the figure below:

Figure: Vehicle Assembly Inspection Process

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The check sheet which the quality control persons use during the main assembly line is shown in the figure below. These check sheets make them able to effectively and efficiently identify different areas and persons working on the assembly line, whose are responsible for the production of defective products. The check sheet also enables the quality personals to identify the different stages form where the problems developed in the product, this help them in not only finding the defective products but also help them to reduce the production of defective products. Through the use of this simple yet very effective tool of quality QC tries to identify and maintain the production of quality products. But if they find out major problem they try to solve it out some other tools as well. Some other tools which they use are cause and effect diagram also know as fish bone diagram, 5 whys strategy which is a questions-asking method used to explore the cause/effect relationships underlying a particular problem. Ultimately, the goal of applying the 5 Whys method is to determine a root cause of a defect or problem.
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1.5.2 Quality Check/Final Inspection: Even products are constantly inspected during the main assembly line but still after completion of the work at main assembly line, the vehicle is then to pass through the inspection/quality check. A group of two quality supervisors have to conduct this inspection. They have to check/inspect the vehicle and have to identify/find out all the defects from minor one to major one if there is any. If they observe any thing out of order, they first try to take the required corrective action at that specific location to correct it, if the problem they identified is a major one, then they mark the defective area (i-e whether there is any dent or color problem, this depend upon the nature of problem) and prepare a report of it, and forward it to the rework department. Then the workers there have to take the required corrective action to satisfy the issue. Also they communicate to the workers working on main assembly line, so that efforts are being made to reduce the production of defective products. Here some major tests are also conducted to find out some other problems as well; Especially Speedometer test, Brake control tests, Electric control test, etc. After the qualifying all these tests, the vehicles are than moved to the storage area. From there the vehicles are than handover to the customers in batches.

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1.6 Warehouse: A warehouse is a commercial building for storage of goods. Warehouses are used by manufacturers, importers, exporters, wholesalers, transport businesses, customs, etc. They are usually large plain buildings in industrial areas of cities and towns. Warehouses are designed for the loading and unloading of goods. Stored goods include any raw materials, packing materials, spare parts, components, or finished goods associated manufacturing or production.
Figure: Warehouse

Warehouse is an important part of the any manufacturing or servicing industry. Like other industries GNDL also give high emphasis to its warehouse inventory, which directly influence the production capability of the industry. In GNDL two types of inventory of parts is maintain, first is the one which is directly imported from Japan (i-e C.K.D parts) and second is the one which is locally manufactured through different vendors. A high priority is given to the first one. These parts are almost defect free. Sometime even in C.K.D parts defect may arise, but this might be due rough handling, or due to improper packaging used for transportation. The time required in receiving the parts from Japan is on the higher side, and also they supply parts in batches. Therefore when monthly master production schedule is developed keeping in view of the market and customers requirement. This production schedule is circulated to all the departments i-e warehouse, production department, and quality control department. Concern managers of these departments interact with each other and discuss the feasibility of the achieving the scheduled production target. They also discuss about the resources they will need in achieving the target, and compare it the resources they have. A bird Eye-View of the Warehouse is shown in the figure below.

Figure: Warehouse Layout Page 28

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After discussions on schedule and proper planning on the quantity and priority of the products they develop list of all the parts they will required in achieving production target, this is known as BOM (Bill Of Material). BOM help them in getting the full knowing of how much quantity of material will be required. After this the warehouse manager has to raise the required inventory through different channels (ie from C.K.D and Local vendors) of the required materials.

Figure: BOM (Bill Of Material)

When it is decided to raise inventory of a certain part or material from local vendors, then the next step is to evaluate between various vendors. At this point the role of quality control department is very much essential, as they are responsible in selecting a vendor, if they select faulty vendor, it will result in the defective production.
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To overcome all these issues, the GNDL quality assurance department has developed inspection programs, which helps them in evaluating the step by step inspection of the vendor products and maintain the required quality. This program focus on the development of any part from its design phase till it is transfer to the GNDL territory. After receiving the part first the warehouse generate a good received report (GRR), and send a copy of GRR to quality department, against which they perform the required inspection. Now it is the responsibility of the quality control department, to inspect and control the quality of received goods, so that to make it possible to receive and accept only products of high/required quality. The quality control department have also pre-defined program for evaluating the quality of the received good. When they carried out the required inspection usually based on sample size, the QC department also prepared a report of either goods no rejection note (GNRN) (i-e if they find zero defects or find defects with-in acceptance range) or goods rejection note (GRN) (i-e if they find defect out side the control limits or acceptance range). If they find out some sort of discrepancy in the received goods which is not control limits or which will create some other problems during the assembling process or it will not fitted satisfactorily during the
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assembling process, then they create a report known as goods rejection note (GRN). The copy of this report is also communicated to the vendor, and also in this report the GNDL quality control personnel forbid the vendor to also lift there rejected product form the company premises with in a defined span of time, usually it is in between 15 to 30 days. Certifications: Ghandhara Nissan Limited always focus its customers and efforts has been made in fulfilling the all the requirements of the customers. Therefore in this customer driven economy, customers are expected to be the king of the market and are also free in making their decisions regarding the products. Therefore efforts are being made not only to attract customers but also to not to lose them. For fulfilling the customers needs and demands, the company is working to meet not only the quantitative aspect of the demand but also the qualitative aspect of the demand as well. GNDL produce products of high quality and standards, efforts are also being made to handover the right or zero defective products to the customers. All this is achieved through proper planning and setting standards, so every they produce products, would probably be of high quality with almost zero defects. GNDL also audited there system not only by the local auditors but from the international auditors as well. Also GNDL is certified ISO Quality Management System, Assurance System, etc.

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1.7 Final Remarks: These are different processes taking place in the GNDL different sections/Departments. The company main focus is its customers, and efforts are being made to fulfill their customers demands and requirements. The company has a good reputation and serves a good share in the local automobile sector in passengers cars, light commercial vehicles and heavyduty trucks and buses. Also GNDL is the only automobile company in the country which has a complete range of vehicles i-e passengers cars, light commercial vehicles and heavy-duty trucks and buses. GNDL is also expected to increase its share in local market in the up-coming years because in the local market the customers are attracted to the NISSAN products due its low cost, high quality and reliability.

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