Acknowledgement

Above all, I would bow my head in sincere gratitude and sense of pleasure in front of the

Almighty, for helping me achieve all that I could.

I am highly indebted to SMLs staff for their guidance and constant supervision as well as for

providing necessary information regarding the project & also for their support in completing the

projects.

These projects would not have been possible without the kind support and help of many

individuals and organizations. I would like to extend my sincere thanks to all of them.

I wish to express my deep sense of gratitude to my Industry Guide, Mr. Abhishek Puri,

Technology Department, SML-ISUZU Ltd. and my Institutes teachers for their able guidance

and useful suggestions, which helped me in completing the project work, in time.

I would like to express my heartfelt thanks to my beloved parents for their blessings and constant

support during the project. My friends/classmates have been very helpful and cooperative and I

would like to take this opportunity to extend my thanks to each one of them.

Aggyapal Singh

2

Summary

Various Departments of Bus Body Plant

1) Personnel Department

2) Research and Development

3) Quality Engineering Department

4) Technology Department

5) Accounts Department

6) Purchase Department

7) Maintenance Department

My Department

I was appointed a trainee in Technology Department, under the guidance of Mr. Balbir Singh

(Head of Department, Technology) and Mr. Abhishek Puri (Senior-Engineer). The Department is

further divided into three sub-departments

Industrial Engineering

Production Engineering

Tool Design

The Main Purpose of Technology department is to assist the Production Line in any Kind of

problem Being Faced by it; the other departments ask Technology Department For any kind of

Fabrication to be done for assisting the line, which may be Gauges for Production line, Material

handling Racks for assembly line etc.

During my training period, i was initially asked to study the Zhong-tong models structure, shell

and assembly line, which later on let me work on two projects related to shell line and assembly

line, one each.

On Shell line of ZT model, my project was to develop gauges meant for marking the cut-outs for

diesel tank, sedimentary tank, air-cleaner and spare wheel flaps. This was my project as an

individual.

3

On assembly line, I worked as a trainee with a team from Technology department, including

Mr.Abhishek Puri, my industry coordinator. Its purpose was to consume the wastages of

Aluminium Chequered Sheet & upholstery and take steps to optimize the raw material/waste

consumption on Assembly line.

Introduction

Company History

History of the SML ISUZU LIMITED (Light Commercial Vehicle) dates back to as in 1975

when the first efforts were initiated by the Punjab State Industrial Development Corporation

Limited (PSIDC) to obtain a letter of intent from the Government of India. The Govt. of India

was interested in installing the unit and issuing the license for an LCV in order to save the fuel

consumption in the economy. Therefore Govt. decided to installed indo-Jap LCV units in 3 states

Punjab, U.P. & M.P.

Started as Swaraj Vehicles limited in 1983.

Mazda came up with Technical assistance renamed as Swaraj Mazda Limited in

1984.

Started commercial operations, indigenously developed buses and trucks. Worked for

defense.

Was Declared a sick company in 1994, developed 4WD trucks in 1996, came out of loss

in 1998

Started growing profits, crossed 50K vehicles in 2001, developed CNG vehicles for

NCR.

Crossed 86000 vehicles in 2005, applied Bharat-III norms on Diesel CNG too.

Crossed 1 lakh and joined hands with ISUZU in 2006

Started Expansion of plant, Developed LT-134 buses for ISUZU

Came up with Luxury class vehicles in 2008

SUMITOMO corporation took over 53.5 % companys share

Renamed as SML-ISUZU Limited in 2011

4

Share holding pattern

Sumitomo Corporation, JAPAN 54.96 %

Isuzu 4 %

MFNB 9.1 %

FIIs 2.67 %

Public 25.22 %

Chart 1 (PIE) Share Holding Pattern

Companys products

From bus body plant (BBP), we get the following products:

Four wheel drive Ambulance (SML)

Cardiac-ICU Ambulance (SML)

CNG School bus (SML)

Executive bus (SML)

NQR bus (ISUZU)

LT 134 Luxury bus (ISUZU)

Zhong-Tong School bus (SML)

Semi low floor AC CNG bus (SML)

Standard Ambulance (SML)

Standard bus (SML)

5

Organizational Setup Flowchart

Flow Chart 1 Organizational Setup

Managing Director

Executive Director

Vice-President Associate

Vice-President

General Manager Deputy General

Manager

Chief-Manager Senior-Manager

Manager

Assistant

manager

Senior

Engineer

Engineer

Junior

Engineer

Assistant

Engineer

6

Project 1

Developing Gauges

As a trainee in Technology Department of Bus-Body plant, I worked on a project of

developing cut-out marking gauges for Zhong-Tong school bus model. Its a Chinese design.

The project was assigned to the Technology Dept. by Production dept.

Normal Process of marking

The time taken to mark the cut-outs for air cleaner, spare wheel, diesel and sedimentary

tank flaps took 5 minutes on an average to mark each cut-out.

Number of workers required 2.

Dimensioning done by workers using standard measuring tape and marker.

Problem faced

Time taken to mark the cut-outs was varying from worker to worker, affecting the shell

line.

Human error intervened every time the marking is done as the worker depends on his

skill of marking.

Total work hours required for marking and correction were more than expected.

Target

To develop marking gauges for Air-cleaner, spare wheel, diesel and sedimentary tank flap cut-

outs. The gauges are meant to mark shapes which later can be cut out by using Plasma cutter

from sheet metal sides of the bus, before it proceeds into the paint shop. The gauges were

developed for four different flaps, namely:

Air cleaner flap (LHS)

Spare wheel flap (LHS)

Diesel tank flap (RHS)

Sedimentary flap (RHS)

7

The gauges were to be developed considering following four criterions:

Gauge should be as per required dimensions ( It should mark the cut-outs as per the

dimensions given in drawing provided by R&D department )

Poke-yoke (As per this criteria, the gauges should be fabricated in such a way that

they cannot be mistakenly used in each others place i.e. one gauge should fix on its

own place and not anywhere else).

Gauge should be handy and easy to use and no-extra labor should be required and

should consume very less time of the worker.

Gauge should be of sufficient durability, could be used for long time without any

problem and without any defects.

Results

Assuming 4 shells of ZT model being produced daily.

Each bus has a total of 4 cut-outs, so for 4 bus shells there are a total of 16(4*4) cut-outs.

Earlier, it took a total of 16*5= 80 minutes for marking the cut-outs.

Using the gauges, it took a total of 16*2= 32 minutes for marking the cut-outs.

Conclusion

A total of 80-32=52 minutes saved for 2 workers per day i.e. 52*2=104 workman minutes saved

in a day.

The gauges after fabrication are tested by Quality Dept. of BBP (Bus-Body Plant) on the basis of

above mentioned criterions and then after that are handed over to Production Dept. for use on

structure line.

The Drawing mentioning the required dimensions is provided by the Research and development

(R & D) department of BBP. It is as shown on the next page.

8

Drawing 1

9

For developing a marking gauge, 2 things were to be developed

Design was to be such that it can hold the gauge on to the surface of bus firmly.

Design was to be made such that it can hold a rectangular sheet of metal of sufficient

dimension, from which the cut out can be cut.

When the cut-out was cut from the rectangular sheet, placing the gauge on to surface of bus,

using the holding mechanism, marking can be done.

Following picture show the sedimentary and diesel tank flap gauges -

Picture 1 & 2

U-shaped cup of 100

mm. height, meant to

hold the vertical tube of

40 mm. width, its main

purpose is to restrict

horizontal movement of

the gauge and thus the

horizontal dimensions

can be finalized as per

vertical pillar of the

shell, whose dimensions

are constrained as per

design.

These Horizontal

bends, are meant

to restrict the

vertical movement

of the gauge,

these settle on

horizontal side

beams of the shell

and thus vertical

dimensions can be

marked as per the

side beams, which

are constrained as

per shell design.

These rectangular

sheets are meant to

be used as marking

region for flaps, we

can cut rectangular

sheet of the same

dimension as of the

flap, then keeping the

gauge on surface of

bus, marking the

inside boundary of left

out rectangle will give

us the flap marking on

surface.

10

Below picture shows the SPARE WHEEL FLAP cut-out marking gauge and its usage

Picture 3

Picture 4. This is how it holds on to a vertical pillar with fixed constraints restricting the

movement of gauge in horizontal direction, the bend is caused by using a hydraulic press.

The shown rectangular

shape is the one whose

inside boundary when

drawn on the flat panel

of ZT bus using a

marker, gives us the

exact dimensions of

spare wheel cut-out.

The shown two bends on left and right are

meant to restrict the movement of gauge

in vertical and horizontal dimensions

respectively. They hold on to such physical

structures whose dimensions are already

constrained as per shell design, there

actual way of working is as shown in

following pics.

11

Picture 5. In a similar fashion as above, it holds on to the lowest horizontal railing and restricts

the vertical movement of the gauge, the horizontal railing is constrained as per design.

Picture 6. After restricting the movement of gauge, the inside boundary of rectangular cut-out is

marked in order to get the dimensions of spare wheel flap.

12

AIR CLEANER flap is cut in a similar way, a gauge using bends to restrict its horizontal and

vertical movement and a rectangular cut-out of the same dimension is used as shown.

Picture 7

Picture 8. As is shown in the above pic, the gauge holds on to the bus body firmly and the worker

can mark the flap using a marker.

This bend holds on to

a vertical pillar of

body, which in turn

has fixed constraints

and thus restricts the

horizontal movement

of the gauge.

The rectangular cut-

out, whose internal

boundary is used to

mark the AIR CLEANER

flap on ZT bus Flat

sheet panel

The bend which holds on to a horizontal railing of ZT bus,

which has its movement constrained thus further restricting

the movement of gauge in vertical direction.

13

Picture 9.This is how it looks when the gauge hangs from the bus surface.

Picture 10. Diesel and sedimentary tank gauges with marking regions on rectangular sheet. The

marking region is cut out using nibbling machine.

Vertical

constraint,

holding

purpose

Horizontal

constraint,

holding

purpose

Rectangular

sheet, which

will be used

for marking

purpose

14

Picture 11. Cut-out region, which is to be used for marking.

Before proceeding any further, all the dimensions are re-checked in order to confirm there is no

error present due to the fabrication defects. If the gauge is as per dimensions, it is checked for its

strength and that will it continue to provide correct dimensions with time.

For providing extra strength, we re-enforce the GI sheets with rectangular cross-section tubes

and paste the tubes on GI sheets using Sikaflex sealant.

For using a Sikaflex sealant to join two metal surface

Firstly, the surfaces are smoothened up using grinder.

Oiliness of the surface is cleaned up.

Primer is applied on the surface of both materials in order to protect the surface from

rust.

After this, a layer of Sikaflex is applied between the layers of metals and left for

settling for a day.

15

Picture 12. Sealant applied on colored primer to join GI metal.

After the sealant settles down, the gauges are painted orange as per companys rules.

Picture 13.self inspection.

16

Final testing of the gauge

Picture 14 & 15. Inspectors inspection.

After the quality department approves of the gauge, it is handed over to production department

for use on shell production line.

The Other Project I was assigned at Zhong-Tong Line was to study the Line Vise Processes on

Assembly line. Its been detailed on from Next page.

17

Processes on assembly line of Zhong-tong School bus

After completion of 1st project, the assembly line of ZT model was studied, which later on gives

us our 2nd

project, but 1st we discuss the assembly line.

Station 1

Flowchart 2. Station 1 Processes of assembly line.

Docking

Moving out the bus body from paint shop and carefully placing it over chassis coming from

Chassis plant of SML-ISUZU Limited. Moving the bus to Zhong-Tong assembly line, the bus is

driven very slowly as till now the body is not attached to the chassis but simply placed on it.

Welding body with chassis

There are multiple welding joints for joining bus body with chassis.

The two long beams of chassis extending from front to back of bus are crossed over by

horizontal beams in perpendicular direction.

Docking

Station 1

Paste floor tape on the shell floor

members

Place cut to size plywoods on floor adjust & minimize

gaps,screw it

Seal the gaps by sealant application

.Grind the floor area

Spray adhesive on floor & paste the

carpet

Inspect the above activities

If found defects, repeat the requisite

process

Station 2

18

The buss body is joined to the chassis by welding at 18 points (2 across each cross tube,

making it a total of 9 tubes).

The buss shell contains rectangular tubes which fit directly over these 9 tubes. These

rectangular tubes are of cross-section 40*40.

Firstly, tap welding is done using MIG welding just to ensure proper fitting of the shell on

chassis, starting from back. For proper fitting, U-shaped cross-section lengths are inserted

vertically between chassis and buss vertical shell tubes to fill in the gap.

After proper fitting is achieved, the welding joints are re-welded properly and completely

using MIG welding.

The two beams of chassis are also welded to the body at the rear end.

The front of chassis is welded to the body at 3 joints.

Picture 16 & 17. Joints before welding , following pics will show the joints after welding

Picture 18 & 19. Welding of body with Right and left beam of chassis, as seen from front of

body.

19

Picture 20. The above piece of rectangular tube measures 20*20*100 (mm.) and joins cabin with

chassis.

Picture 21. Welding of beam and bodys vertical pillars.

The control parameters in welding are :

Current 90A to 120A

Voltage 20V to 24V

Wire size 0.8 mm

Gap between welding joints should not exceed 1.5 mm

Apply anti-corrosive primer on welded joints

These paramaters vary as per material to be welded and also the style of welder too.

The GI part used to fill in the

gap between body and chassis

Bus body

Chassis

20

Joining FES area of body with chassis (drivers cabin)

It is done by welding 10 rectangular hollow tubes of following dimensions :

1. 40X20X108

2. 40X20X108

3. 40X20X115

4. 40X40X242

5. 40X40X242

6. 40X40X240

7. 40X20X108

8. 40X20X90

9. 40X20X85

10. 40X20X85

The cross-sections remain fixed but the length varies as per each buss own tolerance region,

these tubes are cut on the basis of measurements a worker takes by measuring tape.

Picture 22,23,24. Welding of drivers cabin with chassis

Welding FES (Front Engine Space) panels :

After the welding of body and chassis, GI(Galvanised Iron) sheet panels of FES are welded using

MIG(Metal Inert Gas) welding, the different thickness and different shaped panels are generated

21

from GI sheets, which are cut using Hydraulic or mechanical presses, Knibbling machines and

Plasma cutting. The welding spots are then grounded to smoothness.

Picture 25 to 30. GI sheet panels of drivers cabin

Flooring (Fixing Floor panels) :

Plywood panels (12 mm) are fixed on shell tube floor using self tapping screws. It is followed by

grinding of screw tops in order to smoothen up the floor surface, so that when Flooring carpet is

fixed to it the protrusions dont interrupt.

22

Picture 31 & 32. The wooden floor (Ply fixed to shell).

Floor Matting

After the covering of sides and roof, the floor ply sheets are covered with resin mat (pale grey)

using fevicol resin adhesive, the adhesive is applied to both the mat and floor using an air-

pressure spray gun, which spreads a minute layer of adhesive on both the materials. The mats are

pulled forcefully on to the ply so that while they settle on the floor, there are no wrinkles. After

the mats are applied, the floor looks like as shown.

Picture 33. Mat covering on floor.

23

Station 2

Flowchart 3. Station 2 Processes on assembly line.

Wiring

Wiring of body is done in roof, the wiring is for the 3 lights and 3 speekers in the roof, 2 turning

indicators on rear side and 2 turning indicators in front and wiring to controlling console. The

wiring is passed through hollow tubes of roof as shown in picture.

Picture 34 & 35. Wiring through shell.

Station 1

Station 2

Route electrical wiring inside the shell & fit outer

lights

Fit Roof Ply & front dome

Fit Side LH & Side RH plywood

Fit floor aluminium Sections & curtain

railing

Inspect The above activitie

If found defects, repeat the requisite

process

Station 3

24

Picture 36. The above picture shows the three Light Speaker Electric Points in the bus.

Roof

The space between the shells tubes of roof are filled with Polystyrene sheets, its helps by

following ways:

Polystyrene is much light in weight as compared to conventional space-filing material.

Its sheets can be easily cut and used to fill the roof.

Polystyrene as a non-conductor doesnt transfer solar heat into the bus and thus maintaining

passengers comfort.

It makes no unpleasant sound or noise while the bus moves.

Picture 37. Polystyrene sheets used for filling the roof.

25

After this, the inside of the bus body is covered with GI sheets one side of which is beige colored

plastic, the beige side is kept in Visible region and the other side is pasted to roof using screws,

and also it is used to cover the inside left and right hand of bus.The roof above the drivers cabin

is covered with a plastic structure, fixed to shell using self-tapping screws as shown.

Picture 38. Drivers Dome

The partition of these GI sheets is covered and supported by Rubber cum plastic beading which

is screwed to roof as shown in 1.

Picture 39. Beading used to cover roof sheet partitions.

26

The shell from inside, below the region of windows is covered with the same PVC covered GI

sheet with which the roof is covered as shown below. The region with red circle is actually the

GI sheet screwed to shell side. After screwing the boundary, extra strength is given by applying

aluminium rivets by riveting cum punch machine

Picture 40 & 41. Side panels of GI sheets riveted to shell.

Station 3

Flowchart 4. Station 3 processes on assembly line.

Station 2

Station 3

Fit Window frames

Fit driver Door, dickey rubber

beadings, outer locks

Fit inner lights, sunvisor assy

Fit hatracks Inpect all above

activities

If found defects, repeat the requisite

process

Station 4

27

Installing Glass

The windows are locked to body by screwing them into verticle columns of bus body. Then

additional strength and sealing of assembly is done by applying Sikaflex Black-165 sealant

from outside the bus into the boundaries as shown in pic. Sealant takes one day to settle.

Picture 42. Sikaflex black sealant

These passengers windows are of 3 different sizes, supplied as per requirement by wendor, fitted

with tough temperlite glass. The height is same but width is 0.9, 1 and 1.2 mtrs.

Picture 43 & 44. Window frames with 0.9 and 1 mtr. Width.

28

Picture 45. Window frame of 1.2 mtr. Width.

4 other type of glass are to be fitted apart from front and rear wind shield, which are fitted using

Sikaflex sealant a layer of which is supplied on both inside and outside bus body as shown

below.The sealant should be left for a day atleast to properly settle. These are as shown.

Picture 46. 1 & 2 type of glass.

Picture 47& 48. 3 & 4 types of glass.

29

Followed by these windows is the fixing of rear and front wind shields with Sikaflex Sealant, 2

layers of which are applied on inside and outside. These are left to settle for one or more day.

The process of applying sealant is as discussed below.

Before applying sealant, the nearby region or surface of bus body is covered with covering tapes

as shown in figure, it is done in order to protect the bus bodys paint and the paint to spread over

areas where it shouldnt be.

Picture 49. Sikaflex applying technique.

Lighting

The roof is fitted with lighting and speakers with screws, the electric points needed for it have

already been shown, the space provided in roof for these fixings makes it easy to screw them to

the GI sheet. The final look is as shown.

Picture 50. Roof lighting and Speaker System.

Covering of bus surface

by tapes, the central

black line shows the

sikaflex sealant.

30

Interiors

After the covering of sides, roof and floor, the outlines of sheets are covered with beadings

which may be of rubber, plastic or even aluminum, some places where such beading is done are

as shown below:

Picture 51 to 56. The different beadings used to improve interiors look and give strength.

31

Picture 57 to 60. The different beadings and coverings applied into the bus as interiors

Picture 61. Aluminium beading covering the rear axle hump.

32

The dickey is provided with rubber beadin from inside on boundaries as shown in picture, it

keeps the dickey less noisy as well as acts as a water proof seal.

Picture 62 & 63. Dickey before and after beading.

Picture 64 & 65. Inside rear view mirror and shade providing sheet is installed near drivers seat.

Picture 66. The driver door is provided with the plastic covering of door and lock system and a

handle to open and close it.

33

Picture 67 & 68. The drivers door is installed with a chrome handle and steel foot rest for his

conenience.

Picture 69,70,71. The dickey is installed with the wiring of rear lighting and Pneumatic openers.

Break lights

Tail lights Hydraulic

dickey openers

Dickey lock

Number

plate

light

34

Station 4

Flowchart 5. Station 4 Processes on assembly line.

The gear lever is now covered with a cover, providing it a good look as well as easy to hold and

use shape. It looks as shown

Picture 72. Gear knob and gear lever covering

Station 3

Station 4

Fit front windshield, rear windshield,

battery cover

Fit transmission cover,engine hood

cover, roof hatch, RVM front grill/bumper

Fit Dashboard, do electrical connections

Fit Accessories like spare tyre, P door

brush etc.

Inpect all above activities

If found defects, repeat the requisite process

Station 5

35

Dashboard installation

The dashboard which is made by Fiber re-enforced plastic (FRP) in bus body plant only, it is

firstly covered with black resin, the ready dashboard is fixed in FES region by screwing it to the

shell, the final setting looks like as shown in picture.

Picture 73. Dashboard and wooden instrument cluster installation.

Behind drivers seat, battery casing along with a fire extinguisher is also setup, the pillar is used

to give support to both the roof and drivers seat, the front axle is just below the pillar floor.

Picture 74. Battery setup and fire extinguisher.

Battery setup

36

Front bumper

The front bumper is installed after the wiring for the console is done, it is screwed to the bodys

shell by nuts and bolts.

Picture 75 & 76. Front bumper and grill.

Side rear view mirrors are installed on both sides -

Picture 77,78,79. Side rear view mirrors installation mechanism and mirror.

Wipers installation

Before the dashboard is installed, wipers system is to be installed, a geared motor is mounted on

a steel plate, standing vertically on body shell, and the lever system which drives the wipers is as

shown in the following picture.

Front grill installed

separately

37

Picture 80. Wiper driving geared motor

Picture 81 & 82. The flat plate on which wiper motor is mounted.

Picture 83. Quick return mechanism of wiper.

Lever driving

left side

wiper of bus

Lever that drives

right wiper of bus

Quick return

mechanism

38

Picture 84. After the driving mechanism for the wipers is installed, the wiper blades are fixed

onto it from outside.

Station 5

Flowchart 6. Station 5 Processes on assembly line.

After the covering of sides, floor and roof and interiors done, the seats are installed onto the

floor, using screws, the seating arrangement can be minutely modified as per customers

requirement, before fixing the seats, proper marking is done on the floor for drilling screw holes

Station 4

Station 5

Fit All Seats Fit grab handles

PDI

PDI ELECTRICAL Inpect all above

activities

If found defects, repeat the

requisite process

Shower testing region

39

as well to take care of the pitch of seating, that is, the distance between two adjacent seats from

front to back is to remain constant. Conductor side seats are as shown below.

Picture 85.86.87. The side railing on which the seat is supported and floor supoort of seat.

Picture 88. Passengers seating area.

It is a 49 seater bus, but it can be changed upto some extent as per customer.

40

For roof there are two accessories, handle baar railing and cargo keeping rack, they are screwed

to roof as shown in following pics.

Picture 89 & 90. Handle baar railing and cargo rack (I & II)

Stairs support

A railing is provided near the stairs of bus in order to support the body while entering or leaving

the bus. It looks as shown in following pic.

Picture 91. Stairs support railing.

41

Drivers cabin accessories

Seat belts for both conductor and drivers seat.

Picture 92. Seat belt lock.

Grab handles for sitting in conductors and drivers seat. These are screwed on front pillars of

bus shell as shown in pic.

Picture 93 & 94. Grab handles in drivers cabin.

42

Emergency glass breaking hammer, provided near the rear wind shield of the bus. It is fixed in a

case which is screwed down to the body.

Picture 95 & 96. Emergency glass break hammer.

Picture 97. Light in the stair case region. Keeps it easy to climb the stairs at night, the controll is

at drivers console.

Picture 98. To provide extra safety for students sitting on windows side, railings are provided are

as per customers requirement.

43

Picture 99. Emergeny stop button, which notifies the driver if a passenger standing near the door

wants to stop the bus. Its is installed just above the passenger door.

Picture 100. First-aid box and supporting piller behind drivers seat, it is mandatory assistance to

be fixed in every bus.

Pillars for Supporting the roof

As per customers requirement, company provides the school bus with roof supporting pillars for

extra safety, they are screwed between roof and floor on one side of the central path way, as

shown in picture.

44

Picture 101. The 2 pillers supporting the roof in central pathway.

Mudflaps

Rubber mudflaps are installed for each tyre in order to manage the mud or water flying off from

the tyres. They are fixed on to shell by screws.

Picture 102. Mudflaps.

45

Passengers door

The door is installed in the rigion with some accessories, its a folding door, which provides

more space for the students to enter with there school bags not getting tucked in hooks or

something sharp.

Picture 103,104,105. Passenger door and For locking the door when closed.

Side - markers and indicators

Now that the inside of the bus is complete, the outside of the bus is worked upon.Marking for

elctric side markers and turning side indicators is done by simple measuring tape and markers as

per design as shown.

These two plastic

structure engage

into themselves

when the door is

closed, reducing the

vibrations and noise

due to moving bus

46

Picture 106 to 110. Marking of side-marker and indicator respectively.

After the marking is done, the drilling for screws is done and then side markers and turning

indicators are installed. The space for indicator as shown in above right pic is cut by plasma

cutter.

Picture 111 & 112. Side markers and turning indicators.

Side markers Turning indicator

47

Picture 113. The emergency door is installed with the break glass to open handle, the sealing

of it is done with Sikaflex sealant.

Reflective tape

As per customers requirement bus is provided with reflective or Cat eye tapes, marking the

boundaries of the bus.

Picture 114. Golden reflective tape, silver may also be used.

School bus Sticker

As per customers demand, the ZT model is pasted with symbols (sticker) which highlight the

bus as a school bus, the spot to paste the sticker is also as per the customer.

48

Picture 115 & 116. School Bus sticker.

After completing the assembly lines process, the bus is sent to Shower teasting area for washing

and quality inspection.

Project 2

Waste consumption Project

It was a team project, the team was headed by Mr. K K Sharma (Production Dept.)

Target

To consume the wastages of Aluminium Chequered Sheet & upholstery and take steps to

optimize the raw material/waste consumption on Assembly line.

Problem Statement

CASE-1: Aluminium Chequred Sheet wastage accumulation on line for the period Apr

2010 To Feb 2012 results in Rs 30060/- of scrap piled up.

CASE-2: 50 mtrs. of waste inter paneling upholstery costing Rs.13200/- piled up due to

left out length from rolls ( LZ0257571) used for LT-C model .

CASE-3: 92mtrs of Upholstry ( LZ1157510) piled up in small cut length sizes costing

Rs.11132 /-during various cut to size application in Executive model

49

Mission

To consume the waste generation of Rs.30060 and steps to be taken to control scrap

generation by value engineering.

To consume the left out inter paneling upholstery length wastes

(LZ0257571) LT(C) model costing - Rs. 13200/-

(LZ1157510) Executive model costing - Rs 10120/-

Planning

Making of CFTs.

Identification of wastages in Aluminium & Upholstery

Brainstorming meeting.

Action for reclamation, value engineering & communization/interchanging.

Cross Functional Team

Team leader Mr. K K Sharma (Production Dept.)

Senior-Engineers Mr. Abhishek Puri (Technology Dept.)

Mr. Vaneet Verma (Production Dept.)

Assemblers Mr. Shiv Kumar (Production Dept.)

Mr. Pawan Kumar (Production Dept.)

Trainee Aggyapal Singh (Technology Dept. UIET, PU)

Prabhjot Singh (Technology Dept. DIET, PTU)

50

Cost of Wastes

Chart 2. Wastages cost on assembly line.

Case -1 Aluminium Chequered Sheet (Part no. - LZ0269271)

Present Situation

Picture 117. The aluminum sheet being left waste.

0

5000

10000

15000

20000

25000

30000

35000

Al Chequerd Sheet Interpanelling Upholstery Roof Upholstry

In R

up

ee

s

Wastages Cost (Rs.)

Series1

Present (WASTE)-860 x 810 mm sheet , Total 180 kg

51

Suggested Proposal action

It is proposed to use the left out waste sheets by adjusting sizes at places instead of

cutting new sheets for the same size.

Methodology Adopted: Value Engineering

Proposed Sheet Cut-outs

Drawing 2. Waste usage figure.

Savings

Rs. 30060 (Cost of Piled Scrap) + Rs. 540 Per bus (Adjusting Waste)

Used

here

Used here

with minor

adjustments

52

Case 2 Cloth upholstery (Part no. - LZ0257571)

Present Situation

Picture 118.

Suggested Proposal Action

Picture 119. The pic showing the usage of cut piece of cloth instead of 1 piece.

Savings

All Cloth wastage consumed in 05 No.s LT-C model buses

Cost Savings : Rs.13200/-(Scrap Cost ) 5 x Rs.170 (Al section cost) = Rs.12350/-

Single Piece Cloth used

all along the side of

the bus

Cut Piece used

with Aluminum

section covering

53

Case 3. Cloth Upholstery (Part no. LZ1157510)

Present Situation

Picture 120.

Suggested Proposal Action

Picture 121. The waste upholstery used as contrast.

Roof cloth is used

in colour contrast

with side cloth,

Waste

accumulation of

small cut size

lengths

Roof Cloth

interchanged

with side & pillar

cloth for

maintaining

contrast, Roof

cloth wastage

consumed

54

Savings

Cost Saving of Rs 11132/- by consuming the whole waste cloth in Executive model

Total Savings

AL Chequered Sheet Rs. 30,060

Cloth Upholstry (LZ0257571) Rs. 12350

Cloth Upholstry (LZ1157515) Rs. 11132

Total Savings Rs. 53542