SUMMER TRAINING REPORT

ON

“Study of Assembling and Inspection of skin panel”

SUBMITTED BY-

NISHANT KUMAR

13162028, DEPTT-MECHAINCAL ENGG

GJUS&T,HISAR

UNDER THE MENTORSHIP

MR. VIJAYPAL YADAV

Ashok Leyland, Alwar

ACKNOWLEDGEMENT:

Engineering is about reaping the benefits of technology to produce production systems useful to mankind both socially and economically. As a Mechanical Engineering student, I had always been curious to visit an industry, so as to get a practical insight of the implementation of what we study. I really respect the stance of Ashok Leyland, Alwar plant to allow students from different academic streams to undergo summer training here. I am indeed grateful to Ashok Leyland for having me shortlisted in the team of summer trainees. I truly find the time spent here enriching and wonderfully memorable.

In framing my project on “STUDY OF QUANTITY OF DIESEL REMAINING IN PIPES AFTER TESTING OF AN ENGINE.” I got immense support from my project guide Mr. Vijaypal yadav and, I feel so thankful to him, have always been very helpful and willing to share information during my stay.

I would mention my gratitude to all the people working in the area I have been nominated for training. They are well aware of the fundamentals of the operations they engage in, and, proved so kind to share them with me. I wish, the innocent working NTTF students achieve laurels in Ashok Leyland.

Thank you!

Nishant Kumar

CONTENTS

Serial no. Title

1.) Automobile sector trend in India

2.) Company Profile

3.) Plant Layout4.) Background and History5.) Products of ashok layland6.) Various shops in plants7.) Visiting of Dost Asembling Cabin

And Inspection of skin panel8.) Raw material used in skin panels9.) Manufacturing of skin panels

10.) Inspection of skin panels11.) Major defects on skin panels

AUTOMOBILE SECTOR TREND IN INDIA

PRODUCTION

The cumulative production data for April –March 2014 shows production growth of only 1.20 percent over the same period last year. The industry produced 1,685,355 vehicles in March 2014 as against 1,845,868 in March 2013, which declined by (-) 8.70 percent.

DOMESTIC SALES

The overall growth in domestic sales during April- March 2014 was 2.61 percent over the same period last year. While in March 2014 overall sales fell by (-) 7.76 percent over March 2013.

Passenger Vehicles segment grew at 2.15 percent during April – March 2014 over same period last year. Passenger cars declined by (-) 6.69 percent, Utility vehicles grew by 52.20 percent and Vans grew only by 1.08 percent during April – March 2014 as compared to the same period last year. However, in March 2014 passenger cars sales further declined by (-) 22.51 percent over March 2013. Total passenger vehicles sales also declined by (-) 13.01 percent in March 2014 over same month last year. The overall Commercial Vehicles segment registered de – growth of (-) -2.02 percent in April – March 2014 as compared to the same period last year. While Medium & Heavy Commercial Vehicles (M&HCVs) declined by (-) 23.18 percent, Light Commercial Vehicles grew at 14.04

percent. In March 2014, M&HCVs sales further declined by (-) 26.16 percent over March 2013.

Two Wheelers registered growth of only 2.90 percent during April – March 2014. Scooters, mopeds and motorcycles grew by 14.24 percent, 1.53 percent and 0.12 percent respectively over same period last year. However, in march 2014 all sub – segments of two wheelers, scooters, motorcycles and mopeds registered de – growth at (-) 3.18 percent, (-) 8.32 percent and (-) 4.54 percent respectively.

EXPORTS

During April – March 2014, overall automobile export registered de - growth of (-) 1.34 percent compared to the same period last year.

Passenger Vehicles grew by 9.02 percent, while the others segments like Commercials Vehicles, Three Wheelers and Two Wheelers fell by (-) 13.35 percent, (-) 16.22 percent and (-) 0.72 percent respectively. In March 2014, Passengers Vehicles, Two & Three Wheelers grew by 3.07 percent, 3.51 percent and 7.50 percent respectively. While Commercial Vehicles declined by

(-) 28.33 perc

PROFILE

Ashok Leyland has for over six decades been a major presence in the Indian commercial vehicle industry.

Headquartered in Chennai, India, our manufacturing footprint is pan-India with two facilities in Prague and raskhiamah (UAE).

Operating six plants, Ashok Leyland also makes spare parts and engines for industrial and marine applications.

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 passengers’ transportation options ranging from 19 seaters to 80 seaters, Ashok Leyland is a market leader in the bus segment.

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.

Over 7, 00,000 Ashok Leyland vehicles ply on Indian and international roads and our buses carry over 70 million passengers every day.

Joint venture announced with NissanMotors of japan would improve its presence in light commercial vehicle.

PLANT LAYOUT

BACKGROUND AND HISTORYThe Birth of Ashok Motors

Founded by Raghunandan Saran, Ashok Motors was set up in collaboration with Austin Motor Company, England and incorporated on September 7th for the assembly of Austin cars.

The first A40 Assembled

Production began in September at the factory situated at Ennore, South of Madras and soon the first indigenously assembled A40 Austin car was rolled out.

Assembly of Leyland chassis commence

The first Leyland chassis assembled by Ashok Motors at Ennore were four Comet 350 engine tippers sold to the Mangalore tile factory.

Government Approval for Manufacture of Commercial vehicles

The government approved the progressive manufacture of Leyland commercial vehicles and a license for the manufacture of 1,000 Comet a year was granted.

Ashok Motors becomes Ashok Leyland (1955)

Named after Raghunandan son, Ashok, the company was renamed Ashok Leyland with equity participation from Leyland Motors, Ltd.

India’s first double decker arrives (1967)

‘Titan’- The first Indian made double decker with 50% indigenous components was launched.

Production target upped to 10,000 vehicles a year (1972)

The license to manufacture 10,000 vehicles a year was granted.Two major new truck introductions (1980)

India’s first 13-ton truck-‘Tusker’ with a 125 hp engine was launched followed by the country’s first multi-axle truck-‘Taurus’.

First Indian auto company to receive ISO 9001 certification (1993)

This was followed two years later with the ISO 9001 certification.

Another innovation in alternate fuel technology (2002)

The country’s first hybrid electric vehicle was developed and showcased at Auto Expo 2002.India’s first Hybrid CNG Plug-in Bus (2010)

Showcased at Auto Expo 2010 and later did service during the Common wealth Games moving VIPs and media at PragatiMaidan, New Delhi.

A full range player with DOST (2011)

Entry into the Light Commercial Vehicle (LCV) segment.

PRODUCTS OF LEYLANDBUSES

Ashok buses move some 70 million people every day on their destination. From 18 seaters to 80 seaters, Ashok Leyland has an extensive range of buses that fits almost every requirement.

TRUCKS

Ashok trucks have been the wheels of the economy for decades. They offer a comprehensive range for avariety of applications: long haul, distribution, construction, and mining.

LIGHT VEHICLES

The light vehicle segment has come to the fore with fractional, last mile delivers of consumables becoming critical. Their DOST, a vehicle with a rated payload of 1.25 tones, is positioned to meet an evolving market need for slightly heavier tonnage vehicles due to higher aggregation of small loads.

DEFENCE VEHICLES

They have developed two more platforms the COT and the SUPER STALLION. Going forward, they are expanding their stallion range of logistic transport solutions while tactical or armored vehicles will be offered on all three platforms on the back of strategic partnership with KMW, Germany; Pan hard, France, and Paramount, South Africa.

POWER SOLUTIONS

Under the brand name, Leypower, they offer complete power solution by supplying engines for a variety of applications apart from vehicles: be it for running generator sets, for marine applications or for powering earth moving equipment, compressor cranes, harvester combines and the like, Leypower has provided many an industry the power to keep running uninterrupted.

VARIOUS SHOPS IN PLANTS AXLE SHOP

The integrated axle machining and assembly shop has highly automated front axle machining lines and conveyorised front / rear assemblies, all in one shop. Hazardous operations are performed by robots.

PAINT SHOPPowder coating instead of conventional liquid painting eliminates hazardous pollutants while bestowing high corrosion resistance to withstand well over 500 hours of salt spray bath. The change of technology also ensures zero wastage of paint.

WELD SHOPHigh on automation, the shop employs robotics in framing and rear body lines, for better quality and improved ergonomics. Manufacture of door assemblies is performed by robotic roller hemming.

SKIN PANEL INSPECTION SHOP

Visual inspection is popular way of inspecting skin panels. Manually inspecting by wearing inspection Gloves. CMM is used in some critical areas.Oil stoning the panel with Oil stone.

SKIN PANEL ASSEMBLY SHOPThere are 14 skin panel which are assembled in skin panel assembly shop by weldind and jigs & fixture. After assembly of skin panel it goes to the chasis shop.

CHASIS SHOP The chassis assembly is designed to be extremely dexterous to produce the smallest to the largest of vehicles in Ashok Leyland’s product range, including the U-Truck range and other cabbed vehicles. The single chassis testing line can test all the models and variants covering various tests, to generate instant test reports.

ENGINE SHOP Integrated Horizontal Machining Centres (HMC) complex fed by Automated Guided Vehicles (AGV) bestow great flexibility to manufacture a range of engine variants, using components rough machined in an adjoining shop. Auto docking and in-process verification systems directly reduce testing cycle time and optimize test cell requirements. The shop has the capability to produce both the H and the Neptune family of engines.

GEARBOX MANUFATURING SHOP In gearbox manufacturing shop various type of gear are manufactured according to their application or uses. The fully automatic CNC machines are used for manufacturing these gear.

CHASIS TESTING SHOPIn chases testing shop ,after assembly of chasis the testing of chasis is done.

VEHICLE TESTING SHOPAfter complete assembly of vehicle ,the testing of vehicle means the fuel average of vehicle under different condition ,etc. are done.

Visiting of Dost Asembling CabinAnd

Inspection of skin panel of dostSKIN PANEL is a visual outer body of a vehicle majorly CABIN parts.

Proper metal finished skin panels are very important for good ASTHETIC LOOK of a vehicle.

Basically DOST model has 14 SKIN PANELS.

Each panel is identified by a Part No.

All panels are stamped(pressed) in ASHOK LEYLAND press shop.

Sheet metal thickness ranges from

0.7mm to 1.6mm.

The 14 skin panels of DOST are1) Door outer RH 2) Door outer LH

3) Door inner RH 4) Door inner LH 5) Roof 6) Floor

7) Front Panel

8) Sill outer RH 9) Sill outer LH

10) Corner Panel RH11) Corner Panel LH12) Back Panel13) B Pillar RH

14) B Pillar LH

Raw material used in skin panelSTEEL, produced from mined iron ore, the base raw material, is perhaps the most widely used component in auto manufacturing. It accounts for roughly 80% of the weight of an average car. Steel is used to construct a car's chassis and body, including the roof, body and door panels, and the beams between doors.

Manufacturing of Skin panels Skin panels are manufactured with the help of stamping dies. A stamping die is a special, one-of-a-kind precision tool that cuts and forms sheet metal into a desired shape or profile. The dies can be for manual loading press, tandem press lines with robots, transfer lines or coil feed high speed blanking lines.But in Ashok leyland tandem press lines with robots is used.Tandem press lines feature multiple presses with press-to-press transfer by robots or feeders and can be served by coil feed systems or destackers, and may be provided with additional ancillary equipment such as scrap conveyors, scrap chutes, discharge conveyors, etc. For Commercial vehicles stamping dies manufactures Side wall outers, Body side outers, Front walls, Roofs, Door outers, Rear walls, Rear corner outers etc.

The machine used in this press line if of FAGOR company. It presses the skin panel at 670 KN .

Inspection of Skin Panels1. Visual inspection is popular way of inspecting skin panels.

2. Manually inspecting by wearing inspection Gloves

3. CMM is used in some critical areas

4. Oil stoning the panel with Oil stone.

Major Defects On Skin Panel 1. DENTS : Dent refers to shallow deformation on the surface

of a panel or object.

Reason :

1. Due to some dust & foreign particles on die surface.

2. Rarely during loading and unloading of panel.

2. PEAKS : Peak refers to a high point on the surface of a panel or object.

Reason :

1. Dust & foreign particles on die surface.

2. During loading & unloading of panel.

3.WRINKLE :

• Wrinkle refers to waviness formed on surface of panel.

• Wrinkle can also be known as high and low areas.

Reason :

1. Low cushion pressure.

2. Varying Cylinder forces.

4.WELDING DAMAGE :

Welding damage means spot damage.

which may damage the channel, flange.

Reason :

1. Due to mislocation.

2. Urgency.

3. Due to Child part defect.

4. Weld burning, blackening.

5. Due to high current value.

5. CRACKS :Crack is a thin & narrow opening in a flat,

solid material.

Before crack THINNING occurs.

Reason :

1. Due to more holding, blanking pressure.

2. Slug mark.