SML-ISUZU Limited, Ropar

Company’s History1983-92• Started as Swaraj

Vehicles limited in 83.• Mazda came up with

Technical assistance – renamed as “Swaraj Mazda Limited” in 84.

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

1994-2006• Declared a sick company in 94, developed 4WD trucks

in 96, came out of loss in 98 • 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

2007-11• Started Expansion of plant, Developed LT-134

buses for ISUZU• Came up with Luxury class vehicles in 2008• SUMITOMO corporation took over 53.5 %

company’s share• Renamed as SML-ISUZU Limited in 2011

Company’s Products

ISUZU trucks SML buses ISUZU

buses

SML trucks

Bus Body Plant (BBP)Some of the products

From “SML” are

Executive, Ultra-Luxury class vehicle 4WD Ambulance for Defense

AmbulanceCardiac-ICU Ambulance

Semi low floor AC-CNG Bus Semi low floor School bus

SML’s School bus, Staff Coach and also available in CNG model.Deluxe model available with Luxury Seating and quality interiors.

ISUZU buses

NQR model – AC model for Local routes LT-134, Luxury class long route bus

Different Departments in SML-ISUZU Limited• Personnel department• Research and development Department• Quality Engineering Department• Technology department• Accounts Department• Purchase Department• Maintenance Department

Both the Bus body and Truck Plant have same

departments.

Technology Department

Industrial EngineeringTool DesignProduction Engineering

Technology Department is sub-divided

into 3 sub-departments

The Main Purpose of Technology department is to assist the Production Line in any Kind of problem Being Faced by it.

Projects –• Worked on 2 Projects till now.

• Both the Projects for Zhong-Tong bus.

• Firstly, Developing Marking Gauges for Zhong-Tong Bus Sides.

• Secondly, studying the line-vise processes on Assembly line,

starting right after docking.

• This study would help us to make a Process sheet For ZT model.

• Reporting was to be done to Mr. Balbir Singh (HOD, Tech. Dept.)

and Mr. Abhishek Puri (Senior Engineer, Tech. Dept.)

• Future Projects, Studying Paint Shop, Developing Material

handling Racks for supply system of ZT assembly line.

Developing Gauges -

The main Purpose For developing the gauges –• To reduce the time taken to mark the cut out as compared to the time it took

to mark by just using standard measuring tape.• To reduce the human error which creeps into marking due to every time the

marking is done by tape.• The worker depends on his own skill for correct marking of cut out and it is

variable from worker to worker.• To reduce the workman hours for marking and its correction.

* 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 )* Poka-Choka (As per this criteria, the gauges should be fabricated in such a way that they cannot be mistakenly used in each other’s 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.

Criterion for developing -

Requirements - • For making the gauge settle on Bus surface, it is to be provided with holding

arrangements, which would give the gauge a “zero” or constrained horizontal and vertical movement.

• Extending form the holding part, a rectangular sheet of sufficient dimension from which cut out can be cut.

• The sheet should settle on surface as per dimensions.• Once cut out is cut on sheet, it can be used for marking by a simple marker.• If the dimensions are correct, Strength packing is done for long lasting and anti-wear

Performance of gauge.

After the gauge passes through the required criterions and is duly checked by the Quality department, it is handed over to shell line, so that it can be brought into use.

Processes On assembly line - • Docking – Moving the bus body out from paint shop and placing it on chassis • Moving the bus to ZT assembly line• Welding the body with chassis at two rectangular beams of chassis and also, the

front of body is welded to the beams as shown.

• Joining FES (Front Engine Space) Cabin with Chassis, using Rectangular cross-section Tubes of variable length. Length and cross-section vary as per strength requirement.

• After joining the FES cabin, It is covered With GI sheet Panels and welding joints are smoothened up.

• The floor is brought up by screwing 12 mm Plywood onto the shell.• Wiring is done.• The Roof is filled up with non-heat conducting Polystyrene, easy to cut and thus easy

to use.• After filling, the roof is covered with PVC pale grey colored GI sheets, which is Fixed to

Roof by Screws.• The front cabin space roof is covered with a hard plastic cover.• The floor is Covered with resin mat which is pasted onto floor using Fevicol adhesive.

• Roof is fitted with speakers and lights.• Side windows, front and rear windshields and other glasses are installed.• Glass is pasted to the bus using Sikaflex- 165 black sealant, Which holds up the glass

firmly and settles down in one day once applied.• Before installing the dashboard, wiper system is installed.• Dashboard is fixed to shell after that.

• After this, the interior of the bus is covered with beadings so that the joints look good and become strong.

• Seats are installed, taking care of customer’s requirement and constant pitch.• Three roof supporting pillars are fixed between roof and floor

• Now, it’s the time for Installing Accessories.• Mud flaps, Side view and Rear view mirrors, Battery casing, Stair case lights,

Passenger door, Emergency Glass Break Hammer, Side Window Railings for safety, roof railing for supporting Handle bars, Bag carrying Roof Racks, Speed Governors, Side Markers, Turning Indicators, Front and Rear Lights, Front Bumper etc.

• After All Processes complete, bus is sent into Shower testing area.

Thank You!