INTRODUCTION

Ashok Leyland is an Indian automobile manufacturing company based in Chennai, India. Founded in
1948, it is the 2nd largest commercial vehicle manufacturer in India, 4 th largest manufacturer of buses in
the world and 16th largest manufacturer of trucks globally. Operating six plants, Ashok Leyland also
makes spare parts and engines for industrial and marine applications. It sells about 60000 vehicles and
7000 engines annually. It is the second largest commercial vehicle segment with
 FRONT AXLE ASSEMBLY
Load axle beam on the conveyor after verifying the part number
Fitment of spindle assembly with axle beam
Ensure max cut fitment
Fitment of thrust bearing in both side for all FA99 models
Fitment of thrust pad on LHS and bearing on RHS for all models
Ensure grease packing
Fitment of king pin
Ensure end floud on bearing side and pad side
Select the matching cotter pin
Fitment of gasket, top and bottom cover with spindle, tighten with bolt
Fitment of grease nipple on top and bottom cover
Fitment of steering lever in correct position with bolts
Fitment of track rod lever on spindle and tighten with bolts
Fitment of split pin and folding
Fitment of brake shop assembly on to spindle with clev lock nut&washer
Fitment of brake drum on to hub and lock the drum
Fitment of brake chamber and connect with slack adjuster 120NM

REAR AXLE ASSEMBLY

All rear axle assemblies have the same basic design and operate by the same principle
 Rear end variations depend on whether the vehicle has a solid axle or independent rear
suspension, a removable or integral carrier
The major parts of the rear axle assembly are the differential assembly, rear axle assembly drive
axles, bearing and seals
Engine power enters the drive pinion gear through the differential pinion yoke and drive shaft
assembly
The drive pinion gear turns the ring gear
The ring gear is bolted to the differential case
The spider gear transfer the power to the drive axles and rear wheels
The differential assembly has these purposes. It redirects the drive shaft rotaion in a 90 angle
The relative positions of the ring and drivepinion gears must be set exactly, or the gears will be
noisy and wear out permanently
The standard differential is composed of meshing spider and side gears, enclosed in a differential
case
When driving on slippery surfaces, the rear wheels of a vehicle with a standard differential will
often slip
A modified real axle housing is used on vehicles having independent rear suspension
The rear drive axles transfer power from the side gears to the rear wheels

SIDE MEMBER PRESSING(SMP)

Mistake proofing facility in the surface to avoid hole arissing problem
Single piece flow
New product manufacturing is cost effective
 Entire process EEI friendly
Used for production of non tooled up models, small lot size
Introduction of EDMs where tooling updation is not feasible

FUNCTION UNIQUENESS:
Decoiling, straighten, length cutting & camber correction
Process capability: can process from 4mm to 8mm thick sheet
Camber correction achieved within 2mm
Entire process EEI friendly
More flexible process

SHOT BLASTING:
First initially FSM destackens are prepared
After that FSM washing process is done to remove dust and oil from the membrane for painting
After washing shot blasting is done on SMP
Next the FSM are stacked in a section
These FSM are then sent to shunting trolley

FRAME ASSEMBLY
In frame assembly the following processes are done in a sequence

1. Frame laydown
2. Cross member mounting
3. STG cab bracket mounting
4. Reaming -1
5. Reaming-2
6. Row hook/FUP bracket mounting
7. BC lever mounting
8. Frame unloading
9. Loading of frame side member LH&RH
10. Loading & positioning of cross members
11. Fitment, bolting of RSM x MBR gusset
12. Fitment of centre bearing cross member
13. Fitment of rear engine mounting bracket LH/RH
14. Fitment of rear spring rear bracket, rear spring middle bracket & rear spring front bracket with
dummy bolts
15. Fitment of front eng mounting, front spring rear bracket
16. Cleaning of burrs after reaming
17. Fitment of front cab mounting bracket, RAD mounting bracket LH/RH
18. Fitment of front cab mounting bracket along with end gusset LH/RH
19. Fitment & marking of STG box mounting bracket RH side T-90 Nm
20. Fitment of air cleaning mounting bracket
21. Fitment of rear closing cross member LH/RH
22. Fitment of front shock absorber bracket bolts LH/RH
23. Fitment of FVDP mounting bracket along with front cab mounting bracket & end gusset LH/RH
24. Fitment of pintle hook x member bolts LH/RH
25. Fitment of battery carrier LH side
26. Tightening, torquing,of RAD MTR BRKT
27. Fitment of pintle hook MBRLH /RH
28. Tightening, torquing of tail lamp MTR BRKT LH/RT

CHASSIS ASSEMBLY(MDV)
1. Initially frame is loaded in the conveyor
2. Then the brackets are filled
3. Air piping is set after the bracket fitment
4. Torque is tightened after axle is mounted on frame
5. Engine mounting is done when the chassis turn over is finished
6. After engine mounting, radiator fitment and oil filling process is to be processed
7. Cab mounting after oil filling
8. Tyre mounting using special tool
9. Off track test is done at lust
 CHASSIS ASSEMBLY (LCV)
The following process are done in a sequence
1. Frame loading
2. Rear axel dressing
3. Rear axle mounting
4. Air piping
5. Engine chassis turn over
6. Engine mounting
7. Cab mounting
8. Wheel mounting
9. Seat mounting
10. Final torque
11. Oil filling
12. Chassis off track
13. Wheel/ head lamp allignment
 ROAD TEST INSPECTION REPORT (RTP)
In RTP the following inspections are done for leaving the perfect vehicle

1. Engine test
Fan belt test
Engine oil pressure ATMIN
Over heating
2. Clutch test
Pedal free play
Pedal operation
Clutch function
3. Gear box test
G.S lever position
Gear shifting operation
Knock
4. Front axles and steering test
Wheel wobbling
Self centering action
 C-bearing noise
5. Rear axle test
Differential function
Humming
6. Brake test
Brake function
Brake pulling
7. Suspension test
Shock absorbers condition
8. Water leak test
Radiator
Water pump joint
Engine oil mixing with water
9. Air leak test
E2 valve
Brake line flick valve line
10. Diesel leak test
Fuel sensor joint
Feed pump
FIP delivery adaptor
Injector adaptor

Few other tests are done, those include

Engine idling
Compressor noise
Slippage
Axle noise
Wheel wobbling
Bearing noise
Dust cover rubbing
Spring clamp & rivet condition
Bypass hoses
Crankcase dummy plugs
Fuel return line from FIP
Steering lock
Fuel tank drain plug
Exhaust smoke
Oil filler
Gear box filler plug
Rocker cover joint
Axle shaft joint
 PRE-DELIVERY INSPECTION(PDI)
1. Vehicles for testing from RTP
2. PDI & short filament: road test vehicles
3. Shower test and fifth wheel coupling fitment, ABS testing for applicable models
4. Noise shield & spray suppression fitment, painted ,waxed vehicles
5. Load body mounting & completion painted, waxed vehicles

DELIVERABLE:
Road tested vehicles
PDI completed vehicles
PDI completed vehicles for paint to wall up and wax coating
Finished vehicles for sales and for load body mounting if applicable

PDI UNIQUENESS:
Process capability
More flexible process
Camber correction achieved within 2mm
Entire process EEI friendly
 VEHICLE TEST SHOP(VTS)
The following inspection are done under VTS

Torque check
1. Wheel nut
2. Front axle bolts
3. Rear axle bolts
4. Propeller shaft MTG bolts
Oil level check
1. Engine
2. Rear axle
3. Radiator coolant
4. Gear box
5. Clutch master cylinder
Accelerator pedal setting
Brake pedal play
Clutch pedal play
Air leak
All air pipes fouling
Cab latch alignment
Vin tally on frame & vin plate
Tail lamps fitment & cable strapping
Tyre pressure/condition
Grease for sliding parts
Ensure G.S lower rod &reaction rod check nuts tightness
Ensure electric functions:
1. Gauges
2. Wiper motor
3. Cab interior lamp function
4. Wind screen wash function
 5. Head lamp function & focusing
6. Reverse warning function
7. Exhaust brake function
Ensure canopy fitment
Ensure noise shield fitment
Ensure exhaust brake micro switch setting
Fitment of FUPD