About Ashok Leyland

INTRODUCTION
ABOUT ASHOK LEYLAND
1. COMPANY PROFILE
For over five decades, Hinduja Group flagship Ashok Leyland has been a
major presence in India's Commercial Vehicle industry. The Companys product
range spans from 7.5 T GVW to 49T GTW in goods transport and from 19 seaters
to 80 seaters in passenger transport, apart from a host of special.
Served by its own comprehensive R&D base, complemented by collaborations
with global technology leaders, Ashok Leyland has established a tradition of
technological leadership and a strong reputation for product reliability. The history
of the Company has been punctuated by a number of technological innovations,
which have since become industry norms. It was the first to introduce multi - axled
trucks, full air brakes and a host of innovations like the rear engine and articulated
buses in India. In 1997, the Company launched the countrys first CNG bus and in
2002, the first Hybrid Electric Vehicle. In 2006, the first common rail engine
capable of complying with Bharat Stage IV emission norms was launched and in
2008, it developed the country's first H-CNG engine. HYBUS, a CNG Hybrid
Plug-in bus, was developed in 2010.
With seven manufacturing locations at Chennai, Hosur (three plants), Alwar,

Bhandara and Pantnagar, the Company has an annual production capacity of 1, 50,
000 vehicles. An integrated chassis and bus assembly plant in Ras - al - Khaimah
in the Middle East is scheduled to commence production soon.
In 2009-10, the Companys turnover stood at Rs. 7,244.71 Cr with sales
topping 63,926 vehicles. Ashok Leyland has an unbroken track record of
profitability since inception.
AVIA Ashok Leyland Motors in Prague is the Company's beach head in

Europe which produces and markets the famous D-Line series of trucks in
Hungary, the UK, Ireland, Spain and Slovakia in addition to the Czech Republic.
In 2008, the Company formed Albania GmbH in Germany focusing on
development, production and sales of exhaust after-treatment systems.
Ashok Leyland vehicles are exported to over 20 countries worldwide.

Significant presence is still maintained in Sri Lanka, Mauritius and the Middle
East.
Ashok Leyland offers design and engineering services under the brand name
Defiance. Through Defiance Technologies, it provides end-to-end solutions in the
space of design, development, prototyping, testing and validation. In the US,
Defiance Testing & Engineering delivers high-end testing capabilities and along
with Defiance Tech offers integrated Engineering Manufacturing Enterprise
(EME) solutions.
Its other associates companies include Automotive Coaches & Components

Limited (ACCL) which offers an extensive range of fully-built vehicles including
tippers, tip-trailers, bulk pressure tankers and transit mixers, while Hinduja
Foundries Ltd. (HFL) has now emerged as India's largest automotive jobbing
foundry.
To become a full-range player, Ashok Leyland has tied up with Nissan
Motor Company for the light commercial vehicle business. The first product from
this partnership is expected to roll out by 2011.
The 50-50 joint venture with John Deere marks the Company's foray into the
high-potential construction equipment business. Another joint venture with the AL
teams Group of Finland is for the manufacture of high-pressure die-casting
extruded aluminium products while the JV with Continental AG is for design,
development and adaptation of inotropic products and services for the
transportation sector. Committed to Total Quality Management, Ashok Leyland is
the country's first automotive manufacturer to obtain the coveted ISO 9002
certification followed by the more comprehensive ISO 9001:1994 certification, QS
9000 (1998) and ISO 14001(2001). Ashok Leyland is also the first automobile
company in India to receive the world-renowned TS 16949 Corporate Certification
in 2006. These are major milestones in the Company's TQM journey.
Making all this happen is a team of 13,000 who master the ever-changing
technologies and market environment, in a culture of continuous learning.
Employee participation is central to the all-round gains in internal efficiencies the
Company has achieved as it evolves as a global player in Commercial Vehicles.
1.2 INFRASTRUCTURE
The origin of Ashok Leyland can be traced to the urge for self-reliance, felt
by independent India. Pandit Jawaharlal Nehru, Indias first prime minister
persuaded Mr.Raghunandan saran, an industrialist, to enter automotive
manufacture. In 1948, Ashok motors were set up in what was then madras, for the
assembly of Austin cars. The companys destiny and name changed soon with
equity participation by British Leyland and Ashok Leyland commenced
manufacture of commercial vehicles in 1955.
Since then Ashok Leyland has been a major presence in Indias commercial
vehicle industry with a tradition of technological leadership, achieved through tie-
ups with international technology leaders and through vigorous in-house R&D.
The Ennore plant has been divided into seven shops and one separate shop
for heat treatment process. It is detail below.
SHOP 1:
In this shop, the chassis assembly, gear manufacturing and gear box
assembly works are processed.
CHASSIS ASSEMBLY:
Chassis assembly is another divisional operation processing here. For that,

parts are coming from other shops the parts such as frame, front axle, rear axle,
engine, propeller shaft and steering gear boxetc., the parts such as spring,
exhaust pipes, fuel tanks, radiators, tires cabs are out sourced. After assembly all
the parts the fuel tanks in the chassis is filled by fuel. And some parts of the joints
is oiled and greased according to their requirements. After this all the chassis are
sent to PDI department (pre delivery inspection department).
SHOP 2:
This shop is known as engine shop. Because here the entire engine
requirements are fulfilled. The important inside engine parts such as camshaft,
cylinder head, crankcase and connecting rod are prepared here each has separator
division and these divisions are 4c. The engines are assembled in a separate
division called engine assembly shop.
SHOP 3:
Frame assembly and the fabrication of required materials for assembly the
frame are processed here. The plate cutting, whole punching and folding is the
operations carried out in this fabrication the division.
Standard dies are used for folding the plate, an electric riveting machine is used to
rivet the cross members. And these cross members and accessories are getting
assembled in the assembly section called frame assembly section.
SHOP 4:
Front and rear axles are assembled here, so this shop is called by axle
assembly shop. The special conveyors are used to transfer the axles between the
processing stages.
Both the axles are processed in separate divisions. The front axles are
assembled in the separate divisions and the rear axles are assembled in another
division called rear assembly.
SHOP 5:
In this shop, various engine components are assembled. The materials are
transferred to various locations by overhead conveyors. Any defects in those
materials are identified and solved by the quality department.
SHOP 6:
Camshaft, cylinder block and cylinder head are machined in this line.
Operations such as facing, grooving, drilling are performed on the components.

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INTRODUCTION

ABOUT ASHOK LEYLAND

With seven manufacturing locations at Chennai, Hosur (three plants), Alwar,

AVIA Ashok Leyland Motors in Prague is the Company's beach head in

Ashok Leyland vehicles are exported to over 20 countries worldwide.

Its other associates companies include Automotive Coaches & Components

Chassis assembly is another divisional operation processing here. For that,

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