Ashok Leyland Operation Management

A Report on Operations Management……

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Compiled By:-

                                                                Abhinav Gupta

                                                                PG 2014-0459

Ashok Leyland is a commercial vehicle manufacturing company based in Chennai, India. Founded in 1948, the company is one of India's leading manufacturers of commercial vehicles, such as trucks and buses, as well as emergency and military vehicles. Operating six plants, Ashok Leyland also makes spare parts and engines for industrial and marine applications. It sells about 60,000 vehicles and about 7,000 engines annually. It is the second largest commercial vehicle company in India in the medium and heavy commercial vehicle (M&HCV) segment. With passenger transportation options ranging from 19 seaters to 80 seaters, Ashok Leyland is a market leader in the bus segment .The company claims to carry over 60 million passengers a day, more people than the entire Indian rail network. In the trucks segment Ashok Leyland primarily concentrates on the 16 ton to25 ton range of trucks. However Ashok Leyland has presence in the entire truck range starting from 7.5 tons to 49 tons. The joint venture announced with Nissan Motors of Japan would improve its presence in the Light Commercial Vehicle(LCV) segment (<7.5 tons).In 1968, production of the Leyland Titan ceased in Britain, but was restarted by Ashok Leyland in India. The Titan PD3 chassis was modified, and a five speed heavy duty constant-mesh gearbox utilized, together with the Ashok Leyland version of the O.680 engine. The Ashok Leyland Titan was very successful, and continued in production for many years.

Manufacturing Plants in India

Ashok Leyland has currently seven manufacturing plants:-

1. Ennore
2. Hosur : Unit 1
3. Hosur : Unit 2
4. Hosur : Unit 2A
5. Alwar
6. Bhandara
7. Pantnagar

Operation Flow Chart on Ashok Leyland

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Purchase of Raw Material:-

The first process in manufacturing of Ashok Leyland products is purchase of raw materials. It is the basic and primary process in any manufacturing company/firm.

Components Machined:-

The second process, which Ashok Leyland does in the production process is machining of components. Basically, when all the raw materials are made available, they are set up on the various machines and are made ready for the next steps.

Transformation from Raw Materials to Finished Products:-

It comprises of many steps, which are explained as under:-

• Rough Milling - For the first step in transformation, a roughing tool is used to move on to next step. Rouging tool is a single-point cutting tool used to make very heavy cuts and remove metal as quickly as possible.
• Drilling – It is the use of a rotating drill in order to cut a round hole into a workpiece.
• Finish Milling – After drilling, the process of finish milling is done to give fine edges to the product. It’s done basically with the help of finishing tool, which is A single-point cutting tool used to make a very light cut for final touches to achieve precise tolerances or improved finishes.
• Washing – After finish milling, the product comes in contact with dust and cannot be passed on to next step without washing. Therefore, washing is done to make the product clean.
• Boring – After washing, boring is used to achieve greater accuracy of the diameter of a hole, and can be used to cut a tapered hole. Boring can be viewed as the internal-diameter counterpart to turning, which cuts external diameters.
• End Mill - A thin, tall mill cutter with cutting edges that wind up the sides. Both the bottom and side of the end mill are used during milling operations. End mills resemble drills.
• Assembly of Bearing Caps – Bearing cap is a device designed to fit around a bearing to support or immobilize it. It is assembled to the product, and hence finishes the transformation process.

Finished Product :- And hence, the finished product is made.

Input and Output Process

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    Operations Management

• Ashok Leyland is trying to improve efficiency and production quality, reduce costs and increase customer satisfaction.
• Among the means company is adopting just-in-time inventories system.
• The Company has a strong focus on technology upgradation in order to meet the growing demand for newer & better models.
• New benchmarks have been set in automation to minimize activities that cause human fatigue or pose hazards and achieve speed. Gantry Systems are used for axle- beam, axle arm, camshafts and crankshafts lines. Robots are used for ‘handling’ hot axle arms and axle beams.