PPT of my ind. training, way back in 2012.

1. SML-ISUZU
Limited
by:
Aggyapal Singh
Roll no. ue89002
Mechanical 8th Semester

2. 1983-92
•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

3. Sumitomo Corporation, Japan 54.96 %
Isuzu 4 %
MFNB 9.1 %
FII’s 2.67 %
Public 25.22 %

4. Company’s Products
ISUZU
trucks
SML buses
ISUZU
buses
SML trucks

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

6. Standard Ambulance
Cardiac-ICU Ambulance
Semi low floor AC-CNG Bus Semi low floor AC School bus

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

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

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

10. Industrial Engineering
Tool Design
Production Engineering
The Main Purpose of Technology department is to assist the
Production Line in any Kind of problem Being Faced by it.

11. • DEVELOPING GAUGES for ZT model school bus
• Gauges meant to mark the “CUT-OUTS” at 4 points.
• AIR CLEANER, DIESEL TANK, SPARE WHEEL, SEDIMENTARY TANK

12. Gauge
Criterion
As per
Dimension
Easy to use
and handy
Durable
Poke-Yoke

13. • We thought of a STENCIL type gauge.
• HOLDING ARRANGEMENTS - 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 from the holding part, a rectangular sheet of
sufficient dimension from which cut out can be cut. This
would act as a STENCIL
• The sheet should settle on surface as per dimensions.
• STRENGTH PACKING - If the dimensions are correct, Strength
packing is done for long lasting and anti-wear Performance of
gauge.

15. Without Gauges it took = 16*5 = 80 minutes
With gauges it takes = 16*2 = 32 minutes
Time Saved Per Day = 48 minutes/worker
Workman’s minutes saved for company/day = 48*2 = 96
minutes

17. Project 2 - Wastage Consumption
• Project :
To consume the wastages of Aluminium Chequered Sheet &
upholstery and take steps to optimize the raw material/waste
consumption on Assembly line.
CASE-1: Aluminium Chequred Sheet wastage accumulation on line for the
period Apr 2010 To Feb 2012 results in Rs 30060/- of scrap piled up
CASE-2: 50 meters of waste inter paneling upholstery costing Rs.13200/-
piled up due to left out length from rolls ( LZ0257571) used for LT-C
model .
CASE-3: 92 meters of Upholstery ( LZ1157510) piled up in small cut length
sizes costing Rs.11132/- during various cut to size application in
Executive model .

18. Mission:
a) To consume the waste generated of Rs.30060
and steps to be taken to control scrap
generation by value engineering .
b) To consume the left out inter paneling
upholstery length wastes
c) (LZ0257571)–LT(C) model costing Rs.13200/-
d) (LZ1157510)–Ex. model costing Rs.11132/-

19. CASE-1: Aluminium Chequered Sheet
• Present Situation • Suggested Proposal
Action:
Present (WASTE)-860 x 810 mm
sheet.
Waste
Generated
used below

20. • Present Situation: • Suggested proposal
Action :
Single piece
Cloth used
all along the
sides length
Cut Piece used
with Al. section
covering

21. CASE-3: CLOTH UPHOLSTRY
• PRESENT SITUATION : • Suggested proposal
ACTION:
Roof cloth is used in color
contrast with side cloth,
leading to Waste
accumulation of small cut
size lengths
Roof Cloth interchanged
with side & pillar cloth for
maintaining contrast, Roof
cloth wastage consumed

22. TOTAL SAVINGS
• Aluminum Chequered Sheet Net Savings To Company :
Rs.30060 (Cost of Piled Scrap) + Rs.540/bus (Adjusting
Waste)
• Cloth Upholstery(LZ0257571) Cost Savings : Rs.13200/-
(Scrap Cost ) - 5xRs.170(Al section cost) = Rs.12350/-
• Cloth Upholstery(LZ1157515) Savings : Waste consumed
worth Rs.11132
• Total Savings : Rs.53542

23. • This bus is still not officially launched
• Sample buses are being developed for Marketing
purposes
• It’s a Chinese design
• Without AC School and staff bus
• Also to be developed in CNG model

24. * Body welded to Chassis
* Plywood flooring and sealing
of gaps
* Grinding floor for
smoothening
* PVC carpet pasted on floor
using adhesive
* Electrical wiring
* Roof covered with roof ply
and front dome fixed
* LH and RH Ply is fixed
* Floor aluminum beading
fixed
* Fit window frames
* Fit driver’s door, dickey
beading & outer lights
* Fit inner lights and sun visor
assembly
* Fit hat racks
* Front and rear windshield
* Battery cover, engine hood,
RVM, gear lever cover
* Dashboard and electrical
connections installed
* Fit all seats
* Fit grab handles and other
accessories
* Checkout for the working of
electric circuit

25. • 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.

26. • 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.
• 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.

27. • 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.

28. • 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

29. • 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.

30. THANKS !