STUDY OF ASSEMBLY AND INSPECTION OF SKIN PANEL

1. SUMMER TRAINING REPORT
ON
“Study of Assembling and
Inspection of skin panel”
SUBMITTED BY-
NISHANT KUMAR
13162028, DEPTT-MECHAINCAL ENGG
GJUS&T,HISAR
UNDER THE MENTORSHIP
MR. VIJAYPAL YADAV
Ashok Leyland, Alwar

2. ACKNOWLEDGEMENT:
Engineering is about reaping the benefits of technology to
produce production systems useful to mankind both socially
and economically. As a Mechanical Engineering student, I had
always been curious to visit an industry, so as to get a practical
insight of the implementation of what we study. I really respect
the stance of Ashok Leyland, Alwar plant to allow students from
different academic streams to undergo summer training here. I
am indeed grateful to Ashok Leyland for having me shortlisted
in the team of summer trainees. I truly find the time spent here
enriching and wonderfully memorable.
In framing my project on “STUDY OF QUANTITY OF DIESEL
REMAINING IN PIPES AFTER TESTING OF AN ENGINE.” I got
immense support from my project guide Mr. Vijaypal yadav
and, I feel so thankful to him, have always been very helpful
and willing to share information during my stay.
I would mention my gratitude to all the people working in the
area I have been nominated for training. They are well aware
of the fundamentals of the operations they engage in, and,
proved so kind to share them with me. I wish, the innocent
working NTTF students achieve laurels in Ashok Leyland.
Thank you!
Nishant Kumar

3. CONTENTS
Serial no. Title
1.) Automobile sector trend in India
2.) Company Profile
3.) Plant Layout
4.) Background and History
5.) Products of ashok layland
6.) Various shops in plants
7.) Visiting of Dost Asembling Cabin
And Inspection of skin panel
8.) Raw material used in skin panels
9.) Manufacturing of skin panels
10.) Inspection of skin panels
11.) Major defects on skin panels

4. AUTOMOBILE SECTOR TREND IN INDIA
PRODUCTION
The cumulative production data for April –March 2014 shows
production growth of only 1.20 percent over the same period
last year. The industry produced 1,685,355 vehicles in March
2014 as against 1,845,868 in March 2013, which declined by (-)
8.70 percent.
DOMESTIC SALES
The overall growth in domestic sales during April- March 2014
was 2.61 percent over the same period last year. While in
March 2014 overall sales fell by (-) 7.76 percent over March
2013.
Passenger Vehicles segment grew at 2.15 percent during April –
March 2014 over same period last year. Passenger cars
declined by (-) 6.69 percent, Utility vehicles grew by 52.20
percent and Vans grew only by 1.08 percent during April –
March 2014 as compared to the same period last year.
However, in March 2014 passenger cars sales further declined
by (-) 22.51 percent over March 2013. Total passenger vehicles
sales also declined by (-) 13.01 percent in March 2014 over
same month last year. The overall Commercial Vehicles
segment registered de – growth of (-) -2.02 percent in April –
March 2014 as compared to the same period last year. While

5. Medium & Heavy Commercial Vehicles (M&HCVs) declined by
(-) 23.18 percent, Light Commercial Vehicles grew at 14.04
percent. In March 2014, M&HCVs sales further declined by (-)
26.16 percent over March 2013.
Two Wheelers registered growth of only 2.90 percent during
April – March 2014. Scooters, mopeds and motorcycles grew by
14.24 percent, 1.53 percent and 0.12 percent respectively over
same period last year. However, in march 2014 all sub –
segments of two wheelers, scooters, motorcycles and mopeds
registered de – growth at (-) 3.18 percent, (-) 8.32 percent and
(-) 4.54 percent respectively.
EXPORTS
During April – March 2014, overall automobile export
registered de - growth of (-) 1.34 percent compared to the
same period last year.
Passenger Vehicles grew by 9.02 percent, while the others
segments like Commercials Vehicles, Three Wheelers and Two
Wheelers fell by (-) 13.35 percent, (-) 16.22 percent and (-) 0.72
percent respectively. In March 2014, Passengers Vehicles, Two
& Three Wheelers grew by 3.07 percent, 3.51 percent and 7.50
percent respectively. While Commercial Vehicles declined by
(-) 28.33 perc

6. PROFILE
Ashok Leyland has for over six decades been a major presence
in the Indian commercial vehicle industry.
• Headquartered in Chennai, India, our manufacturing
footprint is pan-India with two facilities in Prague and
raskhiamah (UAE).
• Operating six plants, Ashok Leyland also makes spare parts
and engines for industrial and marine applications.
• It is the second largest commercial vehicle company in
India in the medium and heavy commercial
vehicle(M&HCV) segment with a market share of 28%
(2007-08)
• With passengers’ transportation options ranging from 19
seaters to 80 seaters, Ashok Leyland is a market leader in
the bus segment.

7. • In the trucks segment Ashok Leyland primarily
concentrates on the 16 ton to 25 ton range of trucks.
• However Ashok Leyland has presence in the entire truck
range starting from 7.5 tons to 49 tons.
• Over 7, 00,000 Ashok Leyland vehicles ply on Indian and
international roads and our buses carry over 70 million
passengers every day.
• Joint venture announced with NissanMotors of japan
would improve its presence in light commercial vehicle.
PLANT LAYOUT

8. BACKGROUND AND HISTORY
The Birth of Ashok Motors
• Founded by Raghunandan Saran, Ashok Motors was set up
in collaboration with Austin Motor Company, England and
incorporated on September 7th
for the assembly of Austin
cars.
The first A40 Assembled
• Production began in September at the factory situated at
Ennore, South of Madras and soon the first indigenously
assembled A40 Austin car was rolled out.
Assembly of Leyland chassis commence
• The first Leyland chassis assembled by Ashok Motors at
Ennore were four Comet 350 engine tippers sold to the

9. Mangalore tile factory.
Government Approval for Manufacture of Commercial
vehicles
• The government approved the progressive manufacture of
Leyland commercial vehicles and a license for the
manufacture of 1,000 Comet a year was granted.
Ashok Motors becomes Ashok Leyland (1955)
• Named after Raghunandan son, Ashok, the company was
renamed Ashok Leyland with equity participation from
Leyland Motors, Ltd.
India’s first double decker arrives (1967)
• ‘Titan’- The first Indian made double decker with 50%
indigenous components was launched.
Production target upped to 10,000 vehicles a year
(1972)
• The license to manufacture 10,000 vehicles a year was
granted.
Two major new truck introductions (1980)
• India’s first 13-ton truck-‘Tusker’ with a 125 hp engine was

10. launched followed by the country’s first multi-axle
truck-‘Taurus’.
First Indian auto company to receive ISO 9001
certification (1993)
• This was followed two years later with the ISO 9001
certification.
Another innovation in alternate fuel technology
(2002)
• The country’s first hybrid electric vehicle was developed
and showcased at Auto Expo 2002.
India’s first Hybrid CNG Plug-in Bus (2010)
• Showcased at Auto Expo 2010 and later did service during
the Common wealth Games moving VIPs and media at
PragatiMaidan, New Delhi.
A full range player with DOST (2011)
• Entry into the Light Commercial Vehicle (LCV) segment.

11. PRODUCTS OF LEYLAND
BUSES
• Ashok buses move some 70 million people every day on
their destination. From 18 seaters to 80 seaters, Ashok
Leyland has an extensive range of buses that fits almost
every requirement.

12. TRUCKS
• Ashok trucks have been the wheels of the economy for
decades. They offer a comprehensive range for avariety of
applications: long haul, distribution, construction, and
mining.
LIGHT VEHICLES

13. • The light vehicle segment has come to the fore with
fractional, last mile delivers of consumables becoming
critical. Their DOST, a vehicle with a rated payload of 1.25
tones, is positioned to meet an evolving market need for
slightly heavier tonnage vehicles due to higher aggregation
of small loads.
DEFENCE VEHICLES
• They have developed two more platforms the COT and the
SUPER STALLION. Going forward, they are expanding their
stallion range of logistic transport solutions while tactical
or armored vehicles will be offered on all three platforms
on the back of strategic partnership with KMW, Germany;
Pan hard, France, and Paramount, South Africa.

14. POWER SOLUTIONS
Under the brand name, Leypower, they offer complete
power solution by supplying engines for a variety of
applications apart from vehicles: be it for running
generator sets, for marine applications or for powering
earth moving equipment, compressor cranes, harvester

15. combines and the like, Leypower has provided many an
industry the power to keep running uninterrupted.

16. VARIOUS SHOPS IN PLANTS
• AXLE SHOP
The integrated axle machining and assembly shop has
highly automated front axle machining lines and
conveyorised front / rear assemblies, all in one shop.
Hazardous operations are performed by robots.
• PAINT SHOP
Powder coating instead of conventional liquid painting
eliminates hazardous pollutants while bestowing high
corrosion resistance to withstand well over 500 hours of
salt spray bath. The change of technology also ensures
zero wastage of paint.
• WELD SHOP
High on automation, the shop employs robotics in framing
and rear body lines, for better quality and improved
ergonomics. Manufacture of door assemblies is
performed by robotic roller hemming.
• SKIN PANEL INSPECTION SHOP
Visual inspection is popular way of inspecting skin panels.
Manually inspecting by wearing inspection Gloves. CMM is
used in some critical areas.Oil stoning the panel with Oil
stone.

17. • SKIN PANEL ASSEMBLY SHOP
There are 14 skin panel which are assembled in skin panel
assembly shop by weldind and jigs & fixture. After
assembly of skin panel it goes to the chasis shop.
• CHASIS SHOP
The chassis assembly is designed to be extremely
dexterous to produce the smallest to the largest of
vehicles in Ashok Leyland’s product range, including the U-
Truck range and other cabbed vehicles. The single chassis
testing line can test all the models and variants covering
various tests, to generate instant test reports.
• ENGINE SHOP
Integrated Horizontal Machining Centres (HMC) complex
fed by Automated Guided Vehicles (AGV) bestow great
flexibility to manufacture a range of engine variants, using
components rough machined in an adjoining shop. Auto
docking and in-process verification systems directly reduce
testing cycle time and optimize test cell requirements.

18. The shop has the capability to produce both the H and the
Neptune family of engines.
• GEARBOX MANUFATURING SHOP
In gearbox manufacturing shop various type of gear are
manufactured according to their application or uses. The
fully automatic CNC machines are used for manufacturing
these gear.
• CHASIS TESTING SHOP
In chases testing shop ,after assembly of chasis the testing
of chasis is done.
• VEHICLE TESTING SHOP
After complete assembly of vehicle ,the testing of vehicle
means the fuel average of vehicle under different
condition ,etc. are done.

19. Visiting of Dost Asembling Cabin
And
Inspection of skin panel of dost
SKIN PANEL is a visual outer body of a vehicle majorly CABIN
parts.
Proper metal finished skin panels are very important for good
ASTHETIC LOOK of a vehicle.

20.  Basically DOST model has 14 SKIN PANELS.
 Each panel is identified by a Part No.
 All panels are stamped(pressed) in ASHOK LEYLAND press
shop.
 Sheet metal thickness ranges from
0.7mm to 1.6mm.
 The 14 skin panels of DOST are
1) Door outer RH
2) Door outer LH

21. 3) Door inner RH
4) Door inner LH
5) Roof
6) Floor
7) Front Panel

22. 8) Sill outer RH
9) Sill outer LH
10) Corner Panel RH
11) Corner Panel LH
12) Back Panel
13) B Pillar RH
14) B Pillar LH

23. Raw material used in skin panel
STEEL, produced from mined iron ore, the base raw material, is
perhaps the most widely used component in auto
manufacturing. It accounts for roughly 80% of the weight of an
average car. Steel is used to construct a car's chassis and body,
including the roof, body and door panels, and the beams
between doors.

24. Manufacturing of Skin panels
Skin panels are manufactured with the help of stamping
dies. A stamping die is a special, one-of-a-kind precision tool
that cuts and forms sheet metal into a desired shape or profile.
The dies can be for manual loading press, tandem press lines
with robots, transfer lines or coil feed high speed blanking
lines.But in Ashok leyland tandem press lines with robots is
used.
Tandem press lines feature multiple presses with press-to-press
transfer by robots or feeders and can be served by coil feed
systems or destackers, and may be provided with additional
ancillary equipment such as scrap conveyors, scrap chutes,
discharge conveyors, etc.For Commercial vehicles stamping
dies manufactures Side wall outers, Body side outers, Front
walls, Roofs, Door outers, Rear walls, Rear corner outers etc.
The machine used in this press line if of FAGOR company. It
presses the skin panel at 670 KN .

25. Inspection of Skin Panels
1. Visual inspection is popular way of inspecting skin panels.
2. Manually inspecting by wearing inspection Gloves
3. CMM is used in some critical areas
4. Oil stoning the panel with Oil stone.
Major Defects On Skin Panel
1. DENTS : Dent refers to shallow deformation on the surface
of a panel or object.
Reason :
1. Due to some dust & foreign particles on die surface.
2. Rarely during loading and unloading of panel.

26. 2. PEAKS : Peak refers to a high point on the surface of a panel
or object.
Reason :
1. Dust & foreign particles on die surface.
2. During loading & unloading of panel.

27. 3.WRINKLE :
• Wrinkle refers to waviness formed on surface of panel.
• Wrinkle can also be known as high and low areas.
Reason :
1. Low cushion pressure.
2. Varying Cylinder forces.

28. 4.WELDING DAMAGE :
Welding damage means spot damage.
which may damage the channel, flange.
Reason :
1. Due to mislocation.
2. Urgency.
3. Due to Child part defect.
4. Weld burning, blackening.
5. Due to high current value.

29. 5. CRACKS :Crack is a thin & narrow opening in a flat,
solid material.
Before crack THINNING occurs.
Reason :
1. Due to more holding, blanking pressure.
2. Slug mark.