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The Industrial Training In
Ashok Leyland (Bhandara Unit)
Presented By: -
Yogendra P. Tembhurne
Introduction
• Founded in 1948
• India's leading manufacturers of commercial vehicles, such as trucks
and buses, as well as emergency and military vehicles.
• AL transmission exists over the Globe in 40 countries.
• Bhandara Unit established in 1984.
1St , 2nd 3rd, 4th, 5th And Reverse Gear On Main
Shaft
1. Shape Clutch Teeth
2. Hobbing
3. Washing
4. Clutch Teeth Chamfer
5. Gear Chamfering
6. Taper Roll Clutch Teeth
7. Washing
Constant Mesh (CM), 3rd, 4th And 5th Gearon Lay
Shaft
1. Hobbing
2. Gear Chamfering
3. Washing
GEAR HARD LINE
• Bore Grinding
• Grinding Route
• Teeth Grinding
• Shaving Route
• Noise Testing
• Final Inspection- Baker Gauge
Input Shaft, Lay Shaft And Main Shaft Shoft
Line
• Part No. Punching
• Hob Spline
• Hob Gear Teeth
• Chamfering
• Shape Clutch Teeth
• Skin Turning
• Drill Oil Hole
• Washing
Shaft Hard Line
• OD Grinding
• ID Grinding
• Shaving Rout
• Grinding Rout
• Teeth Grinding
• Noise Testing
• Final Inspection
SOFT LINE WORKING OF SYNCRO HUB
• Broaching
• Washing
• Hobbing
• Deburring
• Drilling
• Slot milling
• Washing
• Part No. Punching
SOFT LINE PROCESSING OF SYNCHRO CONE
Input Broaching Washing Hobbing
WashingOil Groove
Tooth
Chamfering
Finish
Turning
Washing
Part No.
punching
Output
SOFT LINE PROCESSING OF SYNCHRO SLEEVE
Input
Part No.
Punching
Broaching Washing
Turning
Tapper
Turning
Scoop
milling
Correction
Broach
Tooth
Chamfering
Finish
Turning
Washing Output
IN HEAT TREATMENT SHOPS
Input
Loading in
fixture
Preheating Carburizing
Oil
quenching
WashingTemperingShotBlasting
Air cleaning
QC
inspection
Output
GEAR BOX ASSEMBLY (GBA)
• Washing
• Sub assembly
• Main assembly
• Testing
• Dressing
• Final passing
TESTING
Testing consists of -
• Noise testing
• Engagement of gear
• Leakage
RECTIFICATION & REASSEMBLY
• In rectification GB is de-assembled manually and any problem is
rectified by operator.
• There are many vibration problems due to any defect during
machining such defects are removed by charging that
gear/sleeve/synchro component.
CASING LINE
Input
Part No.
Punching
No. of m/c 2
Infeed loading
Machining
No. of m/c 6
Outfeed
unloading
Deburring
Washing
No. of m/c 1
Helicoil fitment Output
TQM
• GEMBA
• 5S:- Seiri (Sort out and arrange properly)
Seiton (Set right or set in order)
Seiso (Cleaning)
Seiketsu (Standardize work practices)
Shitsuke (Self discipline)
• EEI (Efforts and Ergonomics Index)
• Waste reduction
• CMI (Cost Management Initiative)
• Suggestion scheme and
• Six sigma
Conclusion
Ashok Leyland is one of the biggest Units of the Bhandara district
employing thousands of people. Creating the one of the best and
reliable gear box (Transmission) for the Latest vehicle to be in race with
the heavy load moving worldwide automobile industrial developments.
Thank You

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Ashok Leyland (Bhandara Unit)

  • 1. The Industrial Training In Ashok Leyland (Bhandara Unit) Presented By: - Yogendra P. Tembhurne
  • 2. Introduction • Founded in 1948 • India's leading manufacturers of commercial vehicles, such as trucks and buses, as well as emergency and military vehicles. • AL transmission exists over the Globe in 40 countries. • Bhandara Unit established in 1984.
  • 3. 1St , 2nd 3rd, 4th, 5th And Reverse Gear On Main Shaft 1. Shape Clutch Teeth 2. Hobbing 3. Washing 4. Clutch Teeth Chamfer 5. Gear Chamfering 6. Taper Roll Clutch Teeth 7. Washing
  • 4. Constant Mesh (CM), 3rd, 4th And 5th Gearon Lay Shaft 1. Hobbing 2. Gear Chamfering 3. Washing
  • 5. GEAR HARD LINE • Bore Grinding • Grinding Route • Teeth Grinding • Shaving Route • Noise Testing • Final Inspection- Baker Gauge
  • 6. Input Shaft, Lay Shaft And Main Shaft Shoft Line • Part No. Punching • Hob Spline • Hob Gear Teeth • Chamfering • Shape Clutch Teeth • Skin Turning • Drill Oil Hole • Washing
  • 7. Shaft Hard Line • OD Grinding • ID Grinding • Shaving Rout • Grinding Rout • Teeth Grinding • Noise Testing • Final Inspection
  • 8. SOFT LINE WORKING OF SYNCRO HUB • Broaching • Washing • Hobbing • Deburring • Drilling • Slot milling • Washing • Part No. Punching
  • 9. SOFT LINE PROCESSING OF SYNCHRO CONE Input Broaching Washing Hobbing WashingOil Groove Tooth Chamfering Finish Turning Washing Part No. punching Output
  • 10. SOFT LINE PROCESSING OF SYNCHRO SLEEVE Input Part No. Punching Broaching Washing Turning Tapper Turning Scoop milling Correction Broach Tooth Chamfering Finish Turning Washing Output
  • 11. IN HEAT TREATMENT SHOPS Input Loading in fixture Preheating Carburizing Oil quenching WashingTemperingShotBlasting Air cleaning QC inspection Output
  • 12. GEAR BOX ASSEMBLY (GBA) • Washing • Sub assembly • Main assembly • Testing • Dressing • Final passing
  • 13. TESTING Testing consists of - • Noise testing • Engagement of gear • Leakage
  • 14. RECTIFICATION & REASSEMBLY • In rectification GB is de-assembled manually and any problem is rectified by operator. • There are many vibration problems due to any defect during machining such defects are removed by charging that gear/sleeve/synchro component.
  • 15. CASING LINE Input Part No. Punching No. of m/c 2 Infeed loading Machining No. of m/c 6 Outfeed unloading Deburring Washing No. of m/c 1 Helicoil fitment Output
  • 16. TQM • GEMBA • 5S:- Seiri (Sort out and arrange properly) Seiton (Set right or set in order) Seiso (Cleaning) Seiketsu (Standardize work practices) Shitsuke (Self discipline) • EEI (Efforts and Ergonomics Index) • Waste reduction • CMI (Cost Management Initiative) • Suggestion scheme and • Six sigma
  • 17. Conclusion Ashok Leyland is one of the biggest Units of the Bhandara district employing thousands of people. Creating the one of the best and reliable gear box (Transmission) for the Latest vehicle to be in race with the heavy load moving worldwide automobile industrial developments.