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Ashok Leyland (Bhandara Unit)
- Ashok Leyland is a leading manufacturer of commercial vehicles in India established in 1948, with a unit in Bhandara established in 1984. - The document outlines the various processes involved in manufacturing transmission gear boxes at the Bhandara unit, including gear cutting, heat treatment, assembly, testing, and quality control methods like 5S and six sigma. - It discusses the steps taken in machining gears, shafts, syncros, and casings and their assembly into the final gear box, which is tested for noise and performance before shipment.
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Ashok Leyland (Bhandara Unit)
- 1. The Industrial TrainingIn Ashok Leyland (Bhandara Unit) Presented By: - Yogendra P. Tembhurne
- 2. Introduction • Founded in1948 • 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 , 2nd3rd, 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, LayShaft 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 WORKINGOF SYNCRO HUB • Broaching • Washing • Hobbing • Deburring • Drilling • Slot milling • Washing • Part No. Punching
- 9. SOFT LINE PROCESSINGOF SYNCHRO CONE Input Broaching Washing Hobbing WashingOil Groove Tooth Chamfering Finish Turning Washing Part No. punching Output
- 10. SOFT LINE PROCESSINGOF SYNCHRO SLEEVE Input Part No. Punching Broaching Washing Turning Tapper Turning Scoop milling Correction Broach Tooth Chamfering Finish Turning Washing Output
- 11. IN HEAT TREATMENTSHOPS 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 isone 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.
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