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SUBMITTED BY:-
AUTOMOBILES
SKIN PANEL
INSPECTION &
METAL FINISHING
PROJECT REPORT ON
ASHOK LEYLAND
Ashok Leyland is the 2nd biggest automobile
manufacturers in India.
Founded in 1948 as ASHOK MOTORS by
Mr.RAGHUNANDAN SARAN, an
Industrialist.
At present there are 6 plants in India, & also
serving in 30 countries around the world.
Mother plant at ENNORE in chennai, in
HOSUR two plants(Unit 1 & Unit 2),ALWAR
in Rajasthan, BHANDARA in Maharashtra &
recently new plant at PANTANAGAR.
ASHOK LEYLAND PRODUCES
 LCV : Light Commercial Vehicles
 MDV : Medium Duty Vehicles
 HDV : Heavy Duty Vehicles
 ICV : Intermediate Commercial
Vehicles
 Recently ASHOK LEYLAND has
stepped in production of Luxury car….
 Buses from 18 to 80 seaters are
manufactured.
 Trucks ranging from 4.5 tones to 49
tones ……….
 Second Largest Automobile Vehicle Manufacturer in INDIA
 ASHOKLEYLAND and IVECO joint
venture in 1993 – 1994
 In 1954, GOVERNMENT approval for
manufacture of commercial vehicles
 The name of the company was changed to ASHOK LEYLAND
LIMITED in 1955
 Our Defence Vehicle is backbone of INDIAN ARMY
Ashok Leyland Passenger Transportation
 Ashok Leyland buses carry more than 60 million
passengers everyday, More comparing to Indian
Railways.
 Ashok Leyland is the India's only manufacturer of
double‐decker buses.
 It head started in alternate energy buses ‐ BS II &
BS III. Eight out of ten metro state transport buses
in India are from Ashok Leyland.
 It is one of the leading suppliers of defense vehicles
in the world and also the leading supplier of logistics
vehicles to the Indian Army.
What is SKIN PANEL ?
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…….
 This report Skin Panel
Inspection report is regarding
the ASHOK LEYLAND’s model
named “DOST”.
 DOST model is in joint venture
with NISSAN MOTORS.
 DOST is awarded as
“LCV of the year 2012”.
DOST
Continues…..
 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
3) Door inner RH
4) Door inner LH
5) Roof
6) Floor
7) Front Panel
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
Assembled CABIN of DOST Front panel of DOST
Left hand door of DOST
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.
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.
DENTS MARK
PEAKS MARK
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.
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.
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.
Tools used for inspection
1. The most important tool for inspection is OIL
STONE.
2. Hand Gloves.
3. Taper Scale.
4. Pin point micrometer.
5. Vernier Caliper.
6. CMM(Coordinate Measuring Machine).
7. Flash light.
METAL FINISHING:-Metal finishing(Rework) is a process which
includes rework of SKIN PANEL DEFECTS, cleaning of panels, providing
proper finish & preparing the panel for next painting stage.
METAL FINISHING OPERATIONS
 In this primarily panels will be cleaned from oil, sealant & rust.
 Rework of defects will be done in this stage.
 For peaks, they will hammer it slowly and will finish with
VERTICAL SANDER then finally with RANDOM ORBITAL
SANDER.
 For dents they will use a special equipment called DENT PULLER.
 For cracks the solution is welding , grinding & matching the surface.
We use MIG(Metal Inert Gas)welding for cracked surface & also for
thinning.
 To remove welded spot in case of weld damage we will use a SPOT
REMOVAEBLE DRILL & after correction it will be welded again.
Ashok leyland motors

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Ashok leyland motors

  • 2. AUTOMOBILES SKIN PANEL INSPECTION & METAL FINISHING PROJECT REPORT ON
  • 3. ASHOK LEYLAND Ashok Leyland is the 2nd biggest automobile manufacturers in India. Founded in 1948 as ASHOK MOTORS by Mr.RAGHUNANDAN SARAN, an Industrialist. At present there are 6 plants in India, & also serving in 30 countries around the world. Mother plant at ENNORE in chennai, in HOSUR two plants(Unit 1 & Unit 2),ALWAR in Rajasthan, BHANDARA in Maharashtra & recently new plant at PANTANAGAR.
  • 4. ASHOK LEYLAND PRODUCES  LCV : Light Commercial Vehicles  MDV : Medium Duty Vehicles  HDV : Heavy Duty Vehicles  ICV : Intermediate Commercial Vehicles  Recently ASHOK LEYLAND has stepped in production of Luxury car….  Buses from 18 to 80 seaters are manufactured.  Trucks ranging from 4.5 tones to 49 tones ……….
  • 5.  Second Largest Automobile Vehicle Manufacturer in INDIA  ASHOKLEYLAND and IVECO joint venture in 1993 – 1994  In 1954, GOVERNMENT approval for manufacture of commercial vehicles  The name of the company was changed to ASHOK LEYLAND LIMITED in 1955  Our Defence Vehicle is backbone of INDIAN ARMY
  • 6. Ashok Leyland Passenger Transportation  Ashok Leyland buses carry more than 60 million passengers everyday, More comparing to Indian Railways.  Ashok Leyland is the India's only manufacturer of double‐decker buses.  It head started in alternate energy buses ‐ BS II & BS III. Eight out of ten metro state transport buses in India are from Ashok Leyland.  It is one of the leading suppliers of defense vehicles in the world and also the leading supplier of logistics vehicles to the Indian Army.
  • 7. What is SKIN PANEL ? 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…….
  • 8.  This report Skin Panel Inspection report is regarding the ASHOK LEYLAND’s model named “DOST”.  DOST model is in joint venture with NISSAN MOTORS.  DOST is awarded as “LCV of the year 2012”.
  • 10. Continues…..  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.
  • 11. The 14 skin panels of DOST are 1) Door outer RH 2) Door outer LH 3) Door inner RH 4) Door inner LH 5) Roof 6) Floor 7) Front Panel 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
  • 12. Assembled CABIN of DOST Front panel of DOST
  • 13. Left hand door of DOST
  • 14. 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. 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.
  • 16. 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. 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. 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.
  • 17. Tools used for inspection 1. The most important tool for inspection is OIL STONE. 2. Hand Gloves. 3. Taper Scale. 4. Pin point micrometer. 5. Vernier Caliper. 6. CMM(Coordinate Measuring Machine). 7. Flash light.
  • 18. METAL FINISHING:-Metal finishing(Rework) is a process which includes rework of SKIN PANEL DEFECTS, cleaning of panels, providing proper finish & preparing the panel for next painting stage. METAL FINISHING OPERATIONS  In this primarily panels will be cleaned from oil, sealant & rust.  Rework of defects will be done in this stage.  For peaks, they will hammer it slowly and will finish with VERTICAL SANDER then finally with RANDOM ORBITAL SANDER.  For dents they will use a special equipment called DENT PULLER.  For cracks the solution is welding , grinding & matching the surface. We use MIG(Metal Inert Gas)welding for cracked surface & also for thinning.  To remove welded spot in case of weld damage we will use a SPOT REMOVAEBLE DRILL & after correction it will be welded again.