Sml isuzu limited

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

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

2. Company’s History

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

4. Bus Body Plant (BBP) Some of the products From “SML” are Executive, Ultra-Luxury class vehicle 4WD Ambulance for Defense

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

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

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

8. Technology Department Industrial Engineering Tool Design Production Engineering Technology Department is sub-divided into 3 sub-departments The Main Purpose of Technology department is to assist the Production Line in any Kind of problem Being Faced by it.

9. Project – 1 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 Normal Marking Process

10. Problems Faced Standard Solution was to develop Gauges for marking

11. Requirements in gauge - 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.

12. Developed Gauges - Air-cleaner Flap Spare wheel flap Sedimentary Tank Flap Diesel Tank Flap

13. Observation Results - 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

14. 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 . Problem Faced -

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

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

17. CASE-2 : Cloth Upholstery Present Situation: Suggested proposal Action : Single piece Cloth used all along the sides length Cut Piece used with Al. section covering

18. 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

19. 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

20. Assembly line of Zhong-Tong bus 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

21. After docking, we have 5 stations

22. 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. Some major Processes -

23. 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.

24. 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.

25. 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

26. 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.

27. THANKS !