1.

Various Departments of SML ISUZU (BUS BODY PLANT)

1. 2. 3. 4. 5. 6. 7. 8. 1. Personnel Department. Production Department Research and Development Quality Engineering Department Technology Department Accounts Department Purchase Department Maintenance Department Personnel Department:-

Objectives of the personnel Department: Recruitment and promotion policies Welfare schemes Discipline and grievance redressal Security Canteen Services Introduction to labour laws 2. Production Department:-

Objectives of the production department: To reach the demand of customer Cost reduction $ max profit Maintain quality Just in time production Suggestion for further improvement

3. Research and Development Department Structure of R&D Department Chief Manager Manager Senior Engineer Engineer Junior Engineer Draft Men

Further plans of R&D Department 1. Research on compressed natural gas (C.N.G) engines. 2. To increase the diameter of clutch. Ultimately increase in size of clutch housing. 3. Installation of modified engine mounting pad test rig. 4. Research on shifting of gears by cables. 5. Bulletproof 4WD vehicles for army.

4. Quality Engineering Department The responsibility of the whole department is to ensure the quality of each incoming as well as outgoing products. The department is divided in sub- department:1. QE(Receipt) 2. QE(Lab) 3. QE(Vendor) 4. QE(Manufacture)

5. Technology Department This department is sub divided in to following department: Industrial engineering. Production engineering. Tool design. 6. Accounts Department Functions of accounts Department Sales Accounts. Purchase Accounts. Labour Accounts. Cost Accounts. 7. Purchase Department Functions of Purchase Department 1. Vendor selection and vendor development. 2. To make list of suppliers. 3. To organize purchase negotiations. 4. Documents/reports generation and their utility. 5. To record vendors performance and subsequent actions. 9. Maintenance Department:-

Objectives of Maintenance Department This main objective of this department is to proper conditions of machines and other equipment and other equipment used in plant and inter- cooling of plant supply of compressed air through the plant to drive the air guns.

6.1 PRODUCTION DEPARTMENT (BUS BODY PLANT)

PRODUCTION CLASSIFICATION

STRUCTURE SHOP

SHELL SHOP

PAINT SHOP
SUB ASSEMBLY AREA

DOCKING

FINAL ASSEMBLY

PDI

7.
This Shop Contains two lines: 1. Line for chassis frame assembly 2. Line for cabin fabrication

BODY SHOP

CHASIS ASSEMBLY
This assembly line has different stations to fabricate different types of chasis(WT48,WT-49).

TEMPRORY ASSEMBLY STATION

At this stage cross members are loosely position on the side members on jig assembly is moved to next station.

TACK WELDING STATION

At this station all other members like various brackets,hangers,supporting members are positioned and on loosely fitted side members and cross members assembly after completing the assembly in fixture according to location of components are tack welded. From here the frame (tack welded) is taken to complete welding station.

STRAIN RELIEVING STATION

Since after welding some strain develops in the chasis. On this station there is special fixture which in addition to having clamping arrangments has hydraulic and mechanical jacks fitted on it. This is to releave the strain developed during the welding. The permissible strain can be read from the scale mounted on the hydraulic jack.

PAINTING BOOTH
A through black painting is done with spraying guns after cleaning it with pressure air. In all above welding process the MIG welding is used.

CABIN FABRICATION
It has following stations: 1. Floor welding station 2. Side frame welding station 3. Cabin welding station 4. Denting and grinding station After these stations which are used to form the main body of cabin, the door panel is assembled on parallel line and is then attached to main body of the cabin. On the last station denting and grinding is done after that the cabin is mounted on trolley and passed to the paint shop. The welding gun houses the electrod, penumatic cyllinder, balancer trolleys, pneumatic circuit and cooling circuit.

8.

PAINT SHOP

In paint shop cabin and cargo boxes are painted before they sent to vehicle assembly shop.

CABIN PAINTING
For the cabin painting the cabin is received from the body shop and the main operations which are used for painting are as: PRETREATMENT In the pretreatment operation the cabin is finished with the help of kerosene oil which is called as swaping of the cabin. DEGRASING After the pretreatment the cabin is taken to the degreasing tank. In this operation the cabin is dipped into a solution of alkaline at temperature of 55degree cent to 60 degree cen. For 5 minutes. RINSE-1 After degreasing operation the rinsing the cabin is carried out with the help of tap water at ambient temp. DERUSTING After rinsing-1 operation the cabin is taking to acidic solution tank and dipped into it at ambient temperature (as and when required). RINSE-2 Rins-2 is same as rinse-1 operation. SURFACE CONDITIONING After rinsing operation the surface conditioning is carried out at ambient temperature.

PHOSPHATING
After surface conditioning operation cabin is taken to phosphate tank fair chemicals are used for this operation. These are phosphate replishner accelerator make up and nexterliser. This operation is carried on cabin to get a smooth finer grained, corrosion resisting paint boundary zinc phosphate coating. The chemical in the tank is maintained at a temperature of 50 degree cent. To 55 degree cent. For 3-5 min. RINSE-3 Rinse-3 is same as rinse-2 so that chemicals can be removed. DM-WATER RINSING This operation is carried out to achieve acid naturalization. The cabin is dipped in the tank 2-3 times. The cabin is dipped 2-3 times in the DM water tank at room temp. BLACK DIPPING Black dipping of the cabin is done to increase the strength of the cabin. Only the floor of the cabin is black dipped in the water soluble black paint at a temp. Of 140degree Celsius for 30 minutes. BAKING After the black dipping the cabin is placed on the trolley and pushed inside the oven where the temp. is maintained at 140 degree Celsius. The cabin is kept for 30 minutes inside the oven so that black coat gets adhere properly to the surface of the cabin. SEALANT Sealant is applied to the cabin body to make it water proof. PRIMER COATING After there cleaning operation the cabin is carried out to paint booth. In the paint booth the primer coating is done on it. FLASH OFF After primer coating cabin is kept for 5-10 minutes in another booth to enable the primer to settle down to some extent.

BAKING After flash off operation again baking of the cabin is done so that the primer gets adhere properly to the surface. DRY SANDING Dry sanding is carried out on the surface of the cabin with the help of sanding. TOP COAT After dry sanding operation the cabin is taken inside the paint booth. The paint booth has the capacity of storing two cabins at a time.

9.
Assembly shop contains four lines as: 1. CABIN ASSEMBLY LINE 2. MAIN ASSEMBLY LINE 3. ENGINE ASSEMBLY LINE 4. TRANSMISSION ASSEMBLY LINE

ASSEMBLY SHOP

MAIN FUNCTION OF ASSEMBLY SHOP The main function of assembly shop is to assembling the different types of components/items on the four lines of assembly shop which are stored on their respective positions. 9.1. CABIN ASSEMBLY LINE

Cabin assembly shop has four different stations. It starts from station no. F-1 and ends at station no. F-4. The cabin/cowl is received from the paint shop at station F1. The different types of components which are assembled on the four stations are follows: STATION F-1 Brkt steering Bolts and screws of different parts no. Pedal clutch and pedal brake Tandem master etc. STATION F-2 Wiper motor Water pipe Tool box etc. STATION F-3 This station is divided into two stations which are as: 1. F-3 RIGHT & 2. F-3 LEFT

At both stations the different components are as: F-3 RH STATION Trim top Switch door Vacuum pipe Hose vent right Pipe assembly Handle assist Grill ventilator etc. F-3 LH STATION This station is also called as DASH-BOARD subassembly station. The different components attached are as: 1. Meter set 2. Front wiring 3. Ash tray etc. F-4 STATION This station has two substations which are as 1. F-4 RIGHT & 2. F-4 LEFT The different components attached here are on both are as: F-4 RH STATION Steering shaft RH side door assembly components F-4 LH STATION LH side door assembly components Front windshield Window glasses Weather strips for front wind shield and for window glasses etc.

9.2. MAIN ASSEMBLY LINE

Main assembly line has ten stations. It starts from station no. F-6 and ends at station F-15. The chassis frame is received from the body shop at station no. F-6. The some major components that are assembled to the chasis at different stations are given as: F-6 STATION Front and rear axles Leaf spring with U-bolts Caster Shekel pins Stopper rubbers F-7 STATION Chassis no. punching Attachment of engine mounting brkt Wiring harness routing Vacuum pipe fitment Radiator stay and rubber holder fitment Fitment of brake pipe, hoss and protector fitment Park brake, Speedo cable fitment F-8 STATION Attachment of bypass filter Starter fitment All bolts and torque marking Fuel filter Checking of any dent on filter F-9 STATION Radiator mtg with cowling Radiator fitment on chassis Cable routing Fuel filter mtg Fuel pipe with hoss Air intake brkt and hoss Battery carrier mounting

F-10 STATION Cabin mounting on chassis Cabin tightness Battery fitment Hand brake adjustment Rubber seal on cabin F-11/F12 STATION Attachment propeller shaft with grease Silencer fitment ok. Air cleaner fitment Fuel tank fitment Connection, electrical, fuel pipe. Head lamp screw fitment F-13 STATION Head lamp fitment Outer mirror fitment Main seat and sub seat attachment Front bumper mounting Jack plate fitment Spare wheel hinge fitment F-14/F-15 STATION Tyre fitment Spare wheel fitment Diesel filling 16lt and capping Mudguard fitment Checking of indicator and head light operation

9.3. ENGINE ASSEMBLY LINE

Engine assembly line has ten stations and one sub assembly station, which is, coded as E-1,E-2,E-3,E-4,E-5,E-6,E-7,E-8,E-9,E-10,E-11etc. The work done and the components assembled at each stations are as: E-1 STATION At this station crank caps are removed from the cylinder block. Then the cylinder is placed on the engine mounting fixture and then the components attached are as: Oil jet mounting Liner fitment Tappets Cam shaft Attachment of crank shaft At this station the ENGINE NO. Also is punched. E-2 STATION Attachment of piston and connecting rod selection is done with depth measuring instrument Locking of pins on both sides of the piston Connecting rod caps cleaning and placement Bearing assembly in connecting rod Checking of crank shaft with piston movement E-3 STATION Crank gear fitment with gear Case timing sub assembly Attachment of mounting block and checking of torque Spindle idle gear checking Oil cooler assy. Fitment on block All gear fitment and timing mark matching E-4 STATION Oil pump fitment Attachment covers timing assy. & torque Water pump gasket assembly

E-5 STATION Attachment of lower pan gasket Flywheel attachment E-6 STATION Attachment of cover assembly and clutch assy. Fitment of crank pulley Fitment of cylinder head bolts E-7 STATION Tighten of cylinder head bolts and torque of rocker arm nut Marking and rotation to 90 degree + 90 degree Assembly of nozzle holder and torque Attachment of return pipes E-8 STATION Sub assembly inlet manifold Assembly of fuel pipe E-9 STATION Attachment of fuel injection assembly Belt fitment Cooler fan Water pump pulley Sub assembly of head cover with sealant E-10 STATION Fitment of exhaust manifold with gasket E-11 STATION This station is also called sub assembly station Sub assembly cylinder head Cylinder head cleaning Valve cleaning Cotter pins and locking Cover timing sub assy. Oil cooler sub assy.

9.4. TRANSMISSION ASSEMBLY LINE

Transmission assembly line has six stations. The details of the parts those are fitted to complete the transmission assembly at different station are given as: T-1 STATION At this station the counter shaft sub assembly and main shaft sub assemblies are done. T-2 STATION & T-3 STATION At these stations the assembly of T-1 station is assembled in the transmission case along with gear main drive, counter shaft and main shaft from a gear system. T-4 STATION At this station case is mounted on a jig, which moves on a pneumatic conveyor T-5 STATION At this station bearing and clutch housing are assembled. After this the transmission is subjected to a leakage test T-6 STATION At this station assembly of brake and brake drum is done. Then it is taken for noise test After engine and transmission test, these are brought to the main line for further assembly operations.

10.

P.D.I SHOP

P.D.I (Pre delivery inspection): In the P.D.I shop the number of tests are carried out on the vehicle, so that is there any fault in vehicle it can be detected and then can be removed. The no. of tests that are carried out in P.D.I station is as follows: 1. BRAKE TESTING 2. SETTING OF TOE AND TURNING ANGLES 3. CHECKING OF R.P.M 4. SHOWER TEST 5. ROAD TEST

11. Company Products Ambulance

Swaraj Mazda Ambulance

Buses
Bus C N G Bus Bus Executive Bus prestige Bus premium

Trucks
Sartaj Sartaj TC Premium Truck Swaraj 4 Wheel Drive Super ZT54 Swaraj Mazda Water Tank Swaraj Mazda Truck Swaraj Mazda T3500 Swaraj Mazda Cosmo Swaraj Mazda Dual Cab Swaraj Mazda Steel High Deck

12. TECHNICAL SPECIFICATIONS OF SML ISUZU T-3500 SERIES

ENGINE Type No. of cylinder Capacity Total oil capacity Coolant capacity CLUTCH Clutch operating method Clutch cover TRANSMISSION No. of gears Oil capacity AXLES Front axle Rear axle Oil capacity STEERING Variable ratio Oil capacity BRAKE Type Parking brake SUSPENSION Front (all models) Rear ELECTRICAL Battery Alternator Stator Wiper motor FUEL TANK Capacity Diesel 4-inline 3455cc 18.5 liters 12.5 liters

Hydraulic Diaphragm type

5 forward & 1 reverse 3.6 liters

Heavy duty forged 1 beam Heavy duty pressured beam with differential carrier 3 liters

Recirculation ball nut 1.25 liters

Hydraulic Hand operated

Single stage leaf spring Double stage leaf spring 12v 12v 12v 180 torques 180 liters for super models