Industrial Visit in SML Isuzu, Roopnagar: (Assistant Professor)

INDUSTRIAL VISIT
in
SML ISUZU, ROOPNAGAR
Dr. Ajay Singh Verma

(Assistant Professor)
P&IED
Production & Industrial Engineering Department

Punjab Engineering College, Chandigarh
SML ISUZU
SML ISUZU LIMITED (SMLI) was incorporated in July 1983 as Swaraj Vehicles Limited to
manufacture Light Commercial Vehicles (LCV) in the state of Punjab. It was the result of
Government of India initiatives for installing the LCV unit in order to save the fuel
consumption in the economy. The best way to address growth opportunities, harness
and open up new markets was through leadership in product technology. The search for
technology brought the company face to face with Peugeot and renault of France,
Volkswagen and Man of West Germany, Leyland of U.K., TAM of Yugoslavia and Isuju
Duihatsu and Mazda of Japan, while evaluating the relevant technologies of these
countries, the criteria that the Management had kept before itself was to select a
vehicle powered by a four cylinder diesel engine, capable of providing maximum pay-
load capacity best suited for local conditions and fuel efficient thus ensuring best value
for money to the Indian consumer. It was this approach that led the company to Tokyo
Kogyo Company Limited (known as Mazda Motor Corporation) the well know Japanese
manufacturers of the internationally known as Mazda Automobiles and LCVs.
Subsequently, the Company was renamed as Swaraj Mazda Limited.
SML ISUZU PRODUCTS
SML Isuzu has a wide range of products. The products include trucks, buses
and special purpose vehicles like ambulances, tipper, recovery van etc.
SMLI is the first company to manufacture and supply state of art fully builds
buses, ambulances and customized vehicles. It has 33 years of experience
in producing light and medium commercial vehicles to meet Indian
customer needs
SML ISUZU BUSES
SML ISUZU TRUCKS
SML ISUZU SPECIAL PURPOSE
VEHICLES
SML ISUZU GS TRUCKS
Major Departments
Major Departments There are 5 major departments in SML ISUZU. All these departments work
together to run the plant at its full efficiency. The role of these departments is explained as
follows:
I. Research and Development Department. The main aim of this department is to build
products based on market research.. In SML Isuzu the adoption of new relative motion
conveyor belt is the function of R&D. Because of this technology the worker can work
with ease as he will move with the assembly itself.
II. Quality Engineering Department. This department carry outs different quality checks in
order to maintain the quality of the products. Quality checks are done at the end of
assembly as well as in between the process. In SML Isuzu the brake oil leakage test is
done during the assembly, while the testing of engine is done after the 100% assembly of
the engine.
III. Purchase and Store Department. This department is responsible for the purchase of sub-
assemblies from different vendors. In SML Isuzu all the components are imported from
outside the plant. Purchase and store department plays a vital role in keeping the
inventory in stock in the plant.
IV. Maintenance Department. The main aim of this department is to carry out maintenance
work in case of failure. This department is also responsible for scheduled maintenance
operations. Maintenance department ensures that the defect is detected before any
major breakdown occurs.
V. Technology Department. The main aim of this department is to assist the production line
if any problem occurs.
Chassis Plant
In the chassis plant all the imported parts are
joined together to form an automobile.
Almost 80 vehicles are manufactured in an
eight hour shift. In the chassis plant various
components of automobile are assembles
together. The Chassis plant consists of:
1. Engine Shop.
2. Transmission Shop.
3. Axle Shop.
4. Chassis Assembly Shop.
5. Global Series Trucks Assembly Shop.
6. Paint Shop.
FLOW CHART OF CHASSIS PLANT
ENGINE SHOP
In the engine shop various imported components are
assembled together. Various BS-4 engines are assembled
in the shop. Both CNG and gasoline engines are assembles
in the plant. The current assembly process in the shop is
manual assembly. There are 17 sections in the engine
assembly shop. At every stage parts are checked for their
proper movements. The step wise assembly process is as
follows:
1. Engine blocks are cleaned and serial number is
punched on the engine block.
2. Liners and oil jets are attached to the engine block.
3. In the next stage camshaft is mounted on the engine
block.
4. Next thrust plate and crankshaft bearing is assembled.
5. Now piston assembly is mounted on the engine block.
6. After this remaining parts of the engine are joined.
ENGINE TESTING LABS
Hot bed engine testing laboratory. In this laboratory the
fully assembled engines are tested for the following:
1. Filling of engine oil.
2. Any leakage in the engine.
3. Abnormal noise and vibrations iv. Oil pressure at high
RPM.
All these tests take about 10 minutes.
Engine performance testing laboratory. In this laboratory
10% of the assembled engines are tested for the
following:
1. Power.
2. Torque.
3. Specific fuel consumption.
4. Smoke.
The test takes about 4 hours to give results.
TRANSMISSION SHOP
The function of any transmission is transferring engine power to the driveshaft and rear
wheels. Gears inside the transmission change the vehicle's drive-wheel speed and
torque in relation to engine speed and torque. In this shop various components are
assembled inside the transmission case. Various sub-stations are as follows:
1. Main shaft sub-assembly.
2. Counter shaft sub-assembly.
3. Top cover assembly
AXLE SHOP
In this shop front and rear axles are assembled at different stages. There are two sub
stations in the shop:
Front axle assembly shop. Various parts like leaf spring, wheel mounting, king pin are
assembled on the axle beam. The assembly is done at 7 stages. The process is manual
And the operator of next stage checks for any assembly mistake done at the previous
stage.
Rear axle assembly shop. Various parts like leaf spring, king pin, wheel mounting and
differential box are assembled on the axle beam. The assembly is done at 7 stages. The
process is manual and the operator of next stage checks for any assembly mistake done
at the previous stage
CHASSIS ASSEMBLY SHOP
In this shop various components of vehicle are assembled on the chassis on a
moving conveyor. The company has adopted a new design of conveyor belt in
order to make relative motion between the worker and chassis zero. Most of
the operations in the shop are manual.
1. First the front and rear axles are mounted on the chassis. The chassis is
then lifted to the next level using a electrical motion system to the next
level.
2. In the next stage transmission is mounted on the chassis.
3. After the assembly of the transmission, engine is mounted on the
chassis.
4. iv. Exhaust system is added to the chassis.
5. Brake oil is now added and different tests are performed to check any
sort of leakage in the system. Next intake manifold and other systems
are mounted on the chassis.
6. Then the body is mounted on the chassis. A synchronous system is
used to mount the body on chassis.
7. Then dashboard and electrical systems is mounted on the system.
8. In the next stage seats, front glass shield etc. are joined in the body.
During the operation a check sheet is maintained. The final assembled
body is tested for quality.
GLOBAL SERIES BODY ASSEMBLY SHOP
In this shop the body is joined together using various sheet metal parts. Most
of the operations carried out in this shop are automatic. Doors and outer body
panel is joined using hemming process. Hemming process is fully automated
process. The inner and outer panel are joined using a robot while a fixture
holds the assmebly. The robots are of Fanuc company. The robot holds the
inner and outer panel of the door while they are glued together. For the
joining of the body spot welding is used. The spot welding is done both
manually as well as automatically. In the automated spot welding four robots
with C-guns of Fanuc company are used. All the 4 robots handle the different
region of the body. All four robots are synchronised together to perform the
operation efficiently.
PAINT SHOP
In the paint shop of SML Isuzu, painting is done at various stages. Painting is done both by
spraying and dipping the body. The various steps in painting of SML Isuzu truck are:
1. First the body is dip into hot water at around 55 degree Celsius at an angle of 17
degrees to remove any sort of unwanted dust and dirt. Heat exchangers are used to
heat water for the process. Pumps are used to lift water to the required height.
2. Now degreasing is done using diluted sulphuric acid (10%) to prepare the surface for
painting. Immersion type degreasing is used in SML Isuzu.
3. Next, the body is dipped in the phosphate tank. The phosphate tank contains
phosphate salts and is used to treat steel. The reaction makes for a rough layer of
small crystals to form on the metal. These crystals will form a sort of 'magnetic' layer
that the paint will stick to well and evenly. The phosphate layer also has excellent anti-
corrosion properties.
4. Phosphates are applied by dipping the body into the tank.
5. After this stage primer is applied to the body by dipping it in the primer solution at an
angle of 17 degrees.
LEAN MANUFACTURING
Lean Manufacturing is essentially a continuous or
repetitive improvement system, whereby one
continuously improves, or tries to improve, ways of doing
a particular task or job. It is a system of continuous
improvements in quality, processes, technology,
productivity, safety, company culture, work force
attributes and attitudes, as well as leadership. Lean
Manufacturing, as a system, was developed in Japan after
World War II, and is now used all over the world.
The basis of Lean involves making every area of your
business better by continuously striving to do things more
efficiently and without defect.
Several basic tenants of Lean Manufacturing:
1. 5 S.
2. Kaizen.
3. Six Sigma.
4. Zero Defects.
BENEFITS OF LEAN MANUFACTURING IN SML
ISUZU
1. In SML ISUZU the following are the benefits gained by adapting 5S
Over time, the 5S methodology leads to many benefits, including:
I. Reduced costs.
II. Higher quality.
III. Increased productivity.
IV. Greater employee satisfaction.
V. A safer work environment.
2. SML ISUZU follows zero defect policy. The scrap is kept on the floor near the assembly
line that reminds the workers to worK efficiently without creating scrap because it
adds to the manufacturing cost and increases the production cycle time.

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INDUSTRIAL VISIT

Dr. Ajay Singh Verma

Production & Industrial Engineering Department

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