SML-ISUZU Limited

by:Aggyapal Singh

Roll no. ue89002Mechanical 8th Semester

Company’s History1983-92• Started as Swaraj

Vehicles limited in 83.• Mazda came up with

Technical assistance – renamed as “Swaraj Mazda Limited” in 84.

• Started commercial operations, indigenously developed buses and trucks. Worked for defense.

1994-2006• Declared a sick company in 94, developed 4WD

trucks in 96, came out of loss in 98 • Started growing profits, crossed 50K vehicles in

2001, developed CNG vehicles for NCR.• Crossed 86000 vehicles in 2005, applied Bharat-III

norms on Diesel CNG too.• Crossed 1 lakh and joined hands with ISUZU in 2006

2007-11• Started Expansion of plant, Developed LT-134

buses for ISUZU• Came up with Luxury class vehicles in 2008• SUMITOMO corporation took over 53.5 %

company’s share• Renamed as SML-ISUZU Limited in 2011

Sumitomo Corporation, Japan 54.96 %Isuzu 4 %MFNB 9.1 %FII’s 2.67 %Public 25.22 %

SHARE HOLDING PATTERN

Company’s Products

ISUZU trucks SML buses ISUZU

buses

SML trucks

Bus Body Plant (BBP)Some of the products

From “SML” are

Executive, Ultra-Luxury class vehicle

4WD Ambulance for Defense

Standard AmbulanceCardiac-ICU Ambulance

Semi low floor AC-CNG Bus Semi low floor AC School bus

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

ISUZU buses

NQR model – AC model for Local routes

LT-134, Luxury class long route bus

Different Departments in SML-ISUZU Limited

• Personnel department• Research and development Department• Quality Engineering Department• Technology department• Accounts Department• Purchase Department• Maintenance Department

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.

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

Time taken to mark each CUT-OUT = 5 minutes

Number of workers involved =

2 nos.

Marking done using steel ruler and black sketch

Normal Marking Process

Time for marking varies as per worker

Human error intervenes

Total workman hours involved vary affecting the line.

PROBLEMS FACED

Standard Solution was to develop Gauges for marking

Gauge Criterion

As per Dimension

Easy to use and handy Durable

Poke-Yoke

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.

Developed Gauges -

AIR-

CLEA

NER

FLA

P

SPAR

E W

HEE

L FL

AP

SED

IMEN

TARY

TAN

K FL

AP

DIE

SEL

TAN

K FL

AP

CUT-OUTs = 4*4 = 16

W/o Gauge => 5 minutes/CUT OUT

With Gauge => 2 minutes/CUT OUT

OBSERVATION

Results - Without Gauges it took = 16*5 = 80 minutesWith gauges it takes = 16*2 = 32 minutesTime Saved Per Day = 48 minutes/workerWorkman’s minutes saved for company/day = 48*2 = 96 minutes

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 -

Mission:a) To consume the waste generated of Rs.30060

and steps to be taken to control scrap generation by value engineering .

b) To consume the left out inter paneling upholstery length wastes

c) (LZ0257571)–LT(C) model costing Rs.13200/-d) (LZ1157510)–Ex. model costing Rs.11132/-

CASE-1: Aluminium Chequered Sheet

• Present Situation • Suggested Proposal Action:

Present (WASTE)-860 x 810 mm sheet.

Waste Generated

used below

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

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

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

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

* Body welded to Chassis* Plywood flooring and sealing of gaps* Grinding floor for smoothening* PVC carpet pasted on floor using adhesive

* Electrical wiring * Roof covered with roof ply and front dome fixed* LH and RH Ply is fixed* Floor aluminum beading fixed

* Fit window frames* Fit driver’s door, dickey beading & outer lights* Fit inner lights and sun visor assembly* Fit hat racks

* Front and rear windshield* Battery cover, engine hood, RVM, gear lever cover* Dashboard and electrical connections installed

* Fit all seats* Fit grab handles and other accessories* Checkout for the working of electric circuit

AFTER DOCKING, WE HAVE 5 STATIONS

• 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 -

• 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.

• 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.

• 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

• 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.

THANKS !