Chapter-1INTRODUCTIONAshokLeyland,Alwarplant isoneoftheproductionunitsof AshokLeylandltd.Alwar city situated in west north in Rajasthan and is very near to Delhi, the capital ofIndia. Alwar comes inNCRNational Capital Re!ion" alsoit islocatedat #IA#atasya Industrial Area" Alwar. $his plant was esta%lished in &'() and hascompletedhis *+years successfully. $his plant knownfor his productivity. It is%asically an assem%ly plant where the chassis is assem%led.Ashok Leyland, Alwar is world,s lar!est CN-vehicles producin! plant. CN-CompressedNatural -as" isusedasanalternatefuel todiesel andisverylesspollutin!. $hispollutionofCN-vehiclesislessthaneven./R01I2vehicleswhich is known for its lesser pollution valve.$he total covered area of Alwar plant is *3) acres. And fencin! is done around &4&acres of area. $he plant comprises of 3 shops called shop &, shop ), shop 3, shop 5 ,shop &&. $he plant has three !ates one main !ate for enterin! the !oods carries and thethird for the products !oin! out of the plant for sale. $here is an administrative office,one6 7 A department%lock, department 1offices, amedicalcentre, acanteen, anewspaper readin! room and li%rary, a trainin! centre and systems department, R80yard and the construction is !oin! on for new stores. $he over view of Alwar plant is $he plant is inau!urated on )) 1 +( 1 &'(). $he total land area is *3).+' acres. 9enced area is &4&.3) acres.11.1 ASHOK LEYLANDAlwar unit is :th manufacturin! unit of Ashok Leyland, other units are located in;=ANDRAAlwar unit is situated at #atasya Industrial Area. In &':( company %e!inner as Ashokmotors. In&'3)it wasrenamedtoLeylandmotorsandin&'33it wasnamedasAshok Leyland limited.1.2 HISTORY OF ASHOK LEYLAND$heori!inof AshokLeylandcan%etracedtotheur!efor selfench markin! products, processes and people a!ainst %est in the industry. Inprocessin! of this plan everyday all permanent workers, en!ineers, mana!ersmount up on -.#>A floor and discuss their pro%lem and solution with eachother. .very day for their improvement su!!estion every !uy is awarded a num%er ofmarks accordin!their performanceandoffers aperiodthehi!hscorer isnominated and awarded %y mission -.#>A award.Var,*5. a.pe1t. *8 the 6,..,*2 GE#A are9 -&" 8hop floor led team initiative focus on creatin! values throu!h empowerment andimprovin! resource utiliJation.)" Dhenapro%lemarises, !oto-.#>AfirstK checkthe relative o%jects taketemporary counter measure on the spot.9ind the root cause standardiJe to preventrecurrence.6*" 8uccessful -.#>AreAuires a chan!e in perception a culture chan!e fromeveryone in the or!aniJation. .veryone must %e a%le to identify all the different kindof waste and work constantly towards eliminatin! it.:" .mployees have the knowled!e to chan!e the work and make it more efficient asthiscreates!reat satisfaction. Intheinformationa!e-.#>A isanywherewhereprocess are performed and information ori!inates or knowled!e is !ained.3" $akeatripto-.#>Atoday. 0%serveandstudythereal valueworkof the-.#>A it just may chan!e your entire prospective of what you do.'2( E88*rt a2- a3r*2*64 ,2-e: 'EEI( 7e2e8,t.9 8ecurin! )nd position in ..I tracker. .mployee involvement increased from **C to ''.3C. Associates know the %enefits of ..I and they take initiation in learnin! of ..ICalculation. *+C associates are aware of doin! calculations. .ffort reductionindoin!theworkandassociates areworkin!withmoreenjoy.'3( C*.t 6a2a3e6e2t ,2,t,at,+e 'C#I( 7e2e8,t.9 8ecurin! *rd position in C#I tracker , norms validated &++C. 0nline inte!ration and trackin! implemented. A%normal cost in consuma%les consumption completely controlled. *+C tools codes standardiJation for all plants'4( H*5.e Keep,23 '"S(9 -#any people think keepin! should %e done %y house wife at home and cleaners at thework place. $hey do not realiJe that they too play an important role in keepin! theirhousesFworkplaces clean. #ore important, they do not know how much they can !ainthemselves %y just practicin!, !ood housekeepin!.The ;".< Repre.e2t. F,+e !apa2e.e =*r-.9 -7 8.IRI; < $ake out unnecessary items and throw them away. 8.I$I0N;< Arran!enecessaryitemsinaproperordersothat theycan%eeasily picked up for use. 8.I80; < Clean your workplace completely so that there is no dust anywhere. 8.IL.$8/; < #aintenance a hi!h standard of housekeepin! and work placeor!aniJation at all items. 8=I$8/L.; < Mrain people to follow !ood housekeepin! disciplinesindependently.e2e8,t.9 8ecurin! *rd position in 38 tracker across all units. 8crap worth 3 corers sold. 6AR .N.C.LL.N$ ADARD to 38 Auality circle team. Introduction to internal and eGternal si!na!e in the factory. 38 layout preparation , 38 at home '"( I2+e2t*r4 e2e8,t.9- 8ecurin! *rd position in inventory tracker across all units. Reduction of ne!ative DI6 from %aseline of :) lacs to 3 lacs. Reduction I8C# lead time 4: hr to &5 hr in 9e%. )++'. Reduction of a%solute item %y &++C. Reduction of non 1 movin! item %y 3+C.'%( I-e2t,84 Cr,t,1a0 #a1h,2e.9 -e2e8,t.9- 8ecurin! &st position in critical machines tracker across all units. 0.. increased from 5*C to ')C. IndianiJation of improved spares to reduce repair and maintenance cost. 5 point $6# implementation in critical machines. Oero accident achievements in critical machines.'>( ?5a0,t4 e2e8,t.9- 8ecurin! &st position in Auality tracker. 8elf certification increased from 45C to '3C. 6rocess audit and product audit improves up to (5C. D#6 reduced from &(( points to &:: points. $op 3 vender,s issues resolves up to 5:C from previous status.81.>N>I @ #ILESTONE IN ASHOK LEYLAND HISTORYAfterthesuccessfullyimplementationoftheN5i durin!theperiodof April +(1#arch +', the company !ot very amount of followin! tan!i%le profits. C9$ C fitment and connectin!.STAGE 139 - -reasin! of nuts, joints, etc off track arran!ements.1.B =ORKSHO) In Alwar plant the various workshops are;11SHO) 19 - Chassis assem%ly takes place in the line %y old assem%ly method and the6DI pre delivery inspection" is carried.SHO) 29 - Chassis assem%ly takes place on conveyor line which is newly installed inthe plant.SHO) "9 -8tructural mem%ers and panel manufacturin! on conveyor which is newlyinstalled in the plant.SHO) >9 - 6re inspection delivery of chassis takes place in this shop which is newlyinstalled in the plant.SHO) 119 - >us %ody manufacturin! takes place on the conveyor line which is newlyinstalled in the plant. 1.1C LAYOUT $he various parameter of the company are12 SHO)S AREA AND DESCRI)TION 3 8=068 &:+ P &++ 1 &:+++ sA.mt. each 8hop office area )5:.3sA.mt. in each shop. 8hop & 1 Assem%ly activity 8hop ) 1 Chassis assem%ly shop 8hop 3