Lean Manufacturing

2. INTRODUCTION
About the Company-
• Ashok Leyland is an Indian automobile manufacturing company under the parent
company of Hinduja Group.
• Founded in 1948 and based in Chennai; It is the 2nd largest commercial vehicle
manufacturers in India, 4th largest manufacturer of buses in the world and 16th largest
manufacturer of trucks globally.
• Ashok Leyland operates in automobiles, engines, and commercial vehicles likes buses,
trucks etc. It also makes spare parts and engines for industrial and marine applications. It
is also in partnerships with armed forces for border forces.
• With operations worldwide and six operating plants in India, It is the second largest
commercial vehicle company in India in the medium and heavy commercial.
• With a joint venture with Nissan Motors of Japan the company made its presence in the
Light Commercial Vehicle (LCV) segment.
Company Name- Ashok Leyland
Industry- Auto Manufacturing
Person Interviewed- Umang Srivastava
Designation- Managers Operation, Ashok Leyland, Uttrakhand

3. 1. Online portal for obtaining and sharing information (http://www.ashokleyland.com/)
2. Internal Repository to keep full up to date information about competitors business
strategy and prospects.
3. Pioneer in Technology due to which they are the largest suppliers of defence logistics.
4. Ashley news and Milestone- A news letter for privileged communication with the
employees.
5. They consider their Human capital as knowledge objects and prefer hiring young and
innovative employees.
6. E-Recruitment portal (http://www.ashokleyland.com/life-at-ashokleyland)
** Rest of the Knowledge Objects are mentioned in the Systems Slide
KNOWLEDGE OBJECTS

4. LEAN MANUFACTURING STANDARD
PROCESS
• Lean manufacturing is a manufacturing system and philosophy that was
originally developed by Toyota and is now used by many manufacturers
throughout the world
• Lean Manufacturing is to cut out the "fat" or waste in the manufacturing
process.
• Waste is defined as anything that does not add value to the customer. It
could also be defined as anything the customer is unwilling to pay for.
• They may not call it Lean, the "Eyeglasses in About an Hour" companies
have applied many Lean principles to their operation.
• What used to take weeks is now done in about an hour, adding value to the
customer. It is no surprise that these operations have opened up all over the
country. What was once thought of as impossible speed of delivery is now
commonplace.

5. CONTINUATION OF THE STANDARD
PROCESS
Some of lean manufacturing tactics
• Mistake proofing - “poka-yoke”
• Value stream mapping
• Work place organisation
• Low cost automation
• Multi machine manning
• Sequencing
• Just in time - jit
• Standard operating procedure
• Visual controls
• Single piece flow etc.

6. WHAT THEY DID DIFFERENT- FABRICATED
TEMPLATES
1. There were a few flaws with the original process which Ashok Leyland decided to
change by adding a two half circle C‟ clamp guide at vertical position. Reason of
arranging the two separate clamps is to reduce material cost and also to adopt the
proper balance. So that we locate two C‟ clamp guide on both sides from the center
position of silencers.
2. The problem of steering box drop arm fitting can be avoided by our fabricated
templates. Actually those problems were analyzed with the use of mistake proofing
techniques. These templates will help the operator to fix the drop arm with correct
position of steering gear box.
3. The misaligned fitting can be avoided in such a way that, when placing our fabricated
templates. And also no need to rotate the steering input wheel manually. Instead of
manual setting we insert the template on the steering gear box. It wills seats on the
bolts.
4. After that, we rotate the input shaft and it will go up to centre position. The template
will be stopping the drop arm when reaching centre position.

7. MERITS OF THE CHANGE
• Nobody can assemble the silencer inlet and outlet position incorrectly
• It can be used as a work bench, so it can reduce the human effects and also
reduce the working time.
• This fabricated design did not affect the regular processes and lay out of
industry
• It occupy minimum space in the working area
• Simple in design so fabrication cost is inexpensive
• No need to inspect the inlet and outlet position in pre delivery inspection shops
• It adopts customer’s complaints and also fulfils customer satisfaction.
• Template is to prevent improper alignment of drop arm fixing.
• It makes work easy to assemblers in assembling unit.

8. Organisatio
n
TeamIndividual
SHAR
E
IDENTIF
Y
CREAT
E
COLLEC
T
ADAPTORGANIS
E
APPL
Y
Leadership Technology
Speed
Culture
Ethics
Business
Process
Organisation
Environment
Human Capital
KM PROCESS/FLOW

9. CONFIRMATION MAIL