Table of Contents

S.No 1.0 2.0 2.1 2.2 2.3 3.0

Topics Executive summary Strategic reengineering Brands Launches ALERT Reengineering on process Conclusion

Page No. 61 61 67 69

Ashok Leyland Ltd.

Genset Application Engines ranging from 15KVA to 250KVA

Their Applications on the engines they do:

1.Executive Summary

>Industrial Segment >Hospitals / Clinics >Commercial / Residential Complexes

> Theatres > Shopping mall / Offices > Rice Mills > Hotels / Restaurants

Ashok Leyland Ltd is a leading Commercial Vehicles in large

manufacturing India which

industry produces

number of Chasis, Trucks etc The technical collaboration with Ashley Alteams makes a steady progress in the implementation of the project and will cater to telecom and automotive industry. The stores department maintains large inventory in accordance with FIFO system. The Labour Unions were dominating the Industry which leads to the improper manufacturing of Chasis. To resolve this problem, the company planning to change labour intensive as a Capital Intensive. The company maintains the Quarterly system of accounts, due to this kind of accounting strategy the company can able to find out the financial position of the concern.

Ashok Leyland Ltd.

Industrial Application Engines with power rating from 40PS to 200PS. > Front End Loaders > Excavators > Compactors > Pavers > Road Sweepers > Harvestor Combines > Compressors > Cranes > Pumps

Marine Application Engines with power rating from 58PS to 193PS >Trawlers, Pure -Seiners, Gillnetters >Sailing Vessels >Marine generating sets >Pavers >Speed Boats >Passenger Launches >Ferries >Auxiliary drive in Vessels

DG Sets for exports Diesel and Natural Gas gensets trom 15KVA 250KVA >Industrial Segment > Theatres >Hospitals / Clinics > Shopping mall / Offices >Commercial / Residential > Rice Mills Complexes > Hotels / Restaurants

2.Production Units 2.1 Brands iBUS A feature-filled concept vehicle developed by a team of young engineers, iBUS is envisioned as the intelligent, innovative, Indian shuttle for tomorrows metros.It is Indian in that the iBUS concept has taken on board the Indian operating conditions and economics, climate and the increasing concern for pedestrian safety. Costefficient solutions to aspirations of city commuters have been found through many

Ashok Leyland Ltd.

innovative ideas and technologies. With the induction of electronics in engine management and air suspension to passenger infotainment and fleet management, iBUS has many intelligent features that deliver new levels of safety, comfort and operating economics like the ABS (Anti-lock Braking System) and collision warning systems. An innovative combination of executive class and economy class addresses optimization of capacity utilization. The iBUS has a 635 mm floor with a single step entry and a 1.5 m wide door. There is also a kneel-down provision. In essence, it offers climate-controlled comfort and safety at an economic cost. The executive class has an airline like ambience with wide LCD screens, reading lights, audio speakers and, for the first time, internet on the move. A GPS system enables vehicle tracking and display of dynamic route information on LCD screens which can also support infotainment packages including

3 live data and news. Meanwhile, LCD displays at bus stops keep commuters informed
of bus arrival details. iBUS is powered by eCORE, a 152 kW, BS III compliant, low noise, common rail engine another first in the commercial vehicle industry. Another innovation is the Automated Manual Transmission (AMT), offering the benefits of fully automatic transmission at Indian cost. The indigenously developed body structure absorbs energy during impact and is designed to meet European rollover safety standards, which will be in the Indian Bus Body code (AS-031). 4935 TT (6x4) Tractor Capable of the highest permitted Gross Combination Weight (GCW) of 49 tonnes, 4935 TT (6x4) Tractor is a high power, high performance tractor engineered to pull over-dimensional cargo. The powerful 345 ps Cummins L series, turbocharged, 9-litre engine is high on torque across a wide range of speeds which along with the 16-speed gearbox with servoshift mechanism ensures an exceptional gradeability of 42o. This vehicle offers substantially higher payloads that translate into better revenues. The indigenously designed NEWGEN cab (with HVAC as option) is roomy, well-ventilated with twin wide berths for the crew. The fully-hydraulic steering wheel, the ergonomically placed instrument panel and adjustable driver seat afford easy access to the driver while the wide windows ensure excellent all-round visibility. The higher grade-ability, the hydraulic actuation of clutch with clutch booster, the 16-

Ashok Leyland Ltd.

speed gearbox with servo mechanism and the easy maneuverability due to lower turning circle diameter all make for fatigue-free, non-stop, round-the-clock operations. The rugged multi-leaf spring suspensions and the telescopic doubleacting shock absorbers serve to reduce the effect of road shocks. Safety is well addressed with the dual line, full air brake with TCV (Trailer Control Valve) for adequate braking while the ABS ensures safety even in panicbraking or on slippery road surfaces. The anti-roll bar in the front suspension and bogie suspension in the rear keep the vehicle stable even on difficult, uneven terrains. The frame side members are of C section, made of high-quality carbon steel for rigidity and high impact strength. The engine meets BSII emission norms, is upgradeable to the more stringent BS III norms. Yet another environment-friendly feature is its asbestos-free clutch. 3135 HD (8x4) Tipper A heavy duty tipper featuring a 345 ps engine (torque : 1450 Nm @ 1500 rpm), an 8-speed gearbox and a climate-controlled NEWGEN cab, 3135 HD Tipper is engineered for 31 tons Gross Vehicle Weight (GVW) in the toughest of operating conditions. The powerful engine, along with the enhanced clutch and the optimallyspaced, heavy-duty 8-speed gearbox, give the vehicle better pulling power and superior acceleration. A higher engine torque and deeper crawler ratio enable easy negotiation of steep gradients, with high 51o gradeability. The fully integral hydraulic power steering for the twin steered front axles gives the vehicle great maneuverability. The anti-roll bar at the front suspension and two inverted spring, bogie rear suspension give it high stability during off-highway, heavy duty applications. Road grip and stability are enhanced by the sturdy frame and nonreactive load equalizing rear suspension. The dual line braking with increased brake sizes, the ABS system and the ASA (Auto Slack Adjuster) ensure uniform braking on slippery and uneven surfaces like that encountered at mining sites. The aerodynamic, tiltable, NEWGEN day cab (with HVAC as option) has been designed for enhanced driver comfort, safety and fatiguefree operations. For ride comfort, the cab is fitted with ergonomic steering wheel and adjustable drivers seat, fully floating cab suspension and short gear shift. High torque, 430 mm diameter clutch and good hub-reduction axle provide greater productivity and reduce maintenance costs. Balanced gearing reduces the torque and stress borne by the axle shaft and differential gearing adds to the long

Ashok Leyland Ltd.

life cycle. For enhanced durability, the 18 cubic meter rock load body is of sandwiched hardwood between Hardox steel sheets to withstand heavy impact loads. It lasts longer and has low maintenance cost. The engine of the 3135 HD meets BSII emission norms and is upgradeable to the more stringent BS III norms. Yet another environment-friendly feature is its asbestos-free clutch. 3121 H (8x2) Multi axle Vehicle Offering the highest rated GVW in a multi axle vehicle, 3121 H (8x2) MAV features the H series engine, 6-speed gearbox and climate-controlled NEWGEN cab. The 3121 H (8x2) MAV is powered by a 205 ps indigenously developed, 6cylinder, turbo-charged, inter-cooled, BSII-compliant engine from the H-series that has already made a name for itself for its fuel efficiency and reliability. The 6-speed

5 ZF 6S 850 synchromesh gearboxes with a high torque rating facilitate swift pick up
and effortless climb on gradients. Thanks to these superior aggregates, the 3121 H (8x2) is able to deliver with speed and fuel efficiency, over 25% extra rated payload than MAVs currently in the market. The twin steered axles at the front give the vehicle greater drivability and even distribution of load as it negotiates difficult terrains. Safety is addressed also through a greater braking area with dual line air brakes the largest in its category for efficient braking in all conditions. The 3121 H (8x2) is fitted with a highcapacity, hydraulic steering pump, non-reactive suspension in the rear and a 380 mm diameter RDC clutch for fatigue-free driving. The indigenously developed NEWGEN cab enhances driver comfort for fatiguefree operations. It is roomy, fitted with a high-capacity steering box, ergonomic controls and windows that provide excellent all-round visibility. The strengthened cylindrical block, the bigger crankshaft and bigger connecting rod provide for higher firing pressure that increases engine durability. The heavy duty propeller shaft with high torque rating has a serrated flange for reliability, durability and lower maintenance cost. The 3121 H (8x2) is tailor-made for applications such as cement, coal, iron ore, tankers (petroleum, bitumen, chemicals), bulkers, parcel and market load. Pioneers in multi axle vehicles, the Company expects this model to define and create a new market segment within MAVs. AVIA D120

Ashok Leyland Ltd.

The D120, which premiered at the Birmingham Motor Show last spring, is a significant addition to the D Line range of trucks from the Prague headquartered AVIA ASHOK LEYLAND MOTORS. The D Line comes in a range of models to fit every fleet plan. The traditional models D60, D75, D80 and D90 start from 5.99 tonnes. The new additions to AVIAs line-up are the D100, D110 and D120 models, offering gross vehicle weights of 9.99 tonnes, 10.99 tonnes and 11.99 tonnes respectively. The stylish, aerodynamic form of the AVIA trucks set them apart from other European trucks - AVIA is the truck with an original, unforgettable face. Design work carried out by the European styling house I.D.E.A and Hawtal Whiting in the UK has produced a truck with clean professional modern lines. The body is compact enough to zip through narrow city streets and tight spaces. The built-in corner spoilers (with an optional air management kit) help keep the side windows clean for excellent visibility, whilst the purposeful lights and repeater indicators ensure maximum safety. The practical low cab-step and floor height make entry and exit easier and safer. AVIA is easy to drive. From the stylish line of the dashboard to its perfect ergonomics, this truck is about comfort and convenience. The cab is packed with comfort features such as air-conditioning (optional), electric windows, a pre-radio installation, adjustable steering wheel, numerous compartments, reading lamps, cup holders and even a coat hook. Add to it all the air suspended seat for extra comfort during long journeys and handy details like a low entrance step and grab handle for easier entry. The cab is also equipped with an air filter, which purifies air entering the cab. Both the cab and chassis designs meet and exceed the most stringent of European legislation. The cab suspension system features high-tech, coil springs with shock absorbers at the rear and generous rubber bushes at the front for maximum comfort. The chassis and suspension are widely praised by drivers for providing a stable ride with good handling characteristics. The D120 comes equipped with an Albion front axle that allows tighter turning circles. Full air ventilated disc brakes, front and rear, brings control whilst the wider profile springs deliver enhanced vehicle stability. The Cummins ISBe4 common-rail diesel features an increased bore and stroke to give a total capacity of 4500 cc. Owners can choose the economical 160 hp (118 kW) or the potent 185 hp (136 kW) engine. The engines roll out 600 Nm and 700 Nm of torque respectively over a wide engine speed range between 1200 and 1700 rev/min.

Ashok Leyland Ltd.

The eco-friendly engine incorporates the Selective Catalytic Reduction (SCR) system, considered the most fuel efficient solution at EURO 4+, while also providing the natural platform for EURO 5 conversion. Besides reducing harmful exhaust emissions, the SCR system, involving injection of AdBlue liquid into the catalytic converter housed within the silencer, reduces fuel consumption by upto 7%. Sensors in the catalyst send feedback signals to dosing pump through the engine ECU to meticulously control AdBlue injection. On reduction in the level of AdBlue, the signal then controls the fuel injection and reduces the power. Combined with aero dynamic form, a six speed ZF gearbox and the extended servicing interval of 50,000 kms between oil changes, the D120 takes fuel efficiency to a new level. 4921 Side Tip Trailer The innovative 4921 Side Tip Trailer is another first from Ashok Leyland. It is a ready-to-use high productivity vehicle with side tipping, offering new levels of 6 flexibility and safety. The 4921 34 cubic meter Side Tip Trailer has a lower centre of gravity owing to a short single-stage tipping cylinder which gives the vehicle greater stability and makes tipping easier. It can be operated even in closed sheds; in construction areas and the side tipping makes for faster turnaround. Its short tipping mechanism reduces tipping time and is low on maintenance cost. 4921 Side Tip Trailer offers the highest payload in tractors and, coupled with lightweight trailers, ensures greater payload, more trips and hence better profits. Powering it is the renowned 205 ps H series engine that is big on power and frugal with fuel, along with a 9-speed ZF gearbox. Drivability of this 49 tonner is enhanced by its efficient power steering and clutch booster while its 9-speed gear box with the crawler gear delivers the traction for steep gradients. The NEWGEN cab, with high structural rigidity, is designed for maximum comfort and safety. It is roomy, well-ventilated, has ergonomically designed seating and controls and its superior bonnet insulation protects the driver from engine heat. A fully floating cab suspension decreases road shocks for the driver. The cab also gives the driver very good all-round visibility especially during tipping. Safety is boosted by an in-built protection valve in the hydraulic system. 4921 Curtain Side Trailer The 4921 Curtain Side Trailer was introduced Ashok Leyland as a international concept for goods transportation in a fully built configuration. The highly durable yet

Ashok Leyland Ltd.

light weight PVC-coated, polyester curtains create more loading area and more payload, which in turn translate into better returns. The 4921 Curtain Side Trailer is ideal for transporting large loads of material that can be lashed into place and do not exert pressure on the walls of the container. The air suspension reduces vibration and other impact on the cargo. While the air-suspended lift axle increases tyre mileage especially on empty return. The 4921 Curtain Side Trailer is powered by the renowned H series engine that is big on power and frugal with fuel. Driving this 49 tonner is effortless because of its efficient power steering and clutch booster while its 9-speed gear box with the crawler gear enhances gradeability. The NEWGEN cab, with high structural rigidity, is designed for maximum comfort and safety. It is roomy, well-ventilated, has ergonomically designed seating and controls and its superior bonnet insulation protects the driver from engine heat. 7 A fully floating cab suspension decreases road shocks for the driver. Integrated twin line air braking systems with high capacity brakes ensure safety. The product addresses the emerging market need for closed cargo movement without compromising the rated payload capacity. MPFI CNG Engine Ashok Leyland has developed the countrys first one-litre-per-cylinder 6 cylinder CNG engine for buses employing Multi Point Fuel Injection (MPFI). The W06DTI H Series CNG engine combines superior power rating (135 kW @ 2400 rpm) with low emissions. This 5.7-litre turbocharged inter-cooled natural gas engine meets Euro IV emission standards ahead of the mandate in India. The high power CNG engine uses stoichiometric combustion technology (chemically correct air-fuel ratio) in combination with three-way catalytic converter to reduce the emissions to the lowest level possible. The Multi Point Fuel Injection system delivers the required gas quantity at the intake manifold, as per the vehicle demand even in transient operating conditions. The Exhaust Gas Re-circulation (EGR) used in this engine not only lowers the NOx emission but also restricts the thermal load on the engine components. The quantity of EGR is controlled by the difference in pressures between exhaust manifold and the turbochargers compressor inlet. The waste gate turbocharger is optimized for max torque. The high performance CNG engine features electronics provided by a new state-of-the-art Electronic Control Unit (ECU) that controls the sequential gas

Ashok Leyland Ltd.

injection and high-energy ignition systems. The plug-on coils used in the engine, along with long life spark plug, makes for maintenance-free operation of the vehicle. Designed and optimized for high power and torque output with low fuel consumption and emission levels, the engine offers better fuel efficiency compared to any engine of its class and is expected to provide value to the customer with low life cycle costs. The launch of this engine marks the entry into the more challenging phase of transient cycles mandated in the Euro IV norms of the future. 2.2 Launches ALERT - A comprehensive Telematics solution for the Indian CV market Hinduja Groups Indian flagship and commercial vehicles major Ashok Leyland 8 has launched ALERT, a GPS-based bundle of Telematics services for the commercial vehicle sector. ALERT introduces the latest in Telematics technologies specially designed for Indian environmental conditions, through tie-ups with international technology leaders and vigorous in-house R&D in the last few years. They start with the two services offered are vehicle tracking and passenger information system. By offering real time information on the vehicles, the fleet tracking and management services enhances fleet productivity, security and control. The passenger information services are a boon to commuters, offering real time information on bus arrival timings at bus stops. A pilot deployment covering 105 vehicles has been successfully functioning in Chennai since September 2007. The two services will benefit fleet owners, corporate end users, public utility services and passenger bus corporations and operators. ALERT is a brand-neutral, technology-driven solution that improves viability of the transportation industry through state-of-the-art, innovative, user-friendly and cost effective services, said Mr. Vinod Dasari, COO, Ashok Leyland. ALERT Telematics employs an On Board Unit (OBU) which is installed in the vehicle cabin. The unit can compute the location, speed, direction of its travel with date and time stamp, on a second-to-second basis. These computed information is stored in a memory and is transmitted to the ALERT-owned data centre on prefixed time period or on demand of the customer. The transmission happens on GPRS communication network. Multiple applications and database are hosted in the ALERT data centre which processes data to user-friendly reports as maps, text and proactive Alerts. The

Ashok Leyland Ltd.

customers can access ALERT services on internet connected computer, mobile phone or can call up ALERT customer helpline. Reliable information means control over mobile assets and a competitive edge, for example, the confidence to do advance booking of return loads, reducing idle time, elucidated Mr. Dasari. ALERT would introduce in a phased manner other applications like online advice to drivers on correct gear shifts, fuel pilferage monitoring, online diagnostics and prognostics, route optimization, telemetry and infotainment services.

Strategy used in first quarter of 2009-10

There is one important aspect that I would like to dwell upon. You would have noticed that our sales numbers for the first quarter of 2009-10 has been lower than normal, even considering the continued sluggishness of the commercial vehicle market. This is because your Company decided on clearing the pipeline of stock lying with dealers. We have since adopted the cash and carry system, which has most importantly released cash for the Company. Further, by being market leaders in the bus segment, we can look forward to a fair share of orders for over 15,000 buses under the Governments Jawaharlal Nehru National Urban Renewal Mission. In addition, the order for ultra-modern low-end buses that we have bagged from the Delhi Transport Corporation is under execution. The Company has forged strategic partnerships with a host of Public Sector Banks thereby creating an interface between these banks and the end customers and dealers, to facilitate cost effective funding of our vehicles. Another significant step being taken in the area of dealer financing is the launch of a financing company named Hinduja Leyland Finance with an initial capital of Rs. 100 Crores. Vehicle finance is a crucial component in closing a sale. I have no doubt that this move will pay rich dividends for your Company in the years to come. 2.3 Reengineering on process From labour intensive to the Capital Intensive To improve the production of the chasis the company has planned to give layoff to the labour so that they can destroy the Unions in the company. For this process the machineries were imported from Germany with high power and new technology processing.

Ashok Leyland Ltd.

The Company has already imported 2 robots in Ennore Unit. And still now only one Robo is in Process a single Robo can process 40 man power works at a time.

3.0

Conclusion Thus the project states the implementations of the company in regard with

the producing items of Ashok Leyland Ltd. This project helped us to know about the companies strategies and the policies they used for.

10

Ashok Leyland Ltd.