Table of Contents

1.Executive Summary

Ashok Leyland Ltd.

S.No Topics Page No.

1.0 Executive summary

2.0 Strategic reengineering 61

2.1 Brands 61

2.2 Launches ALERT 67

2.3 Reengineering on process 69

3.0 Conclusion

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Ashok Leyland Ltd is a leading Commercial Vehicles manufacturing industry in

India which produces large 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.

Their Application’s on the engines they do:

Ashok Leyland Ltd.

Genset Application

Engines ranging from 15KVA to 250KVA

> Industrial Segment> Hospitals / Clinics> Commercial /

Residential Complexes

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

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

Ashok Leyland Ltd.

> Hospitals / Clinics> Commercial /

Residential Complexes

> Shopping mall / Offices> Rice Mills> 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 tomorrow’s 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. Cost-

efficient solutions to aspirations of city commuters have been found through many

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

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

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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, turbo-

charged, 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 grade-

ability 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-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 double-acting 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 panic-

braking 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 optimally-

spaced, 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

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applications. Road grip and stability are enhanced by the sturdy frame and non-

reactive 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 fatigue-

free operations. For ride comfort, the cab is fitted with ergonomic steering wheel and

adjustable driver’s 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 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, 6-

cylinder, 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

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 high-capacity,

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 fatigue-

free operations. It is roomy, fitted with a high-capacity steering box, ergonomic

controls and windows that provide excellent all-round visibility.

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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

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 AVIA’s 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.

Ashok Leyland Ltd.

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.

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

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.

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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

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.

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 country’s 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

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manifold and the turbocharger’s 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

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 Group’s Indian flagship and commercial vehicles major Ashok Leyland

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.

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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

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 Government’s 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.

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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 implementation’s 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.

Ashok Leyland Ltd.