Acknowledgement

Above all, I would bow my head in sincere gratitude and sense of pleasure in front of the
Almighty, for helping me achieve all that I could.

I am highly indebted to SML’s staff for their guidance and constant supervision as well as for
providing necessary information regarding the project & also for their support in completing the
projects.

These projects would not have been possible without the kind support and help of many
individuals and organizations. I would like to extend my sincere thanks to all of them.

I wish to express my deep sense of gratitude to my Industry Guide, Mr. Abhishek Puri,
Technology Department, SML-ISUZU Ltd. and my Institute’s teachers for their able guidance
and useful suggestions, which helped me in completing the project work, in time.

I would like to express my heartfelt thanks to my beloved parents for their blessings and constant
support during the project. My friends/classmates have been very helpful and cooperative and I
would like to take this opportunity to extend my thanks to each one of them.

Aggyapal Singh
Summary
Various Departments of Bus Body Plant –

1) Personnel Department
2) Research and Development
3) Quality Engineering Department
4) Technology Department
5) Accounts Department
6) Purchase Department
7) Maintenance Department
My Department
I was appointed a trainee in Technology Department, under the guidance of Mr. Balbir Singh
(Head of Department, Technology) and Mr. Abhishek Puri (Senior-Engineer). The Department is
further divided into three sub-departments –

 Industrial Engineering
 Production Engineering
 Tool Design

The Main Purpose of Technology department is to assist the Production Line in any Kind of
problem Being Faced by it; the other departments ask Technology Department For any kind of
Fabrication to be done for assisting the line, which may be Gauges for Production line, Material
handling Racks for assembly line etc.

During my training period, i was initially asked to study the Zhong-tong model’s structure, shell
and assembly line, which later on let me work on two projects related to shell line and assembly
line, one each.

On Shell line of ZT model, my project was to develop gauges meant for marking the cut-outs for
diesel tank, sedimentary tank, air-cleaner and spare wheel flaps. This was my project as an
individual.

2
On assembly line, I worked as a trainee with a team from Technology department, including
Mr.Abhishek Puri, my industry coordinator. Its purpose was to consume the wastages of
Aluminium Chequered Sheet & upholstery and take steps to optimize the raw material/waste
consumption on Assembly line.

Introduction

Company History –
History of the SML ISUZU LIMITED (Light Commercial Vehicle) dates back to as in 1975
when the first efforts were initiated by the Punjab State Industrial Development Corporation
Limited (PSIDC) to obtain a letter of intent from the Government of India. The Govt. of India
was interested in installing the unit and issuing the license for an LCV in order to save the fuel
consumption in the economy. Therefore Govt. decided to installed indo-Jap LCV units in 3 states
Punjab, U.P. & M.P.

• Started as Swaraj Vehicles limited in 1983.

• Mazda came up with Technical assistance – renamed as “Swaraj Mazda Limited” in
1984.
• Started commercial operations, indigenously developed buses and trucks. Worked for
defense.
• Was Declared a sick company in 1994, developed 4WD trucks in 1996, came out of loss
in 1998
• 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
• 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

3
Share holding pattern –
Sumitomo Corporation, JAPAN – 54.96 %
Isuzu –4%
MFNB – 9.1 %
FII’s – 2.67 %
Public – 25.22 %

Chart – 1 (PIE) Share Holding Pattern

Company’s products –
From bus body plant (BBP), we get the following products:

 Four wheel drive Ambulance (SML)

 Cardiac-ICU Ambulance (SML)
 CNG School bus (SML)
 Executive bus (SML)
 NQR bus (ISUZU)
 LT – 134 Luxury bus (ISUZU)
 Zhong-Tong School bus (SML)
 Semi – low floor AC CNG bus (SML)
 Standard Ambulance (SML)
 Standard bus (SML)

4
Organizational Setup Flowchart –

Managing Director

Executive Director

Vice-President Associate
Vice-President

General Manager
Deputy General
Manager

Senior-Manager Chief-Manager
Manager

Assistant
manager

Engineer Senior
Engineer

Junior Assistant
Engineer Engineer

Flow Chart – 1 Organizational Setup

5
Project 1

Developing Gauges –

As a trainee in “Technology Department” of Bus-Body plant, I worked on a project of

developing “cut-out marking gauges” for Zhong-Tong school bus model. It’s a Chinese design.
The project was assigned to the Technology Dept. by Production dept.

Normal Process of marking –

 The time taken to mark the cut-outs for air cleaner, spare wheel, diesel and sedimentary
tank flaps took 5 minutes on an average to mark each cut-out.
 Number of workers required – 2.
 Dimensioning done by workers using standard measuring tape and marker.

Problem faced –

 Time taken to mark the cut-outs was varying from worker to worker, affecting the shell
line.
 Human error intervened every time the marking is done as the worker depends on his
skill of marking.
 Total work hours required for marking and correction were more than expected.

Target –

To develop marking gauges for Air-cleaner, spare wheel, diesel and sedimentary tank flap cut-
outs. The gauges are meant to mark shapes which later can be cut out by using Plasma cutter
from sheet metal sides of the bus, before it proceeds into the paint shop. The gauges were
developed for four different flaps, namely:

 Air cleaner flap (LHS)

 Spare wheel flap (LHS)
 Diesel tank flap (RHS)
 Sedimentary flap (RHS)

6
The gauges were to be developed considering following four criterions:

 Gauge should be as per required dimensions ( It should mark the cut-outs as per the
dimensions given in drawing provided by R&D department )
 Poke-yoke (As per this criteria, the gauges should be fabricated in such a way that
they cannot be mistakenly used in each other’s place i.e. one gauge should fix on its
own place and not anywhere else).
 Gauge should be handy and easy to use and no-extra labor should be required and
should consume very less time of the worker.
 Gauge should be of sufficient durability, could be used for long time without any
problem and without any defects.

Results –

Assuming 4 shells of ZT model being produced daily.

Each bus has a total of 4 cut-outs, so for 4 bus shells there are a total of 16(4*4) cut-outs.

Earlier, it took a total of 16*5= 80 minutes for marking the cut-outs.

Using the gauges, it took a total of 16*2= 32 minutes for marking the cut-outs.

Conclusion –

A total of 80-32=52 minutes saved for 2 workers per day i.e. 52*2=104 workman minutes saved
in a day.

The gauges after fabrication are tested by Quality Dept. of BBP (Bus-Body Plant) on the basis of
above mentioned criterions and then after that are handed over to Production Dept. for use on
structure line.

The Drawing mentioning the required dimensions is provided by the Research and development
(R & D) department of BBP. It is as shown on the next page.

7
Drawing 1

8
For developing a marking gauge, 2 things were to be developed –

 Design was to be such that it can hold the gauge on to the surface of bus firmly.
 Design was to be made such that it can hold a rectangular sheet of metal of sufficient
dimension, from which the cut out can be cut.

When the cut-out was cut from the rectangular sheet, placing the gauge on to surface of bus,
using the holding mechanism, marking can be done.

Following picture show the sedimentary and diesel tank flap gauges -

Picture 1 & 2
U-shaped cup of 100 These Horizontal
These rectangular
mm. height, meant to bends, are meant
sheets are meant to
hold the vertical tube of to restrict the
be used as marking
40 mm. width, its main vertical movement
region for flaps, we
purpose is to restrict of the gauge,
can cut rectangular
horizontal movement of these settle on
sheet of the same
the gauge and thus the horizontal side
dimension as of the
horizontal dimensions beams of the shell
flap, then keeping the
can be finalized as per and thus vertical
gauge on surface of
vertical pillar of the dimensions can be
bus, marking the
shell, whose dimensions marked as per the
inside boundary of left
are constrained as per side beams, which
out rectangle will give
design. are constrained as
us the flap marking on
per shell design.
surface.

9
Below picture shows the SPARE WHEEL FLAP cut-out marking gauge and its usage

Picture 3
The shown rectangular
shape is the one whose
The shown two bends on left and right are
inside boundary when
meant to restrict the movement of gauge
drawn on the flat panel
in vertical and horizontal dimensions
of ZT bus using a
respectively. They hold on to such physical
marker, gives us the
structures whose dimensions are already
exact dimensions of
constrained as per shell design, there
spare wheel cut-out.
actual way of working is as shown in
following pics.

Picture 4. This is how it holds on to a vertical pillar with fixed constraints restricting the
movement of gauge in horizontal direction, the bend is caused by using a hydraulic press.

10
Picture 5. In a similar fashion as above, it holds on to the lowest horizontal railing and restricts
the vertical movement of the gauge, the horizontal railing is constrained as per design.

Picture 6. After restricting the movement of gauge, the inside boundary of rectangular cut-out is
marked in order to get the dimensions of spare wheel flap.

11
AIR CLEANER flap is cut in a similar way, a gauge using bends to restrict its horizontal and
vertical movement and a rectangular cut-out of the same dimension is used as shown.

This bend holds on to

The rectangular cut-
a vertical pillar of
out, whose internal
body, which in turn
boundary is used to
has fixed constraints
mark the AIR CLEANER
and thus restricts the
flap on ZT bus Flat
horizontal movement
sheet panel
of the gauge.

Picture 7
The bend which holds on to a horizontal railing of ZT bus,
which has its movement constrained thus further restricting
the movement of gauge in vertical direction.

Picture 8. As is shown in the above pic, the gauge holds on to the bus body firmly and the worker
can mark the flap using a marker.

12
 Horizontal
Vertical
constraint,
constraint,
holding
holding
purpose
purpose

Rectangular
sheet, which
will be used
for marking
purpose

Picture 9.This is how it looks when the gauge hangs from the bus surface.

Picture 10. Diesel and sedimentary tank gauges with marking regions on rectangular sheet. The
marking region is cut out using nibbling machine.

13
 Picture 11. Cut-out region, which is to be used for marking.

Before proceeding any further, all the dimensions are re-checked in order to confirm there is no
error present due to the fabrication defects. If the gauge is as per dimensions, it is checked for its
strength and that will it continue to provide correct dimensions with time.

For providing extra strength, we re-enforce the GI sheets with rectangular cross-section tubes
and paste the tubes on GI sheets using Sikaflex sealant.

For using a Sikaflex sealant to join two metal surface –

 Firstly, the surfaces are smoothened up using grinder.

 Oiliness of the surface is cleaned up.
 Primer is applied on the surface of both materials in order to protect the surface from
rust.
 After this, a layer of Sikaflex is applied between the layers of metals and left for
settling for a day.

14
 Picture 12. Sealant applied on colored primer to join GI metal.

After the sealant settles down, the gauges are painted orange as per company’s rules.

Picture 13.self –inspection.

15
Final testing of the gauge –

Picture 14 & 15. Inspectors inspection.

After the quality department approves of the gauge, it is handed over to production department
for use on shell production line.

The Other Project I was assigned at Zhong-Tong Line was to study the Line Vise Processes on
Assembly line. It’s been detailed on from Next page.

16
Processes on assembly line of “Zhong-tong” School bus

After completion of 1st project, the assembly line of ZT model was studied, which later on gives
us our 2nd project, but 1st we discuss the assembly line.

Station – 1

Spray adhesive on
Inspect the above
Docking floor & paste the
activities
carpet

Seal the gaps by

If found defects,
sealant application
Station 1 repeat the requisite
.Grind the floor
process
area

Place cut to size

Paste floor tape on
plywoods on floor
the shell floor Station 2
adjust & minimize
members
gaps,screw it

Flowchart 2. Station 1 Processes of assembly line.

Docking –

Moving out the bus body from paint shop and carefully placing it over chassis coming from
Chassis plant of SML-ISUZU Limited. Moving the bus to Zhong-Tong assembly line, the bus is
driven very slowly as till now the body is not attached to the chassis but simply placed on it.

Welding body with chassis –

 There are multiple welding joints for joining bus body with chassis.
 The two long beams of chassis extending from front to back of bus are crossed over by
horizontal beams in perpendicular direction.

17
 The bus’s body is joined to the chassis by welding at 18 points (2 across each cross tube,
making it a total of 9 tubes).
 The bus’s shell contains rectangular tubes which fit directly over these 9 tubes. These
rectangular tubes are of cross-section 40*40.
 Firstly, tap welding is done using “MIG welding” just to ensure proper fitting of the shell on
chassis, starting from back. For proper fitting, U-shaped cross-section lengths are inserted
vertically between chassis and bus’s vertical shell tubes to fill in the gap.
 After proper fitting is achieved, the welding joints are re-welded properly and completely
using MIG welding.
 The two beams of chassis are also welded to the body at the rear end.
 The front of chassis is welded to the body at 3 joints.

Picture 16 & 17. Joints before welding , following pics will show the joints after welding

Picture 18 & 19. Welding of body with Right and left beam of chassis, as seen from front of
body.

18
Picture 20. The above piece of rectangular tube measures 20*20*100 (mm.) and joins cabin with
chassis.

Chassis The GI part used to fill in the

gap between body and chassis

Bus body

Picture 21. Welding of beam and body’s vertical pillars.

The control parameters in welding are :

 Current – 90A to 120A

 Voltage – 20V to 24V
 Wire size 0.8 mm
 Gap between welding joints should not exceed 1.5 mm
 Apply anti-corrosive primer on welded joints

These paramaters vary as per material to be welded and also the style of welder too.

19
Joining FES area of body with chassis (driver’s cabin)

It is done by welding 10 rectangular hollow tubes of following dimensions :

1. 40X20X108
2. 40X20X108
3. 40X20X115
4. 40X40X242
5. 40X40X242
6. 40X40X240
7. 40X20X108
8. 40X20X90
9. 40X20X85
10. 40X20X85

The cross-sections remain fixed but the length varies as per each bus’s own tolerance region,
these tubes are cut on the basis of measurements a worker takes by measuring tape.

Picture 22,23,24. Welding of driver’s cabin with chassis

Welding FES (Front Engine Space) panels :

After the welding of body and chassis, GI(Galvanised Iron) sheet panels of FES are welded using
MIG(Metal Inert Gas) welding, the different thickness and different shaped panels are generated

20
from GI sheets, which are cut using Hydraulic or mechanical presses, Knibbling machines and
Plasma cutting. The welding spots are then grounded to smoothness.

Picture 25 to 30. GI sheet panels of driver’s cabin

Flooring (Fixing Floor panels) :

Plywood panels (12 mm) are fixed on shell tube floor using self tapping screws. It is followed by
grinding of screw tops in order to smoothen up the floor surface, so that when Flooring carpet is
fixed to it the protrusions don’t interrupt.

21
 Picture 31 & 32. The wooden floor (Ply fixed to shell).

Floor Matting –

After the covering of sides and roof, the floor ply sheets are covered with resin mat (pale grey)
using “fevicol” resin adhesive, the adhesive is applied to both the mat and floor using an air-
pressure spray gun, which spreads a minute layer of adhesive on both the materials. The mats are
pulled forcefully on to the ply so that while they settle on the floor, there are no wrinkles. After
the mats are applied, the floor looks like as shown.

Picture 33. Mat covering on floor.

22
Station – 2

Fit floor aluminium

Inspect The above
Station 1 Sections & curtain
activitie
railing

If found defects,
Fit Side LH & Side RH
Station 2 repeat the requisite
plywood
process

Route electrical
wiring inside the Fit Roof Ply & front
Station 3
shell & fit outer dome
lights

Flowchart – 3. Station 2 Processes on assembly line.

Wiring –

Wiring of body is done in roof, the wiring is for the 3 lights and 3 speekers in the roof, 2 turning
indicators on rear side and 2 turning indicators in front and wiring to controlling console. The
wiring is passed through hollow tubes of roof as shown in picture.

Picture 34 & 35. Wiring through shell.

23
 Picture 36. The above picture shows the three Light – Speaker Electric Points in the bus.

Roof –

The space between the shells tubes of roof are filled with Polystyrene sheets, its helps by
following ways:

 Polystyrene is much light in weight as compared to conventional space-filing material.

 Its sheets can be easily cut and used to fill the roof.
 Polystyrene as a non-conductor doesn’t transfer solar heat into the bus and thus maintaining
passenger’s comfort.
 It makes no unpleasant sound or noise while the bus moves.

Picture 37. Polystyrene sheets used for filling the roof.

24
After this, the inside of the bus body is covered with GI sheets one side of which is beige colored
plastic, the beige side is kept in Visible region and the other side is pasted to roof using screws,
and also it is used to cover the inside left and right hand of bus.The roof above the drivers cabin
is covered with a plastic structure, fixed to shell using self-tapping screws as shown.

Picture 38. Driver’s Dome

The partition of these GI sheets is covered and supported by Rubber cum plastic beading which
is screwed to roof as shown in “1”.

Picture 39. Beading used to cover roof sheet partitions.

25
The shell from inside, below the region of windows is covered with the same PVC covered GI
sheet with which the roof is covered as shown below. The region with red circle is actually the
GI sheet screwed to shell side. After screwing the boundary, extra strength is given by applying
aluminium rivets by riveting cum punch machine

Picture 40 & 41. Side panels of GI sheets riveted to shell.

Station – 3

Inpect all above

Station 2 Fit hatracks
activities

If found defects,
Fit inner lights,
Station 3 repeat the requisite
sunvisor assy
process

Fit driver Door,

dickey rubber
Fit Window frames Station 4
beadings, outer
locks

Flowchart 4. Station 3 processes on assembly line.

26
Installing Glass –

The windows are locked to body by screwing them into verticle columns of bus body. Then
additional strength and sealing of assembly is done by applying “Sikaflex Black-165 sealant”
from outside the bus into the boundaries as shown in pic. Sealant takes one day to settle.

Picture – 42. Sikaflex black sealant

These passengers windows are of 3 different sizes, supplied as per requirement by wendor, fitted
with tough temperlite glass. The height is same but width is 0.9, 1 and 1.2 mtrs.

Picture 43 & 44. Window frames with 0.9 and 1 mtr. Width.

27
 Picture 45. Window frame of 1.2 mtr. Width.

4 other type of glass are to be fitted apart from front and rear wind shield, which are fitted using
“Sikaflex sealant” a layer of which is supplied on both inside and outside bus body as shown
below.The sealant should be left for a day atleast to properly settle. These are as shown.

Picture 46. 1 & 2 type of glass.

Picture 47& 48. 3 & 4 types of glass.

28
Followed by these windows is the fixing of rear and front wind shields with “Sikaflex Sealant”, 2
layers of which are applied on inside and outside. These are left to settle for one or more day.
The process of applying sealant is as discussed below.

Before applying sealant, the nearby region or surface of bus body is covered with covering tapes
as shown in figure, it is done in order to protect the bus body’s paint and the paint to spread over
areas where it shouldn’t be.

Covering of bus surface

by tapes, the central
black line shows the
sikaflex sealant.

Picture 49. Sikaflex applying technique.

Lighting –

The roof is fitted with lighting and speakers with screws, the electric points needed for it have
already been shown, the space provided in roof for these fixings makes it easy to screw them to
the GI sheet. The final look is as shown.

Picture 50. Roof lighting and Speaker System.

29
Interiors –

After the covering of sides, roof and floor, the outlines of sheets are covered with beadings
which may be of rubber, plastic or even aluminum, some places where such beading is done are
as shown below:

Picture 51 to 56. The different beadings used to improve interiors look and give strength.

30
Picture 57 to 60. The different beadings and coverings applied into the bus as interiors

Picture 61. Aluminium beading covering the rear axle hump.

31
The dickey is provided with rubber beadin from inside on boundaries as shown in picture, it
keeps the dickey less noisy as well as acts as a water proof seal.

Picture 62 & 63. Dickey before and after beading.

Picture 64 & 65. Inside rear view mirror and shade providing sheet is installed near driver’s seat.

Picture 66. The driver door is provided with the plastic covering of door and lock system and a
handle to open and close it.

32
 Picture 67 & 68. The driver’s door is installed with a chrome handle and steel foot rest for his
conenience.

Break lights

Number
plate
light

Dickey lock

Hydraulic Tail lights

dickey openers

Picture 69,70,71. The dickey is installed with the wiring of rear lighting and Pneumatic openers.

33
Station – 4

Fit Accessories like

Inpect all above
Station 3 spare tyre, P door
activities
brush etc.

Fit Dashboard, do If found defects, repeat

Station 4
electrical connections the requisite process

Fit transmission
Fit front windshield,
cover,engine hood
rear windshield, Station 5
cover, roof hatch, RVM
battery cover
front grill/bumper

Flowchart 5. Station 4 Processes on assembly line.

The gear lever is now covered with a cover, providing it a good look as well as easy to hold and
use shape. It looks as shown

Picture 72. Gear knob and gear lever covering

34
Dashboard installation –

The dashboard which is made by Fiber re-enforced plastic (FRP) in bus body plant only, it is
firstly covered with black resin, the ready dashboard is fixed in FES region by screwing it to the
shell, the final setting looks like as shown in picture.

Picture 73. Dashboard and wooden instrument cluster installation.

Behind driver’s seat, battery casing along with a fire extinguisher is also setup, the pillar is used
to give support to both the roof and driver’s seat, the front axle is just below the pillar floor.

Battery setup

Picture 74. Battery setup and fire extinguisher.

35
Front bumper –

The front bumper is installed after the wiring for the console is done, it is screwed to the body’s
shell by nuts and bolts.

Front grill installed

separately

Picture 75 & 76. Front bumper and grill.

Side rear view mirrors are installed on both sides -

Picture 77,78,79. Side rear view mirrors installation mechanism and mirror.

Wipers installation –

Before the dashboard is installed, wipers system is to be installed, a geared motor is mounted on
a steel plate, standing vertically on body shell, and the lever system which drives the wipers is as
shown in the following picture.

36
 Picture 80. Wiper driving geared motor

Lever driving
left side
wiper of bus

Picture 81 & 82. The flat plate on which wiper motor is mounted.

Lever that drives

right wiper of bus

Quick return
mechanism

Picture 83. Quick return mechanism of wiper.

37
 Picture 84. After the driving mechanism for the wipers is installed, the wiper blades are fixed
onto it from outside.

Station – 5

Inpect all above

Station 4 PDI ELECTRICAL
activities

If found defects,
Station 5 PDI repeat the
requisite process

Shower testing
Fit All Seats Fit grab handles
region

Flowchart 6. Station 5 Processes on assembly line.

After the covering of sides, floor and roof and interiors done, the seats are installed onto the
floor, using screws, the seating arrangement can be minutely modified as per customer’s
requirement, before fixing the seats, proper marking is done on the floor for drilling screw holes

38
as well to take care of the pitch of seating, that is, the distance between two adjacent seats from
front to back is to remain constant. Conductor side seats are as shown below.

Picture 85.86.87. The side railing on which the seat is supported and floor supoort of seat.

Picture 88. Passenger’s seating area.

 It is a 49 seater bus, but it can be changed upto some extent as per customer.

39
For roof there are two accessories, handle baar railing and cargo keeping rack, they are screwed
to roof as shown in following pics.

Picture 89 & 90. Handle baar railing and cargo rack (I & II)

Stairs support –

A railing is provided near the stairs of bus in order to support the body while entering or leaving
the bus. It looks as shown in following pic.

Picture 91. Stairs support railing.

40
Driver’s cabin accessories –

Seat belts for both conductor and driver’s seat.

Picture 92. Seat belt lock.

Grab handles for sitting in conductor’s and driver’s seat. These are screwed on front pillars of
bus shell as shown in pic.

Picture 93 & 94. Grab handles in drivers cabin.

41
Emergency glass breaking hammer, provided near the rear wind shield of the bus. It is fixed in a
case which is screwed down to the body.

Picture 95 & 96. Emergency glass break hammer.

Picture 97. Light in the stair case region. Keeps it easy to climb the stairs at night, the controll is
at driver’s console.

Picture 98. To provide extra safety for students sitting on windows side, railings are provided are
as per customer’s requirement.

42
Picture 99. Emergeny stop button, which notifies the driver if a passenger standing near the door
wants to stop the bus. Its is installed just above the passenger door.

Picture 100. First-aid box and supporting piller behind driver’s seat, it is mandatory assistance to
be fixed in every bus.

Pillars for Supporting the roof –

As per customer’s requirement, company provides the school bus with roof supporting pillars for
extra safety, they are screwed between roof and floor on one side of the central path way, as
shown in picture.

43
 Picture 101. The 2 pillers supporting the roof in central pathway.

Mudflaps –

Rubber mudflaps are installed for each tyre in order to manage the mud or water flying off from
the tyres. They are fixed on to shell by screws.

Picture 102. Mudflaps.

44
Passenger’s door –

The door is installed in the rigion with some accessories, it’s a folding door, which provides
more space for the students to enter with there school bags not getting tucked in hooks or
something sharp.

These two plastic

structure engage
into themselves
when the door is
closed, reducing the
vibrations and noise
due to moving bus

Picture 103,104,105. Passenger door and For locking the door when closed.

Side - markers and indicators –

Now that the inside of the bus is complete, the outside of the bus is worked upon.Marking for
elctric side markers and turning side indicators is done by simple measuring tape and markers as
per design as shown.

45
 Picture 106 to 110. Marking of side-marker and indicator respectively.

After the marking is done, the drilling for screws is done and then side markers and turning
indicators are installed. The space for indicator as shown in above right pic is cut by plasma
cutter.

Picture 111 & 112. Side markers and turning indicators.

Turning indicator Side markers

46
 Picture 113. The emergency door is installed with the “break glass to open” handle, the sealing
of it is done with Sikaflex sealant.

Reflective tape –

As per customer’s requirement bus is provided with reflective or Cat eye tapes, marking the
boundaries of the bus.

Picture 114. Golden reflective tape, silver may also be used.

School bus Sticker –

As per customer’s demand, the ZT model is pasted with symbols (sticker) which highlight the
bus as a school bus, the spot to paste the sticker is also as per the customer.

47
 Picture 115 & 116. School Bus sticker.

After completing the assembly line’s process, the bus is sent to Shower teasting area for washing
and quality inspection.

Project 2 –

Waste consumption Project

It was a team project, the team was headed by Mr. K K Sharma (Production Dept.)

Target –

To consume the wastages of Aluminium Chequered Sheet & upholstery and take steps to
optimize the raw material/waste consumption on Assembly line.

Problem Statement –

 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 mtrs. 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: 92mtrs of Upholstry ( LZ1157510) piled up in small cut length sizes costing
Rs.11132 /-during various cut to size application in Executive model

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Mission –

 To consume the waste generation of Rs.30060 and steps to be taken to control scrap
generation by value engineering.

 To consume the left out inter paneling upholstery length wastes

 (LZ0257571) – LT(C) model costing - Rs. 13200/-

 (LZ1157510) – Executive model costing - Rs 10120/-

Planning –

 Making of CFT’s.

 Identification of wastages in Aluminium & Upholstery

 Brainstorming meeting.

Action for reclamation, value engineering & communization/interchanging.

Cross Functional Team –

Team leader – Mr. K K Sharma (Production Dept.)

Senior-Engineers – Mr. Abhishek Puri (Technology Dept.)

Mr. Vaneet Verma (Production Dept.)

Assemblers – Mr. Shiv Kumar (Production Dept.)

Mr. Pawan Kumar (Production Dept.)

Trainee – Aggyapal Singh (Technology Dept. UIET, PU)

Prabhjot Singh (Technology Dept. DIET, PTU)

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Cost of Wastes –

35000
Wastages Cost (Rs.)
30000

25000

20000
In Rupees

Series1
15000

10000

5000

0
Al Chequerd Sheet Interpanelling Upholstery Roof Upholstry

Chart 2. Wastages cost on assembly line.

Case -1 Aluminium Chequered Sheet (Part no. - LZ0269271)

Present Situation –

Present (WASTE)-860 x 810

mm sheet , Total 180 kg

Picture 117. The aluminum sheet being left waste.

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Suggested Proposal action –

 It is proposed to use the left out waste sheets by adjusting sizes at places instead of
cutting new sheets for the same size.

 Methodology Adopted: Value Engineering

Proposed Sheet Cut-outs –

Used
here

Used here
with minor
adjustments

Drawing 2. Waste usage figure.

Savings –

Rs. 30060 (Cost of Piled Scrap) + Rs. 540 Per bus (Adjusting Waste)

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Case 2 – Cloth upholstery (Part no. - LZ0257571)

Present Situation –

Single Piece Cloth used

all along the side of
the bus

Picture 118.

Suggested Proposal Action –

Cut Piece used

with Aluminum
section covering

Picture 119. The pic showing the usage of cut piece of cloth instead of 1 piece.

Savings –

All Cloth wastage consumed in 05 No.s LT-C model buses

Cost Savings : Rs.13200/-(Scrap Cost ) – 5 x Rs.170 (Al section cost) = Rs.12350/-

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Case – 3. Cloth Upholstery (Part no. – LZ1157510)

Present Situation –

Roof cloth is used

in colour contrast
with side cloth,
Waste
accumulation of
small cut size
lengths

Picture 120.

Suggested Proposal Action –

Roof Cloth
interchanged
with side & pillar
cloth for
maintaining
contrast, Roof
cloth wastage
consumed

Picture 121. The waste upholstery used as contrast.

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Savings –

Cost Saving of Rs 11132/- by consuming the whole waste cloth in Executive model

Total Savings –

 AL Chequered Sheet Rs. 30,060

 Cloth Upholstry (LZ0257571) Rs. 12350

 Cloth Upholstry (LZ1157515) Rs. 11132

Total Savings Rs. 53542

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