ASHOK LEYLAND

P15 ENGINE Success Story

K Senthilnathan / R Hariganesh / D Premnath / G Sai Venkatesh

Ashok Leyland
Feb 12, 2013

Agenda
About US The Dost Story / Business Opportunity AL P15-Engine Challenges P15 -ENGINE using PTC Solutions

Positive Benefits
Case studies Roadmap

Q&A

Memorable & Proud Job One Roll out

ASHOK LEYLAND
About Us

Ashok Leyland
Ashok Leyland is a commercial vehicle manufacturing company based in Chennai, INDIA. Founded in 1948, flagship of the Hinduja Group is one of India's leading manufacturers of commercial vehicles, such as trucks and buses, as well as emergency and military vehicles with a turnover of US $ 2.5 billion in 2011-12

2.5 to 49 Tons

70 Million Passengers

19 to 80 Seaters

16170 Engines

101990 Vehicles 7 Plants

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Ashok Leyland - Products & Group companies

Foundry Business

Defence Mobility

M&HCV

Buses

Auto Electronics

Engines & Gensets

LCVs

Construction equipment

Exhaust System Technology

Transmissions ZF

Trucks

Bus

Engineering Manufacturing and Enterprise Services

The Dost Story

Business Opportunity

The Dost Story

Business Opportunity
Capitalizing the recent trend on Hub & Spokes Concept AL LCV Business Strategy was framed JV with Nissan in May 2008 to manufacture Light Commercial Vehicles in India.

The objective of the JV is to deliver Japanese quality with Indian cost First Product is DOST

AL P15-Engine
Story about the Engine

Auto Industry Experts Quotes

Frugal engineering is achieving more with fewer resources. The cost of developing a product in the West is high since engineers there use more expensive tools. In India, they achieve a lot more with fewer resources,"

- Carlos Ghosn, Chief of Renault-Nissan

"They understand frugal engineering, which is something we aren't as good at in Europe or Japan," - Carlos Ghosn

As a group, we have said that is strategically important for us to be in the low-cost vehicle market and there are two reasons for this: Firstly, you cannot just transfer technology X from Europe to a low-cost vehicle. You need new engineering, the intelligence to make things simple and adapt it to low cost markets. Secondly, this is valuable for our engineers who could down the line bring these ideas back to the low-end of the European market. Bernd Bohr, Bosch

P15-Engine in DOST
Story about the Engine
DOST is a successful brand newly offered in the SCV (Small Commercial Vehicle) segment, promising a new experience and technology.

DOST carry an increased payload of 1.25 Tons. It is equipped with a stateof-the-art technology AL-P15 - 57.5 HP, 3 cylinder, 1.5 Litre TDCR engine
DOST is tuned for fuel economy, drivability and gradeability required for Indian roads thanks to the Common Rail technology and an overwhelming torque of 157.5 Nm. DOST is the next-generation product in the Indian LCV industry, rapidly evolving on the lines of the passenger car segment. DOST is meant for discerning customers who want to exert their economic and social status. It is a powerful and highly efficient product, bringing forth to its users, Japanese Quality at Indian Cost.
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Challenges
Process / Business Challenges

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Challenges
Process / Business Challenges
To manufacture product with Japanese Quality at Indian Cost To uplift the phase of commercial vehicle towards Comfort of Car To do a FRUGAL engineering in design and manufacturing To comply with environmental, safety and other regulations

To have best in class fuel economy

To have higher productivity To have effective operational economy(Ease of loading/unloading)

Larger size for loading cargo and shorter turning radius

Highest payload capability

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P15 -ENGINE
using PTC Solutions

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P15 -ENGINE
using PTC Solutions

Data Management

CREO Parametric Windchill PDMLink

CREO View

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P15 -ENGINE
using PTC Solutions
Windchill PDMLink
Data management eBOM Visualization

Creo
Layout Modeling Advanced assembly Mechanism Piping Sheet Metal Surface Detailing BMX

Creo View
Cross sections Markups Notes Annotation sets Water Marks Viewing other formats of documents like PDF, TIF, PLT files etc.

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Positive Benefits

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Design Process
Benchmarking Concept Detailed Layout Detailed Design 3D Model Manufacturing Feasibility 2D Drawing Proto Type Fit / Function / Durability Expert Feedback Stage-1 Release Stage-2 Release Engineering Trials Production Trials Stage-3 Release Start Of Production

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Positive Benefits
First time right design Benchmarking Cloud mapping

State of ART design

Associative design process Standardization of Engineering Processes

Lead time reduction in Product Development

Variant development in less time Product & Development Cost Reduction

DFM / DFA taken care with real-time models

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Case studies

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Parametric Associative Design Process

Challenges
Complicated Inner Profiles (Inlet, Exhaust, Oil, Water Jacket and Upper Oil Gallery cores)

Creo
Top Down modeling process

Benefits
Parametric associative model Parent Child relationship Reduced lead time for Development Application of DFM concepts

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Cloud Mapping

Challenges
Confirmation and comparison of actual part with respect to design intent

Creo
Point Cloud Data

Benefits
3D scanned data compared with designed 3D Model to compare profile accuracy

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Parametric Associative Design Process

WATER JACKET

PCV CORE

INNER CORE

Challenges
Complicated inner profiles (Water jacket, crank case, water pump, oil passage cores)

Creo
Top Down modeling process

Benefits
Parametric associative model Parent Child relationship Reduced lead time for Development Application of DFM concepts

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Crank case blow by volume

P15 - Crank case volume = 6.8 Liters (1st

cylinder in TDC and Oil level 4.5 Liters in sump)

Challenges
Difficult to measure the oil path volume in actual condition Difficult to calculate due to complicate shape and path junction

Creo
Surface Techniques Publish geometry Closed volume

Benefits
Easy to use Reduced the design Optimization time More Accurate

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Clearance Check in Dynamic Condition

Examples: Crank Shaft and Piston Assembly Cam Shaft and Cylinder Head Cover Crank Shaft and Oil Sump Cylinder block and Piston Assembly Valves and Piston

Challenges
Min./Max. Clearance check in Dynamic condition

Creo
Mechanism

Benefits
Get minimum clearance between two or more parts in dynamic condition. Check the clashing between two or more parts.

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VIRTUAL DISPLACEMENT

Boundary

Maintain the MAX clearance with Crank shaft and Con-Rod to design Block Skirt

Challenges
Considering the virtual displacement of con-rod the least clearance as been work out using Creo for Block design

Creo
Analysis / Measure

Benefits
Optimize skirt design there by compact design for Block skirt Reduce the width of Engine.

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Map Keys - Boon for faster design in Creo

Use of mapkeys to perform repetitive, frequent, and multi-pick operations rapidly

Mapkeys are macros that execute a sequence of commands Mapkeys can be used to switch the display mode to Wire frame No Hidden or Shaded

A mapkey can set a defined component display scheme.

Challenges
Switching between Assembly and Part models is difficult during DFA process.

Creo
MAPKEYS

Benefits
Mapkeys can be used for easy switching between modes. Ex:- Dynamic orient ,Cut , View Orient, Reset, etc

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Engine Oil Level - optimization

Engine position in running condition: At 3.5 deg inclination Uphill :At 15 deg inclination Downhill :At 15 deg inclination

Side tilt condition: At 15 deg tilt inclination

Left Right

BS3 SHEET METAL SUMP

Overall Volume 6.18 Liters

Oil Level @ 4.2 Liters

Oil Level @ 3.5 Liters

Challenges
Performance targets demanding complicated test equipments

Creo
Assembly Modeling

Benefits
Accurate tool development with minimal changes. Elimination of infrastructure investment for trials and calibration.

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Design For Assembly

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Vehicle Engine Interface

Challenges
Multi file environment. Integration of 3D data from other modelling softwares

Creo
Shrink Wrap Interface for CATIA

Benefits
Import data without any data loss. Accurate prediction of engine lay out on various vehicle lay outs (FR to FF arrangement)

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Simplified Representations
The Simplified representation includes all assembly variants of P15 engine family. Diesel BSIII Diesel BSIV CNG BSIV Ambulance AC / Power Steering variants, Diesel BSIV Turbo Intercooler Genset FR&FF Layouts Easy to work in Simplified Representation with all variants . We designate the way that individual components also work in Assembly mode. High Quality visualization and quick regeneration times.

Challenges
Visualisation of multiple assemblies in same session for layout comparisons.

Creo
SIMPLIFIED REPRESENTATIONS

Benefits
Assembly models of engine variants compared to meet packaging boundary conditions on vehicle.

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Design Validation & Optimization

Challenges
Design Optimization Reducing number of repeated Iterations

Creo
BMX Creo Advance Simulation Extension

Benefits
Optimized Design outputs Design to Analysis Reduced Lead time

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Oil volume Selection

Challenges
Difficult to measure the oil path volume in actual condition Difficult to calculate due to complicate shape and oil path junction

Creo
Surface Techniques Publish geometry Closed volume

Benefits
Easy to use Reduced the design optimization time More Accurate

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Dynamic 3D Cross Section

Challenges
Analysis of critical wall thicknesses, clearances between adjacent parts.

Creo
VISIBILITIES

Benefits
Allows to CUT thru the assembly model for desired depths to analyse for First Time Right assemblies in DMU.

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Piping

Challenges
Pipes/ Hoses routing in Power train unit

Creo
Piping Behaviour Modeling

Benefits Datum point control

Time saving

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Reduction in Design change implementation time

50 45 40 35 30 25 20 15 10 5 0 Actual time Open model Using Creo to open Spec file first and tool drw file then drw file Loding Time

View Update / Saving Time

Challenges
Taking long time to load drawing files. Due to huge size, some time it exists.

Creo
Blank / Unblank of View Sheets

Benefits
Easy to load drawing file Easy to update view / sheet Eliminate work fatigue Reduction in change implementation time High Productivity

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P-20, 4 Cylinder Variant

Challenges
Adaptation of existing components from 3 Cyl to 4 Cyl

Creo
Top down approach

Benefits
Faster variant development Lead time reduction

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Parametric Associative Design Process

Calculation based on Creo

Existing Layout

Existing Layout Line Diagram

Without Touch idler Proposed layout

Challenges
No change possibility in pulley dia / coordinates / No of Tooth / Belt length / CAM wrap angle / Water Pump wrap angle No compromise in system performance / Noise level / Belt & System life No tooth jump at lower belt tension

Creo
Relations

Benefits
System cost reduction Belt life increased

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Cylinder Head & Piston Design for Multi-Fuel

Challenges
Adaptation of existing component for fuel variant (Diesel & CNG) at early design change

Creo
Top down approach

Benefits
Lead time reduction

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Q&A

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