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INTRODUCTION

KAL incorporated in 1978 as a Government of Kerala undertaking, is set up 16 km south of TVM in Aralammoodu, in NeyyatinkaraTtaluk. It is a public sector automobile manufacturing company in Kerala, India. The company manufactures three wheels suitable for passengers and goods traffic. The prudent product range comprises of auto rickshaw, pickup, delivery van, local carriers etc. KAL is also manufacturing sophisticated components to be used in space programs of VSSC/ISRO. Since commencement in 1984, the company has manufactured and, marketed more than 85,000 there wheelers. The company is ISO 9001:2000ceertified.

PLANT LAYOUT
The plant consists of an assembly unit, a fabrication unit, and workshop. The store room is placed near to Inspection and testing unit. The layout resembles to a process layout, but it also had the features of a line layout. But the machine in the plant placed according to the convenience of the workers.

PLANT DETAILS

MACHINE SHOP

The machine shop contains many machines for performing various operations. They include semi automatic and fully automatic machines. Some of the machines include.


• CNC Lathes
• CNC Milling Machines
• Drilling Machines
• Conventional Lathes
• Turret Lathe
• Capstan Lathe
• Grinding Machine
• Angular grinding Machine
• Power Hacksaw etc.


CNC Lathe




Operation

These machines where used to perform a verity of operations. Some of them include,

• Cutting
• Facing
• Drilling
• Turing
• Grinding
• Threading etc.


FABRICATION

Fabrication when used as an industrial term, applies to the building of machines, structures and other equipment, by cutting, shaping and assembling components made from raw materials.

The plant also contains a fabrication department. All the fabrication works were performed here.
Some of the machines used for fabrication works include,
• Hydraulic Press
• Power Hacksaw
• Arc welding machine
• X-ray welding machine
• Sport welding machine
• Metal Inert gas welding machine
• Sheet forming machine. Etc.

ASSEMBLY SECTION




The Kerala Automobile has got separate assembly unit, where the assembly operations are performed. This section mainly deals with the assembly of gearbox and gearbox-engine. The engine is fitted to the chassis and them to the drive mechanism. After this the body is assembled to the chassis. The electrification stage succeeds the above operations. The assembly operations was aided by following machines, Hoists, universal
Toll kits, fixtures, painting booths.


QUALITY CONTROL

KAL uses computerized design system and testing equipment to ensure the international standards. Quality assurance achieved through satisfied quality control methods has helped KAL to achieved ISO 9001:2000 Certification.
Verification inspection are done on each step of manufacturing and assembled to provide the required specification and stranded. This has been made possible using equipments such as Universal testing Machines, Dynamometers, Exhaust Analyzer, Digital Height Master, Eddy Current Tester etc.
The QC system is designed to provide routine and consists checked to ensure data integrity, correctness and completeness. Qc activities includes general such as accuracy checks on data acquisition and calculation and the use of approved standardized procedure for emission activates include a planned system of review procedures conducted by personal not directly involved in the inventory development process.