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In Pursuit of Perfection

A commercial vehicle represents the fulcrum of life and livelihood for the customer and safety for the passenger. This is why every vehicle that leaves the Ashok Leyland shop floor carries with it great pride in being part of a customer’s journey towards success. It also means taking responsibility for the maximum uptime, reliability, passenger comfort and profitability.

To this end, Ashok Leyland leverages Total Quality Management (TQM), which brings together employees, suppliers and network partners in pursuit of a common goal–ensuring quality in every process.

TQM, a Demanding Journey

The tenacious commitment to TQM at Ashok Leyland was endorsed by an award no less than the prestigious Deming Prize, one of the highest awards on TQM in the world. The Pantnagar facility, with its state-of-the-art equipment and young workforce, is the world’s first commercial vehicle manufacturing facility outside of Japan to win a Deming Prize, in 2016. This was followed by Hosur-2 facility bagging the prize in the very next year making Ashok Leyland the first organisation in the world to win the prize for two successive years.

This milestone was achieved by setting up robust TQM organizations, to create a strong ecosystem of people and processes. Robust systems for problem solving, a phased implementation plan, structured training and the involvement of suppliers and network partners made it a truly collaborative exercise.

0% Compromise for 100% Quality

At Ashok Leyland, our goals are closely linked to the success of the customer’s journey–uninterrupted operations, being on the go without forced breaks – In other words, keeping the business cycle turning smoothly without a hitch.

This central promise of reliability demands unique and uncompromising focus on quality–whether designing a part or aggregate, or putting together an entirely new product that represents hundreds of parts working in complete sync. From the time the product is designed on the drawing board, through the processes by which it takes physical shape, and right up to the moment it is put to work in the real world, the entire journey is tempered with assiduous testing and rigorous observation and improvement.

At the aggregate level, vulnerabilities are exposed and overcome, first through detailed virtual simulations and then in a controlled physical environment. As the aggregates come together and the product begins to take shape, virtual simulations again work complex algorithms to check for vulnerabilities. Real-life conditions are re-created in a special environment to systematically record performance, safety and durability.

The product is then finally put through actual load conditions, put through the unpredictable forces of terrain, temperature and weather and finally, when the product reaches the customer, it stands by him through every challenge.

Quality is a hands-on, collaborative process at Ashok Leyland. One aspect which illustrates this is our ecosystem of supply partners. Over time and through a host of orientation programmes, we ensure that our suppliers share the same vision and commitment that we stand for. Through cross-pollination of ideas and best practices across facilities, our commitment remains consistent over time and across processes. The specifications benchmarked during the exacting design phase are then carried forward at the mass production scale.

The Ashok Leyland shop-floor is an award-winning arena of engineering, which features automation, advanced robotics, quality gates and ever-improving processes to ensure mistake proofing and better standardization. Our manufacturing practices are global examples in blending time-tested processes with tomorrow’s technology.

The impression of a truly ‘factory fresh’ vehicle is achieved by a pioneering Truck-on-Truck concept, where new vehicles are not driven but carried on a cargo truck to the delivery point with a zero odometer reading.

Our commitment to quality extends beyond our own shores. We understand the varied conditions that our products must weather before they arrive at destinations around the world, and take great care in packaging and protection. For instance, with a meticulous process involving poly cover wrapping, engine coat, special chassis wax and dashboard protective cover, we make our products seaworthy.

Winning awards and punching through benchmarks aren’t just proof of Ashok Leyland’s capabilities, but an indication that to us, customers are front and centre. The sole purpose of this level of quality and accountability is to protect pride of ownership, ensure comfort and safety and assure them that we take their journey seriously – whether a short haul run, or the longer road to success.