Ashok Leyland's Defence vehicles roll out of its modern plant in Hosur, near Bangalore, which is equipped with state-of-the-art facilities, backed up by a Quality Management System, accredited for ISO:2002 and TS16949:2006.

The plant has an integrated cab manufacturing facility with Electrostatic process for cabin painting, automated system for FSM painting, conveyorised engine dressing, chassis dynamometer and vehicle simulation rig for cab electrical checks.

The Chassis Assembly conveyor is also equipped with an auto monorail system for cabin and engine transfer / mounting. Torque controlled multi-spindle nut runner system is provided for axle and wheel mounting. The chassis line is equipped with turnover facility enabling inverted chassis assembly prior to engine mounting, for ease of assembly and conformance to various fitment quality parameters.

The Cabin Weld Shop has over 250 spot-weld guns with extensive welding fixture & handling equipment which make it an error-proof system, ensuring geometry and other quality related parameters. These parameters are re-assured through a periodic audit with extensive profile / dimensional fixtures.

The Cabin Painting Line consists of a fully automated Electro Deposition Primer coating process, which gives 1000 hours of Salt Spray Resistance (roughly 5 years of rust free operation). Basic painting is done through a dipping process with a capability for multi-color topcoat.

Another unique facility of the plant is a 5000 tons press capable of making frame side members within 40 seconds. This machine has "Vision Based" automated checking facility that ensures various quality parameters. This press is supported by CNC turret punching press to facilitate faster launching of new models meeting the customer's expectations.

The Frame Assembly Shop integrates frame preparation - washing, shot blasting, degreasing, spray phosphating and electro static frame painting (Automated primer and topcoat painting with baking facility in a conveyorised process).

The Axle Assembly Shop uses an automated slot conveyor system for front & rear axle assembly.

Testing facilities include a Vehicle Dynamometer to simulate road conditions, Brake Tester, Headlamp Aligner and emission check to ensure quality of the final product.