INTERNSHIP REPORT

MUHAMMAD HISHAM NASIR

13IN52
INDUSTRIAL ENGINEERING & MANAGEMENT

PROJECT: FUEL TANK LIFTER

(ERGONOMIC) @

PRODUCTION DIVISION; VFA (VEHICLE

FINAL ASSEMBLY) DEPARTMENT CAR
LINE SECTION

MEHRAN UNIVERSITY OF ENGINEERING

& TECHNOLOGY JAMSHORO
 TABLE OF CONTENTS

COMPANY PROFILE............................................................................

STATICAL PAST DATA OF COMPANY...................................................................

INTRODUCTION ..................................................................................................

1. PRODUCTION DIVISION..................................................................................
(A) VFA (VEHICLE FINAL ASSEMBLY) ....................................................
Car line
ST line

PROJECT CHARTER..............................................................................

INTRODUCTION OF ERGONOMIC............................................................................

PRINCIPLE OF ERGONOMIC..........................................................

FUEL TANK LIFTER DESIGN..............................................................................................

BEFORE IMPLEMENTING PERFOMANCE LEVEL

AFTER IMPLEMENTED PERFORMANCE LEVEL (AS EXPACTED)

 COMPANY PROFILE
Pak Suzuki Motor Company Limited was formed as a joint venture between Pakistan
Automobile Corporation and Suzuki Motor Corporation (SMC) - Japan. The Company was
incorporated as a public limited company in August 1983 and started commercial operations
in January 1984. The initial shareholding of SMC was 12.5% which was gradually increased
to 73.09%.

Pak Suzuki is pioneer in Automobile Business having the most modern and the largest
manufacturing facilities in Pakistan with an Annual production capacity of 150,000 vehicles.
The vehicles produced include cars, small vans, Pickups, Cargo vans and Motorcycle. Pak
Suzuki holds more than 50% Market Share.

Following the aggressive policy of Indigenization, Suzuki vehicles have a healthy local
content up to 72%. This was made possible by strong support of our vendors.

Pak Suzuki has the largest Dealers network offering 3S (Sales, Service and Spare Parts)
facilities across Pakistan.

Caring for the Environment Pak Suzuki was pioneer in introduction of Factory fitted CNG
vehicles.

Pak Suzuki always endeavours to go aggressively for the sound development of the society
by increasing motorization, industrialization and creating job opportunities thus improving
the people’s living standards with the combined efforts of all the dealers, vendors and Pak
Suzuki employees.

Pak Suzuki is also exporting Suzuki Ravi pickup, Liana and components to Bangladesh and
Europe thus earning precious foreign exchange for the country.
Original equipment manufacturing market share for car and light commercial vehicle with respect
to other automobile sector:

OEM WISE MARKET SHARE FOR CARS & LCV (JAN-DEC 15)
OTHERS, 0.20%
INDUS MOTORS,
28.80%

PAK SUZUKI, 59.60%

ATLAS HONDA CAR,
11.40%

Pak Suzuki sales result:

PAK SUZUKI PRODUCTION RESULT (2006-2015)

150,000

100,000

50,000

0
2006 2007 2008 2009 2010 2011 2012 2013 2014 2015

Automobile Motorcycle

Automobile Motorcycle
2006 114,214 20,315
2007 120,899 30,245
2008 90,421 26,692
2009 51,032 14,530
2010 78,840 19,618
2011 92,529 20,119
2012 96,370 21,312
2013 77,142 22,977
2014 80,384 23,871
2015 134,391 19,610
Pakistan automobile and motorcycle sales (2005/6-2014/15)

PAKISTAN AUTOMOBLIE AND MOTORCYCLE SALES

1,200,000
1,000,000
800,000
UNIT'

829,893 820,893
600,000 662,573 737,759 829,893 772,046 766,733
516,640 467,353
400,000 507,924
200,000 5,200
31,922 5,271
38,944 6,545
39,971 3,003 4,680
3,803 29,136 3,067 44,354
4,277 31,863 3,240 52,401
2,458 32,874
29,421
155,514 165,268 147,441 25,130
74,180 112,518 114,633 134,785 105,889 104,014 127,552
0
CALENDAR YEAR2005-6 2006-7 2007-8 2008-9 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15

passenger cars light commerical vehicles trucks and buses motorcycle

passenger cars l i ght commercial vehicles trucks and buses motorcycle

2005-6 155,514 31,922 5,200 516,640
2006-7 165,268 38,944 5,271 467,353
2007-8 147,441 39,971 6,545 662,573
2008-9 74,180 25,130 3,803 507,924
2009-10 112,518 29,136 4,277 737,759
2010-11 114,633 31,863 3,067 829,893
2011-12 134,785 44,354 3,003 829,893
2012-13 105,889 29,421 2,458 820,893
2013-14 104,014 32,874 3,240 772,046
2014-15 127,552 52,401 4,680 766,733

Following some past data which show the economy, sales and profit ratio.

NET SALES AND PROFET:(REPUEEES IN MILLION)

Description 2015 2014 2013

Sales & revenue 84,579 53,665 51,061

Growth % (year on 57% 5% 13%
year)
Profit before tax 8,685 2,623 2,353
Growth % 231% 11% 57%

Profit after tax 5,843 1,922 1,849

Growth % 204% 4% 89%
 INTRODUTION
PSMLC has major fields which acts as a vital role in running the whole company in which some are
mentioned below:

 Production Division
 Information Technology Division
 Supply Chain Division
 Quality Assurance Division
 Sales & Marketing Division
 Finance Division
 Human Resources Management Division

On the very first day of internship at PSMCL all the internees were allotted specific divisions and
around 16 internees including me were assigned the Production Division.

PRODUCTION DIVISION: -
It is the largest division in PSMCL leading 10 departments under its umbrella under the
supervision of SIR MUHAMMAD ALI LODHI (General Manager) which are mentioned below:

 Press Shop
 Welding Shop
 Paint Shop
 Vehicle Final Assembly (VFA)
 Inventory
 Maintenance
 Production Planning
 Engine Shop
 Plastic Shop
 Motor Cycle Department (MCD)

VEHICLE FINAL ASSEMBLY (VFA):-

As the name says itself that it is the department where the whole vehicle is assembled from
the body shell to the complete car with its all specifications following the method Assembly
Line and ready to drive.

Mainly it has two portions:

1. Car Line
2. ST Line
Car Line:-
It has 51 stations and these stations are divided into 4 portions:

 Trim Line (Workstation no. 1–11)

 Overhead-1 (Workstation no. 12-24)
 Overhead-2 (Workstation no. 25-38)
 Car line Final (Workstation no. 39-51)

Specific codes are assigned to each model and right now 4 models are being assembled here
which are given below:

1. Mehran SB308
2. Cultus SF410
3. Wagon R A1J310
4. Swift RS413

Every workstation has its specific task to perform in which the labors fit the parts which are
discussed below:

TRIM LINE:
Workstation no.1: ABS-ON SIS entry and tail door balancer

Workstation no.2: RHS, front and rear door weather strip

Workstation no.3: Floor wiring

Workstation no.4: Grommet

Workstation no.5: Wiper motor

Workstation no.6: Wiper motor (sub assembly)

Workstation no.7: Master cylinder

Workstation no.8: Door striker

Workstation no.9: Regulator machine

Workstation no.10: Door lock

Workstation no.11: Inspection and repairing

OVERHEAD 1 :
Workstation no.12: Sun visor and door mirror

Workstation no.13: A/C pipe and CNG

Workstation no.14: Door glass

Workstation no.15: Door glass (sub assembly)

Workstation no.16: Parcel tray

Workstation no.17: Front bumper

Workstation no.18: Inspection and repairing

Workstation no.19: Lifting station

Workstation no.20: Fuel lining

Workstation no.21: Rear suspension

Workstation no.22: Inspection and repairing

Workstation no.23: Steering gear case sub-assembly and fitting

Workstation no.24: Engine mounting

OVERHEAD 2:
Workstation no. 25: Front disc
Workstation no. 26: Gear lever and front bumper

Workstation no. 27: Balance rod

Workstation no. 28: Underbody inspection (QA)

Workstation no. 29: Torque process

Workstation no. 30: Wheel fitting

Workstation no. 31: Steering column

Workstation no. 32: Brake bleeding process

Workstation no. 33: Brake bleeding process

Workstation no. 34: CNG cylinder pipe fitting

Workstation no. 35: Parking brake

Workstation no. 36: Inspection

Workstation no. 37: Carpet fitting

CAR LINE FINAL:
Workstation no. 38: Battery

Workstation no. 39: CONSOL

Workstation no. 40: Glazing

Workstation no. 41: Inspection and repairing

Workstation no. 42: Seat belt

Workstation no. 43: Show grill

Workstation no. 44: Back seat

Workstation no. 45: Front seat

Workstation no. 46: Door trim panel

Workstation no. 47: Door assembly

Workstation no. 48: Wheel nut torque/Splash guard

Workstation no. 49: Back seat carpet, trim opening

Workstation no. 50: LLC/fuel filling

Workstation no. 51: Vehicle off loading

ST LINE:
It has 22 stations in which Bolan and Ravi are assembled. These 22 stations are divided into
3 portions:

 Trim Line (Workstation no. 1-8)

 Overhead (Workstation no. 9-16)
 ST Final Line (Workstation no. 17-22)

Every workstation has its specific task to perform in which the labors fit the parts at
particular stations which are discussed below:

Workstation no. 0: Viper lining, roof wiring, dust seal, weather strip, viper motor, valve
nozzles

Workstation no. 1: Tail door assembly/Back light filling

Workstation no. 2: Door glass regulator, glass sheet, glass fitting, back bumper, back lock,
stickers

Workstation no. 3: Brake pedal sub assembly and fitting, roof lining fitting

Workstation no. 4: Dashboard, front light, ash tray, head lamp, front door sub assembly
Workstation No 5: Instrument panel, gear lever sub assembly and fitting

Workstation no. 6: Door glass assembly, steering column (sub assembly and fitting)

Workstation no. 7: Seats, battery and battery box

Workstation no. 8: Rear bumper and vehicle transfer from Trim to OHC
Workstation no. 9: Fuel tank, front bumper steering box

Workstation no. 10: Front suspension sub assembly

Workstation no. 11: Rear axle sub assembly and fitting

Workstation no. 12: Front assembly biasis fitment

Workstation no. 13: Engine mounting

Workstation no. 14:

Workstation no. 15: Tyre fitting/Adjustment

Workstation no. 16: Pokayoke & PQCI

Workstation no. 17: Steering, headlight, show grill, air filter, air cleaner, canister bottle

Workstation no. 18: Petrol filling (7 Littre), seat bracket, buckle, front mirror, jack, heat
plate, air cleaner bottle

Workstation no. 19: Center door, brake oil

Workstation no. 20: Panel

Workstation no. 21: Panel assembly, radiator coolant

Workstation no. 22: Repair and inspection

PAK SUZUKI MOTOR COMPANY LIMITED

ERGONOMIC (HUMAN FACTOR ENGINEEING)

PROJECT CHARTER

OVERVIEW

1. Project Background and Description

The project is on FUEL TANK LIFTER which the core process of human factor
engineering(ERGONOMICS) which mean to improve the working posture of the worker during
performing the task according to the principle of ergonomics. Human factor engineering help out to
reduce the fatigue causes behind work in abnormal working posture. Abnormal working posture
reduce the working efficiency of the worker with to time.

2. Project Scope
Scope of the fuel tank lifter is to provide the easiest working environment to the work. Its helps
to increase the working efficiency of worker, improve the working quality, increase the
productivity. Which help out to the company to achieve there specify goal which was settled
in before, and as help to compete in complicated market.

3. Project Goal
Main requirements of this project are:
 Reduced non-value added activities
 Less human fatigue
 Near zero amount of breakdowns
 Improve working efficiency
 Increase productivity

4. Implementation Plan
Implemented plan is to fabrication of fuel tank lifter, that provide the helpful environment to
worker to work without any fatigue and get higher no: of units(product) which fulfil the demand
of market.

Assumption
This project is following a human factor approach and it is assumed that the key stake holders
and administration will totally coordinate in order to implement proposed solutions to achieve
project goal.
APPROVAL AND AUTHORITY TO PROCEED
We approve the project as described above, and authorize the team to proceed.

Name Title Date

Approved By Date Approved By Date

 Introduction:-
ERGONOMICS (human factor engineering)
What is ERGONOMIC?

Ergonomics is Greek word which mean law of working. Today, however, the word is used to
describe the science of "designing the job to fit the worker, not forcing the worker to fit the
job." Ergonomics covers all aspects of a job, from the physical stresses it places on joints,
muscles, nerves, tendons, bones and the like, to environmental factors which can effect
hearing, vision, and general comfort and health.

Physical stressors include repetitive motions such as those caused by typing or continual use
of a manual screwdriver. Other physical stressors could be tasks involving vibration such as
using a jackhammer, or tasks which involve using excessive force, such as lifting a heavy box
of books. Working in an awkward position, such as holding a telephone to your ear with
your shoulder, can also cause problems. Repetitive motions, vibration, excessive force, and
awkward positions are frequently linked to ergonomic disorders; however, the majority of
"Cumulative Trauma Disorders" (CTDs) or "Repetitive Strain Injuries" (RSIs), are caused by
repetitive motions that would not result in undue stress or harm if only performed once.
Carpal tunnel syndrome, Tendonitis, Tenosynovitis, DeQuarvain's Syndrome, Thoracic Outlet
Syndrome, many back injuries, and several other conditions may result from repetitive
motions .

Aim of ergonomic:
o Ensures that human needs for safe and efficient working are met in the design
of work system
o To design
 Appliances
 Technical Systems
 Tasks
 In such a way to improve
o Human Safety
o Health
o Comfort and
o Performance

Benefits of ergonomics:
 Productivity
 Product quality
 Safety
 Health
 Reliability
 Job satisfaction
Principle of ergonomics:

Principle 1
Work in Neutral Postures
Your posture provides a good starting point for evaluating the tasks that you do. The best
positions in which to work are those that keep the body "in neutral."

Maintain the "S-curve" of the

spine

Your spinal column is shaped

more or less like an "S."

It is important to maintain the

natural S-curve of the back,
whether sitting or standing.
The most important part of this
"S" is in the lower back, which
means that it is good to keep a
slight "sway back,"

When standing, putting one

foot up on a footrest helps to
keep the spinal column in
proper alignment.

Working for long periods with

your back in a “C-curve” can
place strain on your back.

Good lumbar support is often

helpful to maintain the proper
curve in the small of your
back.
The “Inverted V-curve”
creates an even greater strain
on your back. Even without
lifting a load, bending over
like this creates a great deal of
pressure on the spine.

One common improvement is

to use a lifter or tilter. Or
there may be other ways of
making improvements
depending upon the situation.

Keep the neck aligned

The neck bones are part of the

spinal column and thus are
subject to the same
requirements of maintaining
the S-curve. Prolonged twisted
and bent postures of the neck
can be as stressful as its
equivalent for the lower back.

The best way to make changes

is usually to adjust equipment
so that your neck is in its
neutral posture.

Keeps elbows at sides

The neutral posture for your

arms is to keep you elbows at
your sides and your shoulders
relaxed. This is pretty obvious
once you think about it, but we
don’t always do it.
Here’s an example of changing
a workstation to get the arms
in neutral. In the illustration at
the left, the product is too
high, and the employee is
hunching her shoulders and
winging out her elbows.

In the right-hand illustration,

the product has been
reoriented and the shoulders
and elbows drop to their
relaxed position.
Keep Wrists in Neutral

There are several good ways to

think about wrist posture. One
way is to keep the hand in the
same plane as the forearm, as
this person is doing here by
using a wrist rest along with
the computer mouse.
A slightly more accurate
approach is to keep your hands
more or less like they would
be when you hold the steering
wheel of your car at the 10 and
2 o’clock position — slightly
in and slightly forward.

Here’s an example of how this

principle applies to tool
design. Working continuously
with the pliers as shown in the
left-hand picture can create a
lot of stress on the wrist. By
using pliers with an angled
grip, however, the wrist stays
in its neutral posture.
 Principle 2
Reduce Excessive Force
Excessive force on your joints can create a potential for fatigue and injury. In practical terms,
the action item is for you to identify specific instances of excessive force and think of ways to
make improvements.

For example, pulling a heavy

cart might create excessive
force for your back. To make
improvements it might help to
make sure the floor is in good
repair, that the wheels on the
cart are sufficiently large, and
that there are good grips on the
cart. Or a power tugger might
be needed.

Or another example of
reducing force is to use a hoist
for lifting heavy objects, like
this vacuum hoist in the
drawing.

Another kind of example is

having handholds on boxes or
carrying totes. Having the
handhold reduces the exertion
your hands need to carry the
same amount of weight.
Point:

There are thousands of other examples and the field of ergonomics

includes much information on conditions that affect force. The basic point
is to recognize activities that require excessive force, then think of any way
you can to reduce that force.
 Principle 3
Keep Everything in Easy Reach
The next principle deals with keeping things within easy reach. In many ways, this principle
is redundant with posture, but it helps to evaluate a task from this specific perspective.

Reach Envelope

One concept is to think about

the "reach envelope." This is
the semi-circle that your arms
make as you reach out. Things
that you use frequently should
ideally be within the reach
envelope of your full arm.
Things that you use extremely
frequently should be within the
reach envelope of your
forearms.
Much of the time, problems
with reach are simply matters
of rearranging your work area
and moving things closer to
you. This is not exactly a hard
concept to grasp; what is
difficult is having the presence
of mind to notice and change
the location of things that you
reach for a lot.

Often it is a matter of habit —

you are unaware that you
continually reach for
something that could be easily
moved closer.
Or sometimes, the work
surface is just too big, causing
you to reach across to get
something. One option is just
to get a smaller surface.
Another option is to make a
cutout — this way your
reaches are cut, but you still
have plenty of space for
things.
Or another common problem
is reaching into boxes. A good
way to fix this is to tilt the
box.

Once again, there are

thousands of other examples of
ways to reduce long reaches.
The point is for you to think
about when you make long
reaches, then figure out how to
reduce that reach.

Principle 4
Work at Proper Heights
Working at the right height is also a way to make things easier.

Do most work at elbow height

A good rule of thumb is that

most work should be done at
about elbow height, whether
sitting or standing.

A real common example is

working with a computer
keyboard. But, there are many
other types of tasks where the
rule applies.
 Exceptions to the Rule

There are exceptions to this

rule, however. Heavier work is
often best done lower than
elbow height. Precision work
or visually intense work is
often best done at heights
above the elbow.
Sometimes you can adjust
heights by extending the legs
to a work tables or cutting
them down. Or you can either
put a work platform on top of
the table (to raise the work up)
or stand on a platform (to raise
YOU up).

Or to be a little more
complicated, there are ways to
make stands and work tables
instantaneously adjustable
with hand cranks or
pushbutton controls.

Principle 5
Reduce Excessive Motions
The next principle to think about is the number of motions you make throughout a day,
whether with your fingers, your wrists, your arms, or your back.

One of the simplest ways to

reduce manual repetitions is to
use power tools whenever
possible.

Another approach is to change

layouts of equipment to
eliminate motions. In the
example here, the box is
moved closer and tilted, so that
you can slide the products in,
rather than having to pick
them up each time.
 Or sometimes there are uneven
surfaces or lips that are in the
way. By changing these, you
can eliminate motions.

As always, there are more

examples, but you should be
getting the idea.

Principle 6
Minimize Fatigue and Static Load
Holding the same position for a period of time is known as static load. It creates fatigue and
discomfort and can interfere with work.

A good example of static load

that everyone has experienced
is writer’s cramp. You do not
need to hold onto a pencil very
hard, just for long periods.
Your muscles tire after a time
and begin to hurt.

In the workplace, having to

hold parts and tools
continually is an example of
static load.

In this case, using a fixture

eliminates the need to hold
onto the part.

Having to hold your arms

overhead for a few minutes is
another classic example of
static load, this time affecting
the shoulder muscles.
Sometimes you can change the
orientation of the work area to
prevent this, or sometimes you
can add extenders to the tools.
 Having to stand for a long time
creates a static load on your
legs. Simply having a footrest
can permit you to reposition
your legs and make it easier to
stand.

We’re going come back to this

point later.

Principle 7
Minimize Pressure Points
Another thing to watch out for is excessive pressure points, sometimes called "contact stress."

A good example of this is

squeezing hard onto a tool,
like a pair of pliers. Adding a
cushioned grip and contouring
the handles to fit your hand
makes this problem better.

Leaning your forearms against

the hard edge of a work table
creates a pressure point.
Rounding out the edge and
padding it usually helps.

We’ve all had to sit on chairs

that had cushioning and so
understand almost everything
we need to know about
pressure points. A particularly
vulnerable spot is behind your
knees, which happens if your
chair is too high or when you
dangle your legs. Another
pressure point that can happen
when you sit is between your
thigh and the bottom of a
table.
 A slightly more subtle kind of
pressure point occurs when
you stand on a hard surface,
like concrete. Your heels and
feet can begin to hurt and your
whole legs can begin to tire.
The answer is anti-fatigue
matting or sometimes using
special insoles in your shoes.

Like the other basic principles

that we’ve covered so far,
pressure points are things that
you can look for in your work
areas to see if there are ways
to make improvements.

Before work load stress on worker during performance:

Chart Title
7 6
6 5
5 4.04 4 4.01
Axis Title

3.36 3.53 3.48

4 3.2 3
3 2
2 1
1
0
1 2 3 4 5 6
hours 1 2 3 4 5 6
performance(min) 3.2 3.36 4.04 3.53 3.48 4.01
Axis Title

hour 15min 30min 45min 60min average hours performance(min)

1 3.1 3.1 3.2 3.7 3.2 1 3.2
2 3.3 3.8 3.32 3.1 3.36 2 3.36
3 4.7 3.9 4.3 3.4 4.04 3 4.04
4 3.16 4.1 3.4 3.18 3.53 4 3.53
5 3.32 3.19 4.06 3.12 3.48 5 3.48
6 4.52 3.98 3.9 3.1 4.01 6 4.01
Proposed fuel tank lifter design:
After work load stress on worker during performance:
As Expected:

Chart Title
10
9
8
7
6
5
4
3
2
1
0
1 2 3 4 5 6

hours performance(min)

hours performance(min)
1 3.2
2 3.36
3 3.3
4 3.2
5 3.3
6 3

This graphical evaluation shows that the level of fatigue and the efficiency level of worker
while during the work. Above first graph is between time and performance which shows
that according to the level of performance the efficiency of worker is reduce with respect to
the time. In first graph the variation shows that the reduction in efficiency of worker.
Whereas the second graph haven’t any variation which try to show that after implementing
proposed design at the problematic place. Its helps to:

 Reduce level of fatigue

 Increase productivity
 Reduce muda
 Reduce hazards
 Increase efficiency