Mahatma Gandhi Mission’s College of Engineering and

Technology Noida, U.P., India

Report on Practical Industrial Training

Carried out at

Sikka Hyundai
ile Pvt. Ltd.)

From 1st July, 2016 to 28th July, 2016

Academic Year 2016-2017

Submitted by: Submitted to:

Name: GOPAL MISHRA Mechanical Engineering Department,
Class: BT-ME MGM’s COET, Noida Univ. Roll No:
1309540023 U.P.
 Mahatma Gandhi Mission’s
College of Engineering and Technology
Noida, U.P., India

Department of Mechanical Engineering

CERTIFICATE

This is to certify that Mr. GOPAL MISHRA of B. Tech. Mechanical

Engineering, Class BT-ME Roll No.1309540023 has completed his
Industrial Training during the academic year 2016-2017 from 1st July,
2016 to 28th July, 2016 at Sikka Hyundai (Sikka Automobile Pvt. Ltd.)
B-88/1, Mayapuri Industrial Area, Phase 1, New Delhi – 110064,
India.

Training Coordinator Head of the Department

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 Acknowledgment

First I would like to thank Mr. Rakesh Bhauguna (GM of company), Mr. Naveen (service
manager), Mr. Jaspreet singh (work shop in charge), Sikka Hyundai, Mayapuri, New Delhi for
giving me the opportunity to do an internship within the organization. For me it was a unique
experience to be in this work shop. It also helped me to get back my interest in mechanical
engineering and to have new plans for my future career.

I would like to thank all the people also that works in the organization. With their
patience and openness they created an enjoyable working environment. Furthermore I want to
thank all the engineers and students, with whom I did the internship. We experienced
great things together and they taught us many more things regarding automobile.

At last I would like to thank Mr. Ramesh Swami (Technician), Mr. Manish (Technician) and Mr.
Ghyanshyam Kumar (floor in charge) who told me all about the organization and Quick services
and also about the major-minor problem observed in the car.

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 ABSTRACT

As l am very fond of automobile engineering. It was a great opportunity for me to do four weeks

internship in Uma motors Maruti Suzuki Mathura Uttar Pradesh. The internship was

concentrated on the car services. At the beginning of the internship l had several queries in

my mind regarding the different technologies used in Hyundai and what skills are needed in

organization. During my internship several queries are cleared by doing some activities. The

objective of this internship is to gather information about the quick services and the

major-minor problem that can be observed in day to day life. In the workshop, I have learnt the

rules and safety instruction which helps me in understanding while working on cars. So, this

internship was a great experience. I found out how much I am strong in automobile field. I

gained new knowledge and skills and met many new people. I achieved many of my

learning goals. I got insight into the work of an organization. The financing is an important factor

and forces to be flexible in attitude and approach. I learned more about the problems which I

have face while working on the cars. Working together with the different background peoples

and by education these threats have to be approached to succeed in my internship the

sharing of knowledge, ideas and opinions is of importance. There is still a lot of discover and

other methods can be improved. At last this internship has given me new insights and

motivation to pursue a career in mechanical engineering.

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 CONTENTS

Pages

Training certificate……………………………………………………………………………....I

Abstract………………………………………………………………………………………....II

Content……………………………………………………………………………………….III-IV

List of figure……………………………………………………………………………….V-VI

CHAPTER 1: INTRODUCTION………………………………………………………….1-2

1.1 Company overview………………………………………………………………………....1

1.2 Company face……………………………………………………………………………....2

CHAPTER 2: WORKSHOP & SHOWROOM.....................................................................3-4

2.1 Workshop……………………………………………………………………………….…..3

2.2.1 Features of workshop……………………………………………………………………..4

CHAPTER 3: WORKING IN WORKSHOP......................................................................5-13

3.1 Body shop…………………………………………………………………………………..5

3.1.1 Denting…………………………….……………………………………………………..6

3.2 Paint shop…………………………………………………………………………………...8

3.3 Service shop………………………………………………………………………………...9

3.3.1 Free service………………………………………………………………………………12

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3.3.2 Paid service……………………..……………………...…………………………………12

3.3.3 Running repair service……………………………………….…………………………...12

3.3.4 Quick service……………………………………….…………………………………….12

3.4 Washing………………………………………………………………………………….....12

CHAPTER 4: WORKING IN DURING SERVICE IN WORKSHOP............................14-23

4.1 Replacement of the oil filter cartridge……………………………………………………..14

4.2 Air filter……………………………………………………………………………………14

4.3 A/C filter…………………………………………………………………………………...15

4.4 Engine oil…………………………………………………………………………………..16

4.5 Clutch plate………………………………………………………………………………...17

4.6 Brake…………………………………………………………………………………….....18

4.6.1 Brake pad…………………………………………….……………………………….….19

4.7 Wheel alignment and balancing………………………………………………………........21

4.8 Final inspection……………………………………………………………………….........22

CONCLUSION………………………………………………………………………….........23

REFRENCES………………………………………………………………………………...24

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Fig. No. Name of figure Page no.

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Fig. 1.1 Front view of Uma motors Maruti Suzuki 2

Fig. 2.1 Workshop area 3

Fig. 2.2 Lifting m/c in workshop 4

Fig. 3.1 Damage car body 6

Fig. 3.2 Body shop 7

Fig. 3.3 Denting shop 8

Fig. 3.4 Painted parts 8

Fig. 3.5 Paint shop 9

Fig. 3.6 Opening of engine 10

Fig. 3.7 Separating of gear box from engine 10

Fig. 3.8 Repairing gear box 11

Fig. 3.9 Repairing A/C system 11

Fig. 3.10 Washing shop 13

Fig. 4.1 Inserting new air filter 15

Fig. 4.2 Left side new A/c filter other side polluted A/c filter 16

Fig. 4.3 Filling engine oil in engine 17

Fig. 4.4 Clutch plate 18

Fig. 4.5 Brake wheel 18

Fig. 4.6 Disc brake assembly 19

Fig. 4.7 Disc brake pad 20

Fig. 4.8 Wheel alignment 21

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Fig. 4.9 Wheel balancing 21

Fig. 4.10 I am doing final inspections 22

Fig. 4.11 Checking all spare parts are tight or not 22

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CHAPTER 1

INTRODUCTION

1.1 Company Overview

Maruti Suzuki India Limited is a publicly listed automaker in INDIA. It is a leading four-wheeler
automaker manufacturer in south a Asia. Suzuki Motor Corporation of Japan holds a majority stake in
the company. It was the first company in India to mass-produce and sell more than a million cars. It is
largely credited for having brought in an automobile revolution to India.

It is the market leader in India and on 17 September 2007, Maruti Udyog was renamed Maruti Suzuki
India Limited. The company headquarter is in Gurgoan, Haryana. Maruti Suzuki is one of India's
leading automobile manufacturers and the market leader in the car segment, both in terms of volume of
vehicles sold and revenue earned.

Maruti Udyog Limited (MUL) was established in February 1981, though the actual production
commenced in 1983 with the Maruti 800, based on the SUZUKI Alto kei car, which at the time was the
only modern car available in India, it’s only competitors- the Hindustan Ambassador and premier
Padmini were both around 25 years out of date at that point Through 2004, Maruti has produced over 5
Million vehicles. Maruti are sold in India and various several other countries, depending upon export
orders.

Models similar to Maruti (but not manufactured by Maruti Udyog) are sold by Suzuki and manufactured
in Pakistan and other South Asian countries. The company annually exports more than
50,000 cars and has an extremely large domestic market in India selling over 730,000 cars annually.
Maruti 800, till 2004, was the India's largest selling compact car ever since it was launched in 1983.
More than a million units of this car have been sold worldwide so far. Due to the large number of
Maruti 800s sold in the Indian market, the term "Maruti" is commonly used to refer to this compact car
model. Till recently the term "Maruti", in popular Indian culture, was associated to the Maruti 800
model. Maruti Suzuki was born as a government company, with Suzuki as a minor partner to make a
people's car for middle class India. Over the years, the product range has widened, ownership has
changed hands and the customer has evolved.

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1.2 Company Face

Fig. 1.1 Front view of Uma Motors Maruti Suzuki

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CHAPTER 2

WORKSHOP

2.1 Workshop

I have done my internship in the workshop of Uma Motors. There, I have work under a mentor
who tells me about the organization and the work procedure, quick repairs, how to solve major
minor problem generally observed in the cars. These are the some pictures of the workshop
where I have done my internship.

Fig. 2.1 Workshop area

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2.2.1 Features of workshop

 Equipped with hi tech lift machined for lifting the car to repair top bottom parts

 All the technicians have their own equipment’s and machinery

 They have a very large floor area for working their

 Time to time sweepers clean the workshop to maintain the good working environment

 All the major & minor faults would be find by manually or through software (G-scan)

 Final inspection can be done by the experts team

Fig. 2.2 Lifting m/c in workshop

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CHAPTER 3

Working in workshop

While working in the workshop I have seen and learnt about how a workshop running at full
speed and achieve target as much faster as they can, so they meet the customer requirement and
satisfaction.

There are four departments in workshop as follows:

1. Body shop
2. Painting shop
3. Service shop
4. Washing

When a car enters the workshop, firstly they made a repair order for the customer in which the
customer tells the problem what he is facing with the car, or it may be its general repairs. Then
the service adviser inspect the car and he told the technician what he find at first stage then the
technician fully examine the whole car & each n every parts of the car and then he noted down in
the job card. Generally the company provide 4 free general services, in which the mechanic or
technician checks the engine oil, lubricating oil, water, air filter, A/C filter and other electronic
controls. And if he detects any problem which might reduce the car efficiency he will notify to
the service advisor and then service advisor calls to the customer and tell him about the defects
and then if the customer is ready to repair it then the service adviser tell to the mechanic and then
mechanic repair the problem so the car run effortlessly.

Defected cars are selected on the basis of their faults and then send to it their specified category
of shop such as if any car having damage related to tits body then it send to the body shop or if
any engine, brake, wheel alignment then it send to the service shop.

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3.1 Body shop

In the body shop of Maruti Suzuki those cars having some damage on its body are repaired.
Dents, breaking of body parts, etc. are some common problems which comes to the body shop.

Fig. 3.1 Damage car body

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 Fig. 3.2 Body shop

3.1.1 Denting

Denting is a process in which the body of the car is not repair or replaced in these a selected
portion or we can say it a defected part of body of the car on which dents, marks, scratches,
stains, are to be repaired by some devices and equipment’s.

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 Fig. 3.3 Denting shop

3.2 Paint shop

Paint shop is the kind of parlor for cars, the aesthetic look of the cars are prepared here in this paint
shop. Priming, painting, etc. are some processes perform in this shop.

Fig. 3.4 Painted parts

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 Fig. 3.5 Paint shop

3.3 Service shop

In service shop, as name shows in this shop the general service or repairing is done like regular
service or any problem related to internal mechanisms, engines, etc. changing of engine oil,
brake oil, clutch oil, gear oil, changing of air filter, etc. comes under this shop.

In this shop four types of services are to be done they are as follows:

1. Free services
2. Paid services
3. Running repair services
4. Quick Services

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 Fig. 3.6 Opening of engine

Fig. 3.7 Separating gear box from engine

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 Fig. 3.8 Repairing gear box

Fig. 3.9 Repairing A/C system

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3.3.1 Free services

Under this type of service category only those types of customer’s cars are to be repaired which
are within period of company’s warranty. When any customer buys a new car the company
provided them first 3 to 4 services are free that means customer did not need to be pay for his
first four services. Only those parts to be repaired which are in fall under warranty period
otherwise it will be go in paid service.

3.3.2 Paid services

In these type of service customer have to pay for his cars services whenever he visit for getting
service. In this category warranty period cover cars are not to be included for repairing, but in
some rushes cases it can be repaired if some might faults are to be solve.

3.3.3 Running repair

In these the running cars to be repaired that means they come & order for repair and then go in a same
day after the service done which are to be listed in job card.

3.3.4 Quick services

In Quick Service Station, the car comes for general repair like to check engine oil, lubricating
oil, water level in battery and wind shied cleaning reservoir, air filter, A/C filter and other
electronic controls and if require top-up it.
According to the repair order the store keeper gives the parts, which are to be used to repair the car
and placed in it carefully. It is a quick and short period of time service.

3.4 Washing

In washing the final cleaning is done with water and car washing shampoo. An automatic machine first
washes the car then the whole washes are done by washers (manpower).
Sometimes it is done first then after service accordingly customer’s requirement.

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Fig. 3.10 Washing shop

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CHAPTER 4

WORKING IN DURING SERVICES IN WORKSHOP

4.1 Replacement of the oil filter cartridge

The oil filter cartridge is present at the bottom of the car which can be open with the rachet. After
opening it the used engine oil is taken out and after that the new cartridge is put in with a new
washer. New washer is used to get proper fitting so that the oil should not leak.

4.2 Air filter

A particulate air filter is a device composed of fibrous materials which removes solid particulates
such as dust, pollen, Mold, and bacteria from the air. A chemical air filter consists of an
absorbent or catalyst for the removal of airborne molecular contaminants such as volatile organic
compounds or ozone. Air filters are used in applications where air quality is important, notably
in building ventilation systems and in engines.

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 Fig. 4.1 Inserting new air filter

4.3 A/C filter

A particulate a/c filter is a device composed of fibrous materials which removes solid particulates
such as dust, pollen, mold, and bacteria from the a/c of car to release filtered cooled air inside the
car. A chemical air filter consists of an absorbent or catalyst for the removal of airborne
molecular contaminants such as volatile organic compounds or ozone. A/c filters are used in
applications where air quality is important, notably in building ventilation systems and in vehicle
cabinet.

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 Fig. 4.2 Left side new a/c filter other side polluted a/c filter

4.4 Engine oil

Motor oil, engine oil, or engine lubricant is any of various well-developed lubricants (comprising
oil enhanced with additives, for example, in many cases, extreme pressure additives) that are
used for lubrication of internal combustion engines. The main function of these lubricants is to
reduce wear on moving parts; they also clean, inhibit corrosion, improve sealing, and cool the
engine by carrying heat away from moving parts.

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 Fig. 4.3 Filling engine oil in engine

4.5 Clutch plate

A clutch is a mechanical device that engages and disengages the power transmission, especially
from driving shaft to driven shaft. Clutches are used whenever the transmission of power or
motion must be controlled either in amount or over time. The vast majority of clutches ultimately
rely on frictional forces for their operation. The purpose of friction clutches is to connect a
moving member to another that is moving at a different speed or stationery, often to synchronize
the speeds, and/or to transmit power. Usually, as little slippage (difference in speeds) as possible
between the two members is desired.

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 Fig. 4.4 Clutch plate

4.6 Brake

A brake is a mechanical device which inhibits motion, slowing or stopping a moving object or
preventing its motion. Most brakes commonly use friction between two surfaces pressed together
to convert the kinetic energy of the moving object into heat, though other methods of energy
conversion may be employed. The brake disc (or rotor in American English) is usually made of
cast iron, but may in some cases be made of composites such as reinforced carbon–carbon or
ceramic matrix composites. This is connected to the wheel and/or the axle. To retard the wheel,
friction material in the form of brake pads, mounted on a device called a brake caliper, is forced
mechanically, hydraulically, pneumatically, or electromagnetically against both sides of the disc.
Friction causes the disc and attached wheel to slow or stop.

Fig. 4.5 Brake wheel

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 Fig. 4.6 Disc brake assembly

4.6.1 Brake pad

Brake pads are a component of disc brakes used in automotive and other applications. Brake
pads are steel backing plates with friction material bound to the surface that faces the disk brake
rotor.

Brake pads are designed for high friction with brake pad material embedded in the disc in the
process of bedding while wearing evenly. Friction can be divided into two parts. They are:
adhesive and abrasive.

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Depending on the properties of the material of both the pad and the disc and the configuration
and the usage, pad and disc wear rates will vary considerably. The properties that determine
material wear involve trade-offs between performance and longevity.

The brake pads must usually be replaced regularly (depending on pad material, and drive style),
and some are equipped with a mechanism that alerts drivers that replacement is needed, such as a
thin piece of soft metal that rubs against the disc when the pads are too thin causing the brakes to
squeal, a soft metal tab embedded in the pad material that closes an electric circuit and lights a
warning light when the brake pad gets thin, or an electronic sensor.

Generally road-going vehicles have two brake pads per caliper, while up to six are installed on
each racing caliper, with varying frictional properties in a staggered pattern for optimum
performance.

Early brake pads (and linings) contained asbestos, producing dust which should not be inhaled.
Although newer pads can be made of ceramics, Kevlar, and other plastics, but again inhalation of
brake dust should still be avoided regardless of material.

Fig. 4.7 Disc brake pad

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4.7 Wheel alignment & balancing

Wheel alignment and Wheel Balancing are totally two different things. Wheel alignment consists
of adjusting the angles of the wheels so that they are perpendicular to the ground and parallel to
each other. The purpose of these adjustments is maximum tire life and a vehicle that tracks
straight and true when driving along a straight and level road. Wheel Balancing, on the other
hand allows the tires and wheels to spin without causing any vibrations. This is accomplished by
checking for any heavy spots on the wheel-tire combination and compensating for it by placing a
measured lead weight on the opposite site of the wheel from where the heavy spot is.

Fig. 4.8 Wheel alignment

Fig. 4.9 Wheel balancing

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4.8 Final Inspection

In final inspection, the last inspection is done so, that there should not be any single problem left in
the car before handle to the customer.

This work station is just for the zero error service. This increases the customer satisfaction and hence
increases the standard of the workshop as well as the service which is providing.

Fig. 4.10 I am doing final inspection

Fig. 4.11 Checking all spare parts are tight or not

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CONCLUSION

It was a great internship in Uma motors maruti full of knowledge. I really enjoyed the training
period. I have learnt about different services and the major minor defects generally seen in the
car and how to solve them.
Most of the time I used to do the free services and some repair also like I have change the brake
pads, tiers, replacing the engine oil, coolant and many other things, I also learned how to drive
car with ease, and how to check all the sensors are working or not if not so, then I have made a
note for that in repair order.
I also seen that how an organization work under extreme pressure and how to handle it like when
so many cars have to repair in the limited time it is really a very big task, I have also worked
with GM and completed a small project there.
Overall it was a good experience and it increases my interest in the Automobile engineering, now i
am planning to enhance my skills in this field.

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REFERENCES

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