A REPORT ON
INDUSTRIAL ATTACHMENT
AT
KUBER AUTO WORKS PVT. LTD
DHARAN, SUNSARI
Report submitted to
IOE- PURWANCHAL CAMPUS, DHARAN
For the fulfillment of the requirements
For
THE DEGREE OF BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING
BY
NABIN PARAJULI (PUR075BME048)
NIRAJ KAFLE (PUR075BME053)
PRABESH BABU SODARI (BME056)
DEPARTMENT OF MECHANICAL ENGINEERING
IOE PURWANCHAL CAMPUS
DHARAN, SUNSARI
JULY/AUGUST 2022
a
ACKNOWLEDGEMENT
We would like to express our deepest thanks and appreciation to Kuber Auto Works Pvt. Ltd.,
Dharan for providing us with a supportive and encouraging platform during our On The Job
(OTJ) Training within their organization. We extend our sincere gratitude to the Department of
Mechanical Engineering, IOE Purwanchal campus, for providing us the opportunity to
participate in the Eastern Auto point on-the-job training. We would like to express our gratitude
to Er. Sunil Kumar Sharma for his invaluable suggestion, motivation, guidance, and support
throughout the internship. Lastly, we would like to thank supervisors, technicians, officers, and
staff who taught and helped us to answer our questions.
Nabin Parajuli
Niraj Kafle
Prabesh Babu Sodari
IOE Purwanchal Campus
Dharan, Sunsari
b
TABLE OF CONTENTS
COVER PAGE ……………………………………………………………………………………a
ACKNOWLEDGEMENT .............................................................................................................. b
ABSTRACT..................................................................................................................................... f
OBJECTIVES ................................................................................................................................. g
1,. Company Profile ........................................................................................................................ 1
1.1. Products and Services: ......................................................................................................... 2
1.2. Organizational Structure and Hierarchy:.............................................................................. 6
2. Workshop Layout........................................................................................................................ 7
2.1 Customer Service .................................................................................................................. 8
2.2 Sales Department................................................................................................................... 8
2.3 Technical department ............................................................................................................ 8
3 Maintenance at Kuber Auto Works ............................................................................................. 9
3.1 Job allocation process: .......................................................................................................... 9
3.1.1. General Maintenance/ Servicing: ................................................................................ 13
3.1.2. Welding: ...................................................................................................................... 13
3.1.3. Painting: ....................................................................................................................... 13
3.1.4. Pressure Washing: ....................................................................................................... 13
3.2.
Tools used: ..................................................................................................................... 13
3.2.1. Toolbox:....................................................................................................................... 13
3.2.2. Hydraulic Lift/lift: ....................................................................................................... 15
3.2.3. Two Post Lift: .............................................................................................................. 15
3.2.4. Air Compressor: .......................................................................................................... 17
3.2.5. Gear Oil Pump and Dispenser: .................................................................................... 17
c
3.2.6. Torque Wrench: ........................................................................................................... 18
3.2.7. Oil Can:........................................................................................................................ 19
4.
job performed ........................................................................................................................ 19
4.1. social control and supervision Works ................................................................................ 20
4.2. Mechanic Work .................................................................................................................. 20
5.
Learnings: .............................................................................................................................. 22
6.
Recommendation: .................................................................................................................. 23
7.
Conclusion: ............................................................................................................................ 23
References ..................................................................................................................................... 24
List of Figures
Figure 1: Logo of Mahindra ............................................................................................................ 1
Figure 2: Mahendra Bolera PIKUP................................................................................................. 2
Figure 3: Mahindra Scorpio PICKUP ............................................................................................. 2
Figure 4: Mahindra Bolero.............................................................................................................. 3
Figure 5: Mahindra Thar ................................................................................................................. 3
Figure 6: Mahindra Scorpio ............................................................................................................ 3
Figure 7: Mahindra TUV 300 ......................................................................................................... 4
Figure 8: Mahindra Marazzo M6 .................................................................................................... 4
Figure 9:Mahindra XUV 500 .......................................................................................................... 5
Figure 10: Mahindra KUV 100 ....................................................................................................... 5
Figure 11: Mahindra XUV 300 ....................................................................................................... 5
Figure 12: MHXP800 battery ......................................................................................................... 6
Figure 13: Advance Thermal Battery ............................................................................................. 6
Figure 14: Mahindra Lubricants ..................................................................................................... 6
Figure 15: Kuber Auto Works Pvt. Ltd.'s Organizational Structure ............................................... 7
Figure 16: Workshop Layout .......................................................................................................... 7
Figure 17: Service Order ............................................................................................................... 12
d
Figure 18: ToolBox ....................................................................................................................... 14
Figure 19: Hydraulic Jack ............................................................................................................. 15
Figure 20: Two Post Lift ............................................................................................................... 16
Figure 21: Compressor .................................................................................................................. 17
Figure 22: Gear Oil Pump and Dispenser ..................................................................................... 18
Figure 23: Torque Wrench ............................................................................................................ 19
Figure 24: Oil Can ........................................................................................................................ 19
e
ABSTRACT
This report contains a brief description of the 15 days Internship program inside Kuber Auto
Works Pvt. Ltd., Dharan. It contains both technical as well aa s managerial portions of the
automobile dealer. This report includes general workshop operation of vehicles and describes the
service department of Mahindra and Mahindra’s various automobiles. This report also outlines
different abbreviated systems and maintenance equipment. It also includes managerial aspects,
performed jobs, different vehicle parts, commonly used vehicles, and vehicle support
accessories. Case studies with common vehicle defects etc. and reasons for the various problem,
their remedies, the duration of the solutions,s, and conclusions about the research are provided
inside. This report highlights the different aspects of the f automobile industry. It reveals the
mechanism behind different mechanical and electronic devices used in automobiles. The various
knowledge regarding automobiles, organizational structure, plant layout, ongoing working
process, and job card process was gained. We have gained a lot more knowledge on the subject
matter and also in the working procedure, their coordination much many more such virtue.
f
OBJECTIVES
The main objectives of this Industrial Attachment are to:
I.
II.
To expose ourselves to a real and practical business environment.
To have on-the-job experience.
III.
Integration of theoretical and practical knowledge.
IV.
Opportunity to observe the recent technologies being used in the companies.
V.
To buildup self-confidence to enhance professional skills, communication skills, etc.
g
1,. Company Profile
Kubler Auto Works Private Limited is a workshop that looks after the maintenance service, and
Spare parts for Mahendra passenger vehicles and pickups. Kuber is the official distributor of
spare parts of this company in Dharan. Currently, the managing director of the company is
Figure 1: Logo of Mahindra
Praveen Agrawal.
Mahendra group is one of the reputed companies in the field of Automobiles globally. However,
today the company is involved in several other sectors as well. It was established on October
2nd, 1945 by J. C. Mahindra, K. C. Mahindra, and M. G. Muhammad. Its headquarter is in
Mumbai, India. As of 202,1, the net worth of the company was 445 billion INR (Statista, 2022).
The subsidiary, Mahindra and Mahindra works solely in the field of automobiles. They produce
Scorpio, Pickups, Bolero, XUV, KUV, Tractors, etc. The company is also one of the largest
producers of automobiles in India.
In Nepal, Mahindra has been officially selling its vehicles since 1991. For more than 3 decades,
Mahindra has contributed a lot to raise the living standard of people through their reliable
passenger vehicles. The Pickups, Scorpio, and Bolero are the most popular segments in Nepal,
that can be observed on the roads of the terai to the Himalayan region.
1
1.1. Products and Services:
Commercial Vehicles
Name
Pictures
Models available
Maxi Truck Plus P/S
Mahindra
2WD
Bolero
Camper SC XL FB
PIKUP
2WD with P/S
PikUp 2WD P/S 1.5T
Figure 2: Mahendra Bolera PIKUP
Camper SC 4WD
Camper DC 2WD
with P/S
Camper DC 4WD
with P/S
Mahindra
Pikup D/C S4 2WD
Scorpio
Pikup D/C S6 2WD
PIKUP
Pikup D/C S6 2WD
Pikup D/C S10 4WD
Figure 3: Mahindra Scorpio PICKUP
Personal Vehicles
2
XL NAC 2WD
Mahindra
9STR
Bolero
Power+ SLX 2WD 7
STR
Figure 4: Mahindra Bolero
Power+ SLX 2WD
ABS 7 STR
Mahindra
CRDe 4WD STD
Thar
Figure 5: Mahindra Thar
S5 2WD (7/8/9
Seater)
S5 4wd (7/8/9 Seater)
Mahindra
S11 2WD (7/8/9
Scorpio
Seater)
Figure 6: Mahindra Scorpio
S11 4WD (7/8/9
Seater)
S7 2WD (7/8/9
Seater)
3
S11 2WD (7/8/9
Seater)
S11 4WD (7/8/9
Seater)
T4+
T6+
Mahindra
T8 100
TUV 300
T8 100 BHP DT
T10 100 BHP
T10 100 BHP DT
Figure 7: Mahindra TUV 300
Mahindra
Marazzo
M6 8 STR
M6
Figure 8: Mahindra Marazzo M6
4
Mahindra
FWD W5
XUV 500
FWD W7
AWD W11
Figure 9:Mahindra XUV 500
NXT K4+ G80
(5STR)
Mahindra
NXT K6+ G80
KUV 100
(5STR)
K8 G80 (5STR)
Figure 10: Mahindra KUV 100
K8 DT G80 (5STR)
K6 D75 (5STR)
W4 PET 5STR
W6 PET 5STR
W6 PET 5STR
Mahindra
W8 (O) PET 5STR
XUV 300
W4 DSL 5STR
W6 DSL 5STR
Figure 11: Mahindra XUV 300
W8 DSL 5STR
W8 (O) DSL 5STR
Batteries
5
Exide
Battery
ATB
MHXP800
Figure 13: Advance Thermal Battery
Figure 12: MHXP800 battery
Lubricants and Oils
Mahendra
Maximile Elite
Maximile
Maximile Premium
Eco
Figure 14: Mahindra Lubricants
Maximile Synchro
UV2
Source: (Mahindra, 2022)
1.2. Organizational Structure and Hierarchy:
6
Figure 15: Kuber Auto Works Pvt. Ltd.'s Organizational Structure
2. Workshop Layout
Figure 16: Workshop Layout
7
2.1 Customer Service
This department deals with the registry of incoming vehicles for servicing and maintenance. The
customer registers the problem in his/ her vehicle and a job sheet is printed out. The job sheet
contains the vehicle number, history of the vehicles, type of maintenance to be performed, and
the total cost of maintenance. The price of vehicle parts is standard according to Mahindra’s
regulation and is added automatically from the software program. However, some parts have to
be manufactured at local workshops and their price tags are added manually. Customer service
also deals with vehicle traffic management inside the workshop. Besides that, the
manager(engineer) deals with his job here. Sometimes when the problem in the
electronic/electrical section of a vehicle such as wiring, dust sensor, oil level sensor, fuel
injection, engine positioning sensor, thermal sensor, etc. occurs the vehicle is diagnosed via a
software program. Such diagnosis is performed by an engineer which helps to find fault in the
system effectively and efficiently. the software program they used in Kuber is ISMART
GLOBAL, a standard program written and launched by Mahindra company.
2.2 Sales Department
This is the section of the workshop where the parts that are to be repaired and replaced are
stored. Mahindra’s standard parts as well as locally made parts are stored here. Although the cost
and the list of parts are included in the job sheet registered in customer service, distribution of
those parts is performed in the sales department accordingly as provided in the job sheet. The
sales department has 3-4 staff working and is under the constant surveillance of CCTV camera as
well.
2.3 Technical department
This is the actual section where the repair and maintenance of the vehicle are performed. The
person with maximum experience related to extremely sensitive vehicle parts leads the
department and directs other workers in case of any problem.
8
In the case of Kuber Auto works, most of the technical works related to engines were performed
by a senior mechanic of the technical department. This highlight that the company takes zero risk
when it comes to extremely complicated maintenance and repair. Mahendra has its software
named ‘Ismart’ for the diagnosis of their vehicles. Some technicians were trained for using the
software effectively. Any vehicle with starting problems and overheating or engine issues was
diagnosed after going through an initial checkup. The software was capable of detecting broken
connections of electric wiring, tire pressure, Vibration, the temperature of different parts of the
engine, etc.
3 Maintenance at Kuber Auto Works
The company as mentioned earlier is the official distributor of services, spare parts, and repairs
in Dharan. Here, the tasks that are performed inside the workshop of the company are discussed.
3.1 Job allocation process:
There were various types of maintenance and repair services available at Kuber Auto Works Pvt.
Ltd. There was a process that was to be followed by every customer that visits the company for
works to be done on their vehicle. The Job allocation process included the following processes.
I.
Entry from the main gate in a proper way
II.
Entry of the vehicle details on the job card
III.
Detail explanations of the vehicle problem from the owner to the service engineer
IV.
Inspection of the item by the service advisor/ engineer
V.
VI.
VII.
VIII.
IX.
X.
Listing of the initial problems and parts to be changed as problem remedy
Allocate the job to the mechanic
Perform other solutions and get new items from storage as per the need
Test verification
Billing
Handover to the owner
9
I.
Entry from the main gate in a proper way
With proper care and control, the owner is supposed to drive the vehicle inside the chamber gate
of the service department. In case the driver finds it difficult to do so, workers inside the campus
are to be requested to do the entrance work.
II.
Entry of the vehicle details on the job card
The vehicle no., chassis no., engine no. and other various ownership details are recorded on the
job card
III.
Detail explanations of the vehicle problem from the owner to the service engineer
The exact problems or the complaints of the vehicle are detailed over to the advisor by the
vehicle owner
IV.
Inspection of the item by the service advisor/ engineer
After listening to the complaints, the service advisor inspects the exact cause of the problems and
the part to be made or changed or repaired as per the problem.
V.
Listing of the initial problems and parts to be changed as problem remedy
After the inspection, the plans and solutions as well as the parts that are to be changed are listed
to do the proceedings.
VI.
Allocate the job to the mechanic
Then the job is allocated to the specific mechanics/technicians depending upon the degree of the
seriousness of the problems generally under the guidance of the head technician.
VII.
Perform other solutions and get new items from storage as per the need
In process of work if any other changes of parts or other items are required after concerning with
the advisor or the senior technician, then it is listed in the job card and brought from the store for
repair
VIII.
Test verification
10
After completing the above-mentioned tasks, the vehicle is taken for the test ride verification to
convince that the repair has gone well enough to solve the issues.
IX.
Billing
After the satisfaction of the customer from the repairment process, the billings of all the items
taken for the repairment process are carried out and payment is done.
X.
Handover to the owner
After the bill payment is made, the vehicle is ready to give it back to the owner.
11
Figure 17: Service Order
12
3.1.1. General Maintenance/ Servicing:
For general maintenance and servicing the company had Five Bays with hydraulic lifts to lift the
vehicle for inspection and required servicing. The regular servicing includes;
I.
II.
Mobile/ Lubricant replacement
Inspection of brake pad and brake shoe
III.
Inspection of oil filter/change
IV.
Inspection of Air filter/ change
V.
Brake oil level checking
3.1.2. Welding:
In this section the, vehicle that had accidents or the old vehicles that needed work over their
chassis or body was brought and welding or other hand operation was done by totally opening all
the parts of the vehicle. Both arc and gas welding were used depending upon the thickness of the
working surface or material.
3.1.3. Painting:
In this section, the vehicle from the welding section was brought and was painted with the
required color on the dents and scratches by grinding and sanding the surface where the paint
was to be applied. The painting was applied through the machine to ensure a uniform and thin
layer is sprayed each time.
3.1.4. Pressure Washing:
After every work on the vehicle is completed including all the maintenance, and repair. The
vehicle is driven to the pressure wash section. Here, the vehicle was washed using a liquid
(detergent liquid) and water, and then it was dried using an air wash.
3.2. Tools used:
3.2.1. Toolbox:
In the company, a toolbox was provided for each Bays. It included all the essential tools like
sockets, wrenches, combinations, hammers, screwdrivers, L-N key, T handle, Claw hammer,
rachet, etc.
13
Figure 18: ToolBox
a) Wrenches:
They were used to provide grip and mechanical advantage during the time of
applying torque while tightening or losing nuts and bolts. They are of various
types such as open-ended, box-ended, combination wrenches, etc.
b) Sockets:
Socket wrenches come in sets for a wide variety of sizes, depending on
requirements. Socket extenders are indispensable items that help to reach those
almost-unreachable nuts and bolts.
c) Screw-driver:
A screwdriver is a small handy tool, usually manual, for driving or removing
screws. It has a handle, a shaft, and a tip. The tip has either plus “+” or minus “-”
cross-section which fits into the screw head while turning the screw. The shaft is
usually made up of toughened steel so that the tip does not wear easily.
d) Pliers:
Pliers are tools accustomed to holding objects firmly, presumably developed from
14
pair of tongs used to handle hot metal. they're additionally helpful for bending
and pressing a good variety of materials.
e) Hammers:
It is a tool used to apply impact to any object like nail, screw, forge metal, fit
parts, etc while repairing or replacing the parts of any vehicle.
3.2.2. Hydraulic Lift/lift:
It is used for lifting and transporting heavy objects like engines, flywheels, gearbox, etc from one
place to another for maintenance. It provides easy and safe installment and removal of heavy
objects during the job.
Figure 19: Hydraulic Jack
3.2.3. Two Post Lift:
There was a total of five two-post lifts in the maintenance section for mechanical support to hold
the vehicles during the maintenance or servicing. Among five four were hydraulically operated
and one was based on the screw thread principle.
15
Figure 20: Two Post Lift
16
3.2.4. Air Compressor:
There were various pneumatic tools used in the workshop including air wash, air gun/ Pneumatic
air gun, etc. These all tools were driven by air pressure in the compressor.
Figure 21: Compressor
3.2.5. Gear Oil Pump and Dispenser:
It is a machine/tool for filling the oil in the differential and gearbox. It is driven by hand. This
machine can even draw oil from any location higher than the machine and also discharge oil in
that location during the need.
17
Figure 22: Gear Oil Pump and Dispenser
3.2.6. Torque Wrench:
A wrench is {employed} wherever the tightness of screws and bolts is crucial. It permits the
operator to live the torsion applied to the fastener, thus it is often matched to the specifications
for a selected application. this allows for correct tension and loading of all parts. This device was
principally employed throughout the modification of the loony and bolts of the engine head. It is
usually taken while opening or closing the engine components.
18
Figure 23: Torque Wrench
3.2.7. Oil Can:
This can is used for easy and light use of lubricant over a surface either to drop down the friction
or sound being produced from the surface or parts in contact.
Figure 24: Oil Can
4. job performed
During the time of our industrial OJT period, varied tasks were appointed by the supervisor. we
tend to were 1st trained so given the task of addressing customers and enquiring regarding their
issues and then creating the duty orders, knowledge gathering, service, and assurance check,
19
furthermore as doing the particular work beneath the steering of mechanics that staggeringly
helped us in knowing the items that we learned in sensible life. Following field works and
assignments were done throughout our post days:
4.1. social control and supervision Works
The subsequent tasks were bimanual out under the supervision of the floor supervisor:
a) Customer’s queries and issues were completely noted and analyzed and a convenient
answer was discussed.
b) Identification and drawing of solutions of the vehicles brought for pairing/maintenance
c) gap job card and individual gate pass for all the incoming vehicles.
d) Job order placement to a mechanic
e) knowledge entry on pc (details of the customer, vehicles, job order, appointed mechanic,
and job completion confirmation).
4.2. Mechanic Work
These tasks were done under the superintendence of the head mechanic and floor supervisor.
General servicing furthermore as some basic repairing/maintenance jobs were assigned to us by
the top mechanic. Special and tough works were additionally inspected.
4.2.1 General repairing:
General servicing was drained in three phases. first servicing was done once the vehicle lined
20,000km distance. Similarly, 2d and third servicing was done after 40,000km and 60,000km
respectively. the subsequent tasks were finished servicing of vehicles.
a) Changing engine oil and filter
b) cleanup or replacement of air filter
c) change of diesel filters
d) changing of differential oil
e) Change of drugs oil
f) Change of Crown oil and Break oil
20
g) Brakes check and adjustment
h) Pressure wash
4.2.2 General scrutiny:
General checkups of vehicles embrace the subsequent points.
a) info examination
b) Brakes checkup
c) Battery and lights checkup
d) Door checkup
e) Distance traveled by the vehicles
f) coolant level, brake fluid level, wiper fluid level, and power-assisted steering fluid level
checkup
4.2.3 Clutches and brake:
It includes:
a) Checking front and rear brake pads.
b) Checking brake oil.
c) Cleaning of brake shoe, disc, and drum.
d) Adjusting handbrake and dynamical cable if necessary.
4.2.4 Engine Overhauling
It includes:
a) lever setting.
b) Coolant level check.
c) Timing belt order and fan belt check.
d) Nozzle pressure check.
21
e) Lubricating belts if necessary.
4.2.5 Gearbox check-up:
It includes:
a) Checking clutch plate and pressure plate
b) dynamical clutch plate
c) dynamical gear and counter for increasing acquire
5. Learnings:
We learned so many things in fifteen days. Firstly, we have experienced that the theoretical
environment that we live in and the actual practical job is too different from one another. Most of
the people in the workshop were found to be weak in the theoretical part but they had their type
of understanding regarding the mechanisms, tools, processes, etc. and the interesting fact is they
were not wrong either. We found out the importance of leadership in the success of any business.
Good leadership and proper management can only make a business successful. Kuber Auto
Works Pvt. Ltd. has been successful in Dharan due to its good leadership skills, proper training,
working environment, the value of time(punctuality), etc.
Secondly, we felt that the language of instruments that we use during the study in our college and
labs may not be the same in workshops. The workers had their ascent modified names for some
of the tools and machines. This helps us understand that language has created barriers to some
extent in learning and globalizing things. However, people can understand the principles and
mechanisms.
Thirdly, communication skills were found to be one of the major driving factors of any business.
It was the communication skills like the choice of words, politeness, calmness, and way of
interaction that creates a bond with the customers to gain their trust. It is trust that creates brands.
Mahendra was not built in a day. It took several years for the company to build up this trust and
recognition.
22
Talking about the technical lessons and knowledge gained, we learned a lot regarding the
vehicles and different parts of vehicles. Within 15 days we became able to inquire about the
problems of the vehicle and carry out general servicing of the vehicle on our own.
6. Recommendation:
Although the operation of the company was smooth, customers were satisfied with the services
they are delivered here, still, there was some space for improvements. Some of the changes and
improvements to be made are suggested below.
a) The leakage of compressor air from the pneumatic air gun during the idle condition was
causing the compressor to be turned on again and again. The leakage is to be fixed to
ensure hassle-free maintenance works.
b) There was no proper supervision of work. The head technician is to be hired as a
supervisor.
c) There was no proper waiting area and entertainment facility like television for the
customer to wait till the vehicle servicing is completed.
7. Conclusion:
Mahindra and Mahindra have been contributing a lot to uplifting the economic status of people
by providing small passengers and commercial vehicles for business from small scale to large
scale. Thus, it can be said that Mahendra has been a major part of the country’s economy. The
opportunity to have the internship program in this company was an honor. We learned various
skills during our internship period. The staff and management team was really friendly. The
technicians were trained, skilled and credible for the task to be accomplished that is assigned to
them.
To conclude, Kuber Auto Works Private Limited was a great place to experience and visualize
our theoretical knowledge. The company has been running a successful business since its
establishment in Dharan. With consistent and continuous evolution in terms of technology, and
culture of improvements the company is sure to lead the market for decades.
23
References
Mahindra, 2022. Mahindra Automotive. [Online]
Available at: https://bit.ly/3PDlpMV
[Accessed 26 July 2022].
Statista, 2022. Mahindra and Mahindra. [Online]
Available at: https://bit.ly/3cQui7G
[Accessed 26 July 2022].
24