KATHMANDU UNIVERSITY

SCHOOL OF ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL TRANING REPORT ON

REPORT ON KATHMANDU AUTO ENGINEERING PVT. LTD.

Submitted to:
Lect.Hari Dhakal
INSTRUCTURE
Kathmandu University

Submitted by:
Keshav Verma (42084)

July, 2019
 INTERSHIP EVALUATION

INTERNSHIP AT KATHMANDU AUTO ENGINEERING Pvt. Ltd.By

Keshav Verma
This is to certify that I have examined the internship report and have found that it is
complete and satisfactory in all respects, and that any and all revisions required have
been made.

Mr. Lakshman Lama

Managing Director
Kathmandu Auto Engineering Pvt. Ltd.

Mr. Pratisthit Lal Shrestha

Internship Coordinator
Kathmandu University

ii
 ACKNOWLEDGMENTS
I forward my vote of thankfulness and gratitude to Kathmandu Auto Engineering Pvt. Ltd,
Banepa, Kavre, my supervisor and Managing Director Mr. Lakshman Lama who motivated
and helped me in my Industrial Training. I would like to express my thankfulness to our
intern coordinator Mr. Pratisthit Lal Shrestha, Department of Mechanical Engineering for
giving me opportunity to learn and be familiar with professional life. I would also like to
thank the Marketing manager Mr. Juwar Lama and all the Technicians (Mr. Arjun
Chaudhary, Mr. Khem Bahadur Chaudhary, and Mr. Surendra Chaudhary) and other
employees (Operator, Accountant, Driver) at KAE who assisted & facilitated with all the
required information.
 ABSTRACT
The objective of having this industrial training is to give exposer to the students to the real
working life. This internship report serves the purpose to record of my industrial training
which was conducted at Kathmandu Auto Engineering. This report covers the details of my
internship in the service sector at KAE. It consists description of the task that were performed
during the time of internship which were defined by the company.
This report present the study which was done on different causes of engine failure and
preventive measure for these failure. It consist of a report which was prepared on engine
Repair and Maintenance. It also provide details regarding various case study report on
different engine repaired at KAE.
 TABLE OF CONTENTS
INTERSHIP EVALUATION................................................................................................................................ II
ACKNOWLEDGMENTS.................................................................................................................................. III
ABSTRACT.................................................................................................................................................... IV
LIST OF FIGURE........................................................................................................................................... VII
CHAPTER 1 INTRODUCTION.......................................................................................................................................2
1.1 BACKGROUND.......................................................................................................................................................2
1.2 VISION 2
1.3 MISSION.............................................................................................................................................................................................................2
1.4 OBJECTIVE OF THE COMPANY...............................................................................................................................2
1.5 SCOPE OF THE STUDY............................................................................................................................................2
1.6 ORGANIZATIONAL STRUCTURE AND HIERARCHY.................................................................................................3
1.7 UNIQUE OBSERVATION ABOUT THE COMPANY...................................................................................................5
CHAPTER 2 TECHNICAL SPECIFICATION ABOUT THE COMPANY.................................................................................6
2.1 MACHINES AND EQUIPMENT’S.............................................................................................................................6
2.1.1 Crankshaft Grinding Machine.......................................................................................................................6
2.1.2 Engine Reboring Machine.............................................................................................................................6
2.1.3 Connecting Rod Boring Machine...................................................................................................................7
2.1.5 Surface Grinding Machine............................................................................................................................8
2.1.6 Honing Machine............................................................................................................................................8
2.17 Lathe..............................................................................................................................................................9
2.1.7 Main line checking Machine.........................................................................................................................9
2.1.8 Hydraulic press.....................................................................................................................................10
2.1.9 Drill Press and Bench grinder................................................................................................................10
2.1.10 Tool Box 11
2.1.11 Valve seat cutter tool kit.....................................................................................................................11
2.1.12 Dial Bore Gauge.................................................................................................................................11
2.1.13 Feeler Gauges.....................................................................................................................................12
2.2 SERVICING AND REPAIR PROCEDURE...........................................................................................................12
2.2.1 Procedure.............................................................................................................................................13
2.3 SERVICING FLOW CHART......................................................................................................................................................................14
2.4 PLANT LAYOUT......................................................................................................................................................................................16
2.5 INVENTORY MANAGEMENT.........................................................................................................................17
2.6 QUALITY MANAGEMENT..............................................................................................................................18
CHAPTER 3 INTERNSHIP DETAILS.................................................................................................................. 19
3.1 BRIEF OVERVIEW..................................................................................................................................................................................19
3.1.1 My role in Service Center......................................................................................................................19
3.2 INTERNSHIP METHODOLOGY.......................................................................................................................20
3.3 WORK ASSIGNED..................................................................................................................................................................................21
3.4 WORK ACCOMPLISHED................................................................................................................................21
3.5 LITERATURE REVIEW ON ENGINE REPAIR AND MAINTENANCE...................................................................21
3.5.1 Major Causes for an Engine Failure......................................................................................................21
3.5.2 Brief discussion of the causes of these failure.......................................................................................24
3.5.3 Preventive Maintenance of these Failures............................................................................................25
3.5.4 Crankshaft Crack Testing......................................................................................................................27
3.6 CASE STUDIES.......................................................................................................................................................................................28
3.6.1 TATA CUMMINS EURO II......................................................................................................................28
3.6.2 POWER TRAC / FRAM TRAC..................................................................................................................29
3.6.3 MARUTI ALTO (Head Only)..................................................................................................................30
3.6.4 EICHER MINI TRUCK.............................................................................................................................31
3.6.5 TATA 207..............................................................................................................................................32
 3.6.6 MAHINDRA ZOOM...............................................................................................................................33
3.6.7 HYUNDAI SANTRO (HEAD ONLY).........................................................................................................34
3.6.8 EICHER BOSS........................................................................................................................................35
3.6.9 JCB DIESELMAX TC-68.........................................................................................................................36
3.7 LIMITATIONS.........................................................................................................................................................................................36
3.8 PROBLEMS ENCOUNTERED.........................................................................................................................36
3.9 GANTT CHART.......................................................................................................................................................................................37
CHAPTER 5 CONCLUSION............................................................................................................................ 38
RECOMMENDATION................................................................................................................................... 39
BIBLIOGRAPHY............................................................................................................................................ 40
 LIST OF FIGURE

Figure 1.1 Hierarchy Structure of Kathmandu Auto Engineering Pvt. Ltd............................2

Figure 1.2 Organizational Structure of Kathmandu Auto Engineering Pvt. Ltd...................3
Figure 1.3 Crankshaft Grinding.............................................................................................5
Figure 1.4 Engine Reboring Machine.....................................................................................6
Figure 1.5 Connecting Rod Boring Machine..........................................................................6
Figure 1.6 Surface Grinding Machine.....................................................................................7
Figure 1.7 Honing Machine.....................................................................................................8
Figure 1.8 Main line Checking................................................................................................9
Figure 1.9 Valve seat cutter tool kit.......................................................................................10
Figure 1.10. Engine Servicing Flow Chart…........................................................................14
Figure 1.11 Plant Layout........................................................................................................16
Figure 1.12 Engine cooling system........................................................................................24
 CHAPTER 1 INTRODUCTION
1.1 Background
Kathmandu Auto Engineering is a service company established in 2018 A.D. The company
director Mr. Lakshman Lama established this company to provide expert advice and services
in engine repair and maintenance. Having wide range of professional’s mechanics who have
work in the field of service for more than 10yrs, they assure to perform the task with
optimum quality and time. There are altogether nine employees (a Manager, 2 Head
Technician & 3 junior Technician, a driver, accountant). All kind of vehicles engine such as
Tata Cummins, Mahindra zoom, Hyundai santro, Farm track etc. are checked and repaired
here. They have highly advance and automated equipment’s which ensure the standards of
maintenance. The location of the service was selected based on data’s which assure that wide
range of area can be covered for providing the service. They plan to further expand their
service throughout Nepal.
1.2 Vision
To provide a quality Service and repair taking optimum time at best rate in the field of engine
repair and maintenance throughout Nepal.
1.3 Mission
To improve their service time, quality and reduce cost through use of advance technology and
professional human resource.
1.4 Objective of the company
1. To provide quality service by using standard procedure and professional for repair.
2. To make engine service more reliable and effective using advance machines.

1.5 Scope of the study

The scope of the study is limited within service department of Kathmandu Auto Engineering.
It is specifically dealing with the basic servicing and repairs of engine by specific equipment
and machine where I spent most of my internship period. Besides, some basic information
about the company profile has also been presented in the report. The report also contains a
detail description of my learning & experiences which I gathered through my work.

2
1.6 Organizational Structure and Hierarchy

Figure 1.1 Hierarchy Structure of Kathmandu Auto Engineering Pvt. Ltd.

This service station is managed by the General Manager. Under the General Manager there
are two Senior Technicians. The Senior Technicians are the major people who made sure that
everything in the shop operated well. There are a total of 5 technician who work on the shop
floor. With the years of experience, the senior technicians guided the junior technicians and
acted as trouble-shooters helping others whenever needed. The junior technicians were
responsible for most jobs and were aided by trainees.
 Figure 1.2 Organizational Structure of Kathmandu Auto Engineering Pvt. Ltd.

This organization structure defines how activities such as task allocation, coordination, and
supervision are directed toward the achievement of organizational aims. This structure
provide clear view about which individual can participate in which level of decision making
process
with final decision made by the chairman. It measure the individual capacity to change and
shape the action taken by the organization.
2.2 Servicing and repair procedure
Whenever the engine comes in initial cleaning and drying process using kerosene oil, water
and air jet are performed. After that engine head are thoroughly inspected for cracks and
depressions, valves are also checked along with guide and seat. The crankshaft is inspected
by using two kind of test they are powder test and fluorescent die test. The engine block liner
is inspected and if its diameter is not standard it is replaced. Connecting rod bushes are
checked, and connecting rod is also checked for deflection, piston head is check for over burn
effects. Then a card is filled up contains the technician inspection conclusion and its possible
solution, and type of repair required and the estimated cost of repair. After the customer
agrees for the service stated, the senior technician assigns a particular technician to work on
it. The technician studies the problem and also consults with the customer regarding his/her
complaint. If he needs any material or spare parts, he informs the manager about it and the
parts are ordered.

The customer is allowed to stay within the main work field to get the real time assessment of
the service being provided if he/she wished. After all jobs are done, the engine is assembled
and the free rotation of the crankshaft is checked. The tightness and fitting of each and every
parts are checked. The Manager verifies the jobs done on the vehicle and calculates the total
cost incurred for the service. The customer then pays the bills in the billing.
2.2.1 Procedure
Engine repair at KAE follows stepped procedures from engine entry to vehicle exit. These
procedures are listed below:
1. Cleaning of the engine and its parts
 Cleaning using kerosene oil/Diesel.
 Cleaning by water jet.
2. Drying by the use of air jet – Drying process.
3. Marking with code number for proper identification.
4. Check and Inspection
 Each cylinder Crank journal diameter check by the use of micrometer.
 Each cylinder bore diameter check by use of dial gauge.
 Crankshaft check for cracks.
 Crankshaft Diameter check.
 Liner wear and diameter check by use of dial bore gauge.
 Oil pump pressure check manually
 Engine head plane level check.
 Connecting rod bending sign and stroke check
 Piston ring wear check
 Piston Head check for Excess carbon deposition or sign of cracks and wear
 Value grooves and stem check for sign of wear and grind
5. Documentation
The problems are documented and the duration for repair and maintenance is allocated.
Required parts are listed.
6. Ordering
The necessary engine parts are then order as request by the technicians
7. Machining
After all check and inspection machine process is carried out. The crankshaft Journals
are machined as suggested by the technical to proper standards. The old liner are either
replaced or polished according to the report. Cylinder boring are done on the Reboring
machine and then liner are hammered down. Honing process are implemented using
grinding rectangular stone of particular grain size according to requirement and cross
hatch pattern are made in the liner. The head can be faced using surface grinding
machine making it at a level which is measured using sprit level. The seat can be
removed using
 chisel and hammer or j shape work piece and hammer. After removal, new seat can be
replaced. Grinding process can be done for making 30 degree and 45 degree seat slop
using hardened steel grinding toothed wheel of standard size. Smooth Grinding are done
using grinding paste making it near tolerance. Connecting rod small end bush are made
to that of the pin using CR bush grinding machine.

8. Final cleaning
 Using kerosene oil and waterjet for cleaning the engine and then delivered.

2.3 Servicing Flow Chart

Cleaning
&
Drying

Marking

Check and Inspection

 Documentation &
Ordering

Machining

Final Cleaning

Figure 1.10. Engine Servicing Flow Chart

2.4 Plant Layout

Figure 1.11. Plant Layout

A – Engine Arrival section

B – Engine Cleaning and Inspection section
1 – Inventory
2 – Reception and cash counter
3 – Welding Section
4 – Grinding Section
5 – Crankshaft grinding
Machine 6 – Reboring Machine
7 – Honing Machine
8 – Tools Rack
9 – Main line checking Machine
10 – Lathe Machine Section
11 – Hydraulic Machine
The machine work space are properly managed at KAE. These machine are located on basic
on daily usage and power required.
 Engine Arrival section
The engine are delivered in this section by the delivery van. They are brought from
various area and vendors. Some engine are brought up by their owner at this section.
 Engine Cleaning and Inspection section
The engine are then cleaned by use of kerosene and water jet. They are dried by the
use of air jet. Senior technician perform inspection at this area using various tools and
method.
 Inventory
The parts for engine repair are stored here. This inventory consists of highly moving
parts that fails frequently but need to replace frequently. Example: valves, guides,
seats, Gasket, piston etc.
 Reception and cash counter
The card are issued here. All the parts that are needed are ordered here. The amount
for repair are paid here.
 Welding Section
 Grinding Section
 Crankshaft grinding Machine
 Reboring Machine
 Honing Machine
 Tools Rack
 Main line checking Machine
 Lathe Machine Section
 Hydraulic Machine
2.5 Inventory Management
Inventory management is the most challenging aspect of any organization as it is very
difficult to predict exact amount of future requirement of parts. In KAE the future demand is
predicted by the trend present in previous actual data. The inventory levels are checked
periodically and as inventory level reaches below certain limit the parts are reordered. In
KAE inventory parts are managed according to its usage and frequency of the particular
engine.
This inventory consists of highly moving parts that fails frequently but need to replace
frequently. Example: valves, guides, seats, gasket, etc. These inventories are relatively
predictable and are available. The inventory level depends on the engine that comes for
repairs. Basically the parts such as liner, piston head, connecting rod etc. are also kept as
inventory but of only particular and frequently coming engines. Example: TATA Cummins,
TATA 207, Mahindra ALTO, Farm Track, Mahindra Zoom, etc. The part are ordered for
others engine whose frequency of arrival is low. The use of standard part provided by
particular engine company is used for better efficiency. These may include the parts of
Eicher, Mahindra, Hyundai and TATA engine.
2.6 Quality Management
The quality of service provided is managed by taking feedback from the customer and is
measured depending on the response of the customer. To maintain quality level KAE uses
only genuine parts from authorized suppliers. Workers are given special training to be
familiar with the quality level needed in repair/service work.
 Chapter 3
Internship Methodology
My internship was divided in different segments according to monthly basis. During intern
period I interacted with the manager and senior technicians to understand the different
problems and their troubleshooting procedure. I not only got to learn about the trouble
shooting procedures but also got to see and learn closely the various new innovations and
aspects of the engine and the workspace which to me where previously only confined to
course-books.
In the first month of my internship, I was given a brief introduction about company, the
equipment’s used, rules and regulations, introduced to the staff members and gave me safety
instructions to be followed throughout the course of the internship. I was assigned freely on
the floor so that I could learn from every technician regarding engine diagnosis throughout
the course of the internship. I was given the task to study different journal and research paper
regarding engine, its failure, and its repair and maintenance analysis of the engine. I needed
to learn the general procedure that is needed to repair an engine part such as valves seat,
crank journal, liner etc.
In the second month of my internship, my internship in the field started. I got to know about
the various aspects of the machine used at KAE and their basic functionalities. Throughout
that week, with close guidance from the technical advisors, I learned the basic service
procedure of the engine and about the various technologies used to achieve the proper and
efficient outcomes. I started diagnostic tasks. Along with my technical mentor, I got the
opportunity to know different problems that arises in an engine and performed basic service
procedures in the ones which required one.
During third month, I learned various engine repair and prepare a case report on engine repair
that comes for repair like TATA Cummins, Farm Track, Mahindra Zoom, Eicher Boss, JCB,
etc. Throughout the whole week the jobs which I mostly got to undertake were preparing
report on Engine repair of different engine and documenting the methods used for repair and
comparing it with standard.
Remaining weeks, I got to work on the managerial and quality control aspects of the
workspace and also to work closely with the manager. At the end of the week I was given
time to prepare report and undergo change in it with the details given by the supervisor.
3.1 Work Assigned
 To understand the management of workshop and its operation
 To understand working of the machine for repair of an engine at KAE.
 To prepare a flowchart of proper procedure of work being carried out at KAE.
 To Study different causes of engine failure, causes for these failure and preventive
measure for these failure and prepare a report on engine Repair and Maintenance.
 To prepare case study report on different engine for repair at KAE.
3.2 Work Accomplished
 Working of the machine for repair of an engine at KAE were studied.
 Flowchart of proper procedure of work being carried out at KAE was Prepared.
 Literature Review on Different causes of engine failure, causes for these failure and
preventive measure for these failure and prepare a report on engine Repair and
Maintenance was done.
 Case study report on different engine for repair at KAE was made.

3.3 Literature Review on Engine Repair and Maintenance

Engine are devices which burns the fuel and provide power to a vehicle. In our context we
work on internal combustion engine both diesel and petrol with or without turbo. There are
many problems in a vehicle the can lead to engine failure and cause problem in an engine. In
this report we are going to study major causes for an engine failure and reasons behinds these
failure and how they can be avoided.
3.3.1 Major Causes for an Engine Failure
1. Over Heating:
The engine generally operated at an optimum average temperature with high temperature up
to 3000k at the time of power stroke. The is thermal energy release during the power stroke
which is converted into mechanical energy but a portion of the energy is release as heat
which is absorbed by part within the engine such as cylinder, piston , piston ring etc. It’s very
important for proper dissipation and disposal of these heat with the help of proper cooling
and lubrication system.
When cooling system fails, it results in overheating of engine. It occurs due to:
 Leakage of coolant or low level of coolant in its reservoir.
 Water pump failure.
  Failure of the thermostat which causes improper flow of the coolant to the engine.
 Not having cooling system flushed according to your vehicle manufacturer's mileage
schedule which make sure the system is in good shape and is properly keeping your
engine cool.
2. Improper lubrication:
Engine may fail as a result of getting less oil than it needed i.e. engine oil starvation. Result
in metal to metal contact in an engine which may result in failure in parts such as crankshaft
journal wear i.e. Gap between the main and rod bearing, connecting rod bush failure etc. The
main causes for the starvation is improper and unpressurized flow of oil which is caused by
faulty oil pump, improper schedule change of oil and oil filter.
3. Petrol / Diesel Engine Detonation/Knocking:
Inside the combustion chamber, due to improper combustion or untimely combustion or
abnormal combustion can result in engine failure. These combustion results in excessive heat
and pressure inside engine chamber and its parts. It causes unusual noise in the engine and
unneeded vibration.
The reason behind these combustion can be due to failure of Exhaust Gas Recirculation
system which is responsible for sending signal to ECU for the control of air/fuel mixture
depending upon the load on an engine for petrol engine.
Diesel engine knocks when there is accumulation of fuel in the combustion chamber which
happens when the injected fuel fails to burn as there will be a huge delay period. At a specific
time all mixture burns simultaneously which causes increase in peak pressure and shock
waves travel at higher speeds and can lead to permanent damage to piston crown and cylinder
wall and head. [6]
4. Contaminated Fuel System (Fuel Filtration System)
A diesel engine is only as efficient and powerful as the fuel that is used to provide power. If
the fuel that is put in the tank of diesel engine is contaminated by anything from dirt to small
microscopic organisms, it generates sludge buildup in the tank and can clog the filters, cause
fuel pump failures and finally engine related problems.
Likewise, water condensation can be a big problem with diesel fuel, and even an excess of air
pressure within the tank can change how the fuel is delivered to the engine. So if a fuel
system filter is dysfunctional, it can change both air pressure and water condensation levels in
the tank, which can definitely be problematic for diesel engine.
5. Electronic Control Module Improperly Calibrated
The electronic control module (ECM) is like the computer system for diesel engine, handling
all kinds of micro processed tasks at any given moment during operation. The ECM has
really important function to perform such as control of injection timing, metering and
distribution and control of information from sensors and switched of fuel system.
If problem in ECU arises, it can cause the whole diesel engine to shut down. As it will not get
adequate fuel when the injectors need it and the engine will not be able to protect itself from
fuel overload so it simply shuts down. [7]
6. Head Gasket Failure
A head gasket failure can occur due to overheating resulting in more heating of the engine.
This failure may cause compressed air/fuel to escape making loss of compression causing
low engine power and rough running of engine. It can also allow the coolant and oil to mix,
resulting in contaminated oil that will ruin the engine’s bearings if left unattended.
3.3.2 Brief discussion of the causes of these failure
1. Overheating failure causes:
Normally engine is operates at an average temperature of 195-220 Fahrenheit. The engine
is kept cooled with the help of coolant flow through the engine. The boiling point of the
coolant is increased with the help of pressure maintained by the radiator cap. So proper
functioning of the radiator cap should be checked. [8]

Figure 1.12: Engine cooling system

The problem overheating arises when there is:

 Low coolant level or a coolant leak (through internal or external leaks)
 Poor heat conductivity inside the engine because of accumulated deposits in the water
jackets
 A defective thermostat that doesn't open.
 Poor airflow through the radiator
 Improper functioning of the cooling fan
 A collapsed lower radiator hose
 An eroded or loose water pump impeller
 A defective radiator cap
 Faulty coolant sensor
 Overall the cooling system should be checked and maintained.
2. Improper Lubrication failure causes:
 When lubrication oil are not changed as per schedule there is subsequent low engine
oil level in the engine which results in lubrication related problems. So major focus
must be to follow the schedule.
 Faulty oil pump – Oil pump provide oil throughout the engine and its bearings and
need very less servicing and repair but it must be check for pressure routine wise and
its failure may damage the engine. When failure of pump occur the pressure required
decrease providing less oil around the engine resulting in rubbing of components
which causes the heat inside the engine to increase. Without adequate oil, these parts
will stop functioning correctly or quietly.
 High mileage wear and tear
3. Contaminated Fuel System Causes
Fuel contamination by debris and moisture, corrosion particles and other visible particle.
These particles clog important part of fuel system such as strainers, filters and the fuel
pump itself. This blockage ultimately impairs the flow of fuel, which may affect the
vehicle during acceleration, among other long-term impairments. Electrical faults are also
significant contributors to fuel pump failures. The most common electrical issues are
rusted connectors, loose connectors, or melted wiring and connectors. [9]
4. Head Gasket failure causes
Head gasket failures are usually the result of an engine overheating which may be result
of faulty cooling system including radiator, radiator cap etc.
3.3.3 Preventive Maintenance of these Failures
Prevention is better than cure.
1. Overheating Failure Prevention
Properly working cooling system check including:
 A visual inspection of all cooling system components, including belts and hoses
 A radiator cap pressure test to check the recommended system pressure level
 A thermostat check for proper opening and closing
 A pressure test to identify external leaks to the cooling system parts including the
radiator, water pump, engine coolant passages, radiator, heater hoses and heater core
 An internal leak test to check for combustion gas leakage into the cooling system [10]
2. Head Gasket failure Prevention
Head gasket failures are usually the result of an engine overheating, so the best way to
prevent a head gasket failure is to ensure your cooling system is in good condition. Ensure
the system has no leaks, the radiator is working efficiently, and the coolant is up to the
correct level. Also, make sure electric fans are working correctly, and that the thermostat
opens at the temperature it should.
A replacement head gasket itself is not too expensive but the repair is very labor intensive,
which significantly increases the cost of repair. [8]
NOTE: If the oil is contaminated due to head gasket failure, repair requires a complete
engine oil flush as well as a replacement oil filter to ensure all traces of contaminated oil
are removed from the engine. [10]
3. Improper Lubrication Failure Prevention
• Lubrication oil should be changed as per schedule and when there is subsequent low
engine oil level in the engine
• Check for Faulty oil pump –it must be check for pressure routine wise. This can be
checked manually or by pressure gauge.
 Oil Galleries should be checked for blockage or chips so that oil flow is adequate.
4. Petrol / Diesel Engine Detonation/Knocking Prevention
Detonation/Knocking occurs both in CI and SI engines but the cause for which they occur
is different in both the cases. For SI engines, it occurs due to pre-ignition of fuel at the
farthest end and in CI engine it occurs due to ignition delay.
• Fill up tank only from reputable gas stations for quality fuel.
• Use fuel with higher octane ratings or be sure to follow owner’s manual on
recommended minimum octane ratings
• Make sure spark plugs are regularly changed as recommended by owner’s manual
• Reduce the throttle immediately if there is any type of pinging or engine knock.
• Eliminate or prevent carbon deposit buildup by using a quality fuel additive designed
specifically to reduce carbon buildup.
5. Contaminated Fuel System Prevention
 Schedule repair and change of fuel Filter
 Check of electrical circuits for loose wire, rusted connectors, loose connectors, or
melted wiring and connectors.
  Better quality fuel not contaminated by anything from dirt to small microscopic
organisms.
 Check for Faulty fuel pump- It must be check for pressure routine wise. This can be
checked manually or by pressure gauge.
 Weather Tightness of Tanks-The better the weatherproofing, the less the chance of
rainwater seepage into the tank.
3.3.4 Crankshaft Crack Testing
1. Dye penetrant Testing
Dye penetrant inspection is a sensitive technique for surface-connected defects such as
porosity and cracks. In this process, the casting is bathed or immersed in a dye, a liquid
designed to be highly wetting so as to penetrate small holes and fissures rapidly. The castings
is withdrawn from the die, washed and coated with a ‘developer’ in the form of a fine white
powder that can absorb the dye by capillary attraction as a blotting paper, sucking the die out
of its crevice and into the developer layer where it can be seen. The most sensitive dyes
fluoresce in ultraviolet light, and are therefore viewed in a darkened area.
The dye penetrant inspection approach is of course limited to the detection of surface-
connected defects; any internal defects, which may be major faults, remain undetectable.
2. Powder Testing
It is a technique used for surface crack detection. In this process, the crankshaft is wash using
kerosene oil or diesel and is then dried using air jet. The shaft is then coated with fine white
powder that can absorb the kerosene oil or diesel by capillary action. The shaft is hammered
so as the remaining powder are left out during the inspection and does not cause any
misreading.
 Types of Forecasting method
1. Qualitative methods
2. Quantitative methods

1. Under Qualitative methods

 Jury of Executive Opinion
 Sales force composite
 Consumer Market survey
 DELPHI method

2. Under Quantitative methods

 Naive approach
 Moving averages
 Exponential smoothing
 Trend projection
 Linear regression

 Naïve Approach
Assumes demand in next period is the same as demand in most recent period. e.g., If January Demand were 320, then
February sales will be 320 for a Product. Sometimes cost effective and efficient.
 Moving Average
Forecast based on an average of recent values. It is a series of arithmetic means.

Moving Average=
∑ Demand ∈previous N period
N
In 2018 the actual services provided to the customer from January to December are listed below. The forecasting for
2019 from January to December on the base on Moving Average of 3 month is calculated.
Month Demand Moving average
Janaury 320 404
February 410 427
March 480 447
April 390 454
May 470 427
June 500 414
July 310 370
August 430 430
September 370 412
October 490 427
November 375 395
December 415 415

Graph of the above Data

 Moving Average
600

500

400

300

200

100

0
ry ar
y ch ril ay ne Ju
ly st be
r
be
r
be
r
be
r
au ru ar Ap M Ju gu to m
a n b M Au em c ve
m
ce
J F e pt O
Se No De

Demand moving Average of 3 month

 Weight Moving Average

Forecast based on a moving average with weights that vary. It is used when some trend might be present .
In this trend older data usually less important, hence given less weighted.

Weight moving average=

∑ (Weight for period n¿)×(demand∈ period n) ¿
∑ Weights
In 2018 the actual services provided to the customer from January to December are listed below. The forecasting for
2019 from January to December on the base on Moving Average of 3 month is calculated.

Month Demand 3 month weighted average

Janaury 320 430
February 410 424
March 480 445
April 390 472
May 470 400
June 500 402
July 310 380
August 430 440
September 370 413
October 490 415
November 375 415
December 415 415

  Weight Applied Period

  1 Last month
  2 Previous
  3 Recent
Total weighted 6  

Graph of above Data

 Weight Moving Average
600

500

400

300

200

100

Demand 3 month weight average

 Exponential Smoothing
In this forecasting method every new forecast is equal to the previous forecast plus a percentage of the previous
error.This method of forecasting depend upon the previous forecasting. Smoothing constant Alpha is used in this
method.
Today forecast=Forecast of yesterday + Alpha * Forecasting Error
Ft=Ft-1 +ꭤ(At-1 –Ft-1)
Forecasting Error= At −1−Ft −1
In 2018 the actual services provided to the customer from January to December are listed below. The forecasting for
2019 from January to December on the base on Exponential Smoothing is calculated.

Month Actual Forecasting with ꭤ=.7

January 320 350
February 410 329
March 480 386
April 390 452
May 470 409
June 500 452
July 310 486
August 430 363
September 370 410
October 490 382
November 375 458
December 415 400

Graph of above data

 Exponential Smoothing
600

500

400

300

200

100

Actual New Forecasting with ꭤ=.7

 Exponential Smoothing with Trend Adjustment

When a trend is present, exponential smoothing must be modified to respond to trend Forecasting.
Forecast including = trend Exponentially Exponentially smoothed + smoothed forecast trend
(FITt) = (Ft) (Tt)
Ft = ꭤ(Actual Demand last period) + (1 - ꭤ)(Forecast last period + Trend estimate last period)
Ft = ꭤ(At-1) + (1 - ꭤ)(Ft-1 + Tt-1)
Tt = ẞ(Forecast this period - Forecast last period) + (1 - ẞ)(Trend estimate last period)
Tt = ẞ(Ft - Ft-1) + (1 - ẞ)Tt-1
Ft = exponentially smoothed forecast of the data series in period t
Tt= exponentially smoothed trend in period t
At= Actual demand in period t
ꭤ= smoothing constant for the average
ẞ= smoothing constant for the trend
In 2018 the actual services provided to the customer from January to December are listed below. The forecasting for
2019 from January to December on the base on Exponential Smoothing with Trend adjustment is calculated.
Smoothed Smoothed
Month Actual Forecast Trend Forecast Including Trend
January 320 350 10 360
February 410 336 3 339
March 480 382 16 398
April 390 447 31 478
May 470 425 15 440
June 500 458 21 479
July 310 492 25 517
August 430 393 -13 380
Septembe
r 370 410 -4 406
October 490 385 -11 374
November 375 444 11 455
December 415 407 -4 403
 smoothing constant for the average(ꭤ) 0.6
smoothing constant for the trend(ẞ) 0.3

Graph of above data

Exponential Smoothing with trend

1200

1000

800

600

400

200

0
ry ry ch ril ay ne Ju
ly st be
r er be
r
be
r
ua rua ar Ap M Ju gu m tob m
J a n
eb M Au
te Oc em ce
F ep N ov De
S

Actual Forecast Including Trend

 Trend Projections
The last time series forecasting method. This technique fits a trend line to historical data points to project into the
medium to long-range forecasts. Linear trends can be found using the least squares technique.
^y =a+bx
Where
^y = computed value of the variable to be predicted (dependent variable)
a = y-axis intercept
b = slope of the regression line(or the rate of change in y for a given changes in x)
x = the independent variable
Equations to calculate the regression variables
^y =a+bx
b=
∑ xy−n x́ ý
x 2−n x´2
∑
a= ý−b x́

Where,
b = slope of regression line
∑=Summation sign
x = known values of the independent variable
y = known values of the dependent variable
x́ = average of the x- values
ý = average of the y- values
n = number of data points or observations
In 2018 the actual services provided to the customer from January to December are listed below. The forecasting for
2019 from January to December on the base on least square method.
Month Time(X) Actual(Y) x2 XY
January 1 320 1 320
February 2 410 4 820
March 3 480 9 1440
April 4 390 16 1560
May 5 470 25 2350
June 6 500 36 3000
July 7 310 49 2170
August 8 430 64 3440
Septemb
er 9 370 81 3330
October 10 490 100 4900
Novembe
r 11 375 121 4125
Decembe
r 12 415 144 4980
2
∑ x =¿65 xy =¿ ¿32
∑
n=12 ∑X=78 ∑Y=4960 0 435
ý=¿413.33
  x́ =6.5 33    

b=1.3636
a=404.46
y=404.46+1.36x

Graph of above data

Trend Projection
600

500

400

300

200

100

0
1 2 3 4 5 6 7 8 9 10 11 12

Time(X) Actual(Y) Linear (Actual(Y))

 Linear regression
All above method are time series models but the linear regression method is associative models. This models also
used the least square methods to calculate the forecasting. An other method to calculate the linear regression by using
correlation coefficient. The correlation coefficient lies between -1 to 1.
r=-1 represent the decreasing but less scatter
r=0 represent more scatter
0<r<1 represent the increasing but scatter
r=1 represent the increasing but less scatter

Actual
600

500

400

300

200

100

0
0 2 4 6 8 10 12 14
Our data is increasing and scatter.
 CHAPTER 5 CONCLUSION
It was a wonderful learning experience at Kathmandu Auto Engineering. The time spent
during internship at KAE resulted as the best start for my career. I was able to work on
different machines there at KAE for repair and prepare a flowchart of engine servicing
procedure. Literature Review was also done on different causes of engine failure and
preventive measure for these failure and a report on engine Repair and Maintenance was
prepared. Case study report on different engine for repair at KAE were carried out. Overall,
my internship at KAE has been a success. I was able to gain practical skills, work in a
fantastic environment, and make connections that will last a lifetime. I could not be more
thankful.
 RECOMMENDATION

Use for more advance and digital machines for more accurate repair of engines. Improvement
can be done regarding process of documentation (making job sheet) by making it more
descriptive i.e. including more details of the problem, cost and duration of servicing. Personal
Protective Equipments and service clothing can be provided to the technicians at the time of
repair. Inventory can be made descriptive by providing a sheets which may include the parts
at a time in inventory and duration to order next cycle.
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