VISVESVARAYA TECHNOLOGICAL UNIVERSITY

“JNANA SANGAMA”, BELAGAVI – 590 018

REPORT
On

IN-PLANT TRAINING
Submitted in partial fulfillment of the
Requirements for the award of the degree of

BACHELOR OF ENGINEERING
in
MECHANICAL ENGINEERING
By

FAZLUR RAHAMAN SHARIFF

(4GL16ME018)

Under the Guidance of

DR. LAKSHMIDEVAMMA M M B.E M.Tech, Ph.D
Dept. of Mechanical Engineering
Government Engineering College
Kushalnagar-571 234

DEPARTMENT OF MECHANICAL ENGINEERING

GOVERNMENT ENGINEERING COLLEGE
KUSHALNAGAR – 571 234, KARNATAKA
2019-2020
 GOVERNMENT ENGINEERING COLLEGE
KUSHALNAGARA - 571234
KODAGU, KARNATAKA

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE
This is to Certify that FAZLUR RAHAMAN SHARIFF
(4GL16ME018) has successfully presented A REPORT on “IN-PLANT TRAINING” in
partial fulfillment of the requirement for the completion of BACHELOR OF ENGINEERING
in MECHANICAL ENGINEERING as prescribed by VISVESVARAYA
TECHNOLOGICAL UNIVERSITY during the year 2019-2020. The in-plant training report
has been approved as it satisfies the Academic requirements with project work prescribed for
the mentioned degree.

Signature of the HOD Under the Guidance of

Dr. M M BENAL B.E M.Tech, Ph.D
Head of the department
Dept. of Mechanical Engineering
Govt. Engineering College
Kushalnagar
DR. LAKSHMIDEVAMMA M M B.E M.Tech, Ph.D
Assistant Professor
Dept. of Mechanical Engineering
Govt. Engineering College
Kushalnagar
ABSTRACT

In order to get faster result over a particular period, maximum utilization of is very much
required. So if the proper utilization of time will be done then the maximum efficiency will
be produced with in the industry. My topic “Time study of ETSA & Rear axle sub assembly
and design layout of line no.1 (assembely-1)”at Maruti is very much related with above
fact.

There are many reasons for wanting to know the amount of time a particular task should
take to be completed. It may simply be for reasons of curiosity. But realistically, it is for
any of three reasons: (1) to accomplish planning, (2) determine performance and (3)
establish costs.

In this project I have calculated the total time that the each worker at each station took to
complete its task in ETSA(Engine Transmission Sub Assembly of WagonR) and rear axle
sub assembly of line no-4 (Eeco & Ritz) and I also design the layout of line no.1(Omni &
Ritz).I have calculated time at different station with the help of stop watch and for layout
design I visit all the station of line no.1 to find how many workers are engaged there and
note all the workers working in different sections of line no.1 and know its
category(category such as permanent, T.T, casual, apprentice, repairmen & reliever. After
finding various details of 3 sections –trim, chassis and final of line no.1, I designed the
layout of line no.1.
 ACKWOLEDGEMENT

On presenting the report on “IN-PLANT TRAINING”, I feel great to express my

humble feeling of thanks to all who have helped me directly or indirectly.
I am grateful to the institution of Government Engineering College, Kushalnagar
and Department of Mechanical Engineering for imparting me the knowledge with which
I could do my best.
I would like to thanks our beloved guides Mrs. LAKSHMIDEVAMMA M M
Assistant Professor, Dept. of Mechanical engineering who has helped me a lot and for
continuous encouragement and guidance throughout.
For the overall supervision and direction, I am grateful to our respected
Dr. M.M.BENAL Head of the Department of mechanical engineering, Government
Engineering College, Kushalnagar. Finally, I would like to thank our teaching and
nonteaching staff of Department of Mechanical Engineering department, GECK.

FAZLUR RAHAMAN SHARIFF

(4GL16ME018)
 LIST OF FIGURES

SL NO NAME PAGE NO
1 Front view 1
2 Work shop inside view 2
3 Work shop 2
4 Workshop 9
5 Body shop 11
6 Denting 12
7 Paint shop 13
8 Gear mechanism 15
9 Chain mechanism 15
10 Engine 16
11 4 Stroke engine 16
12 Washing 17
13 Air filter 18
14 Engine oil 19
15 Clutch plate 20
16 Brake 20
17 Internal view of disk brakes 21
18 Leverage 22
19 Disc brakes 23
20 Opposed piston type disc brakes 24
21 Floating caliper type disc brakes 24
22 Floating caliper type disc brakes 25
23 Brake pad 26
24 Wheel alignment 27
25 Wheel alignment and balancing 27
26 Engine setup 28
 CONTENTS
CHAPTER TOPIC PAGE NO

1 INTRODUCTION 1
1.1 COMPANY PROFILE 1
1.2 COMPANY OVERVIEW 3
2 WORKSHOP & SHOWROOM 9
2.1 WORKSHOP 9
3 WORKING IN WORKSHOP 10
3.1 BODY SHOP 11
3.1.1 DENTING 12
3.2 PAINT SHOP 13
3.3 SERVICE SHOP 14
3.3.1 FREE SERVICES 14
3.3.4 QUICK SERVICES 15
3.4 WASHING 17
4 WORKING IN WORKSHOP 18
4.1 REPLACEMENT OF THE OIL FILTER 18
4.2 AIR FILTER 18
4.3 ENGINE OIL 19
4.4 CLUTCH PLATE 19
4.5 BRAKE 20
4.6.1 BRAKE BASICS 21
4.6.1a LEVERAGE 22
4.6.1 b HYDRAULIC SYSTEMS 22
4.6.1 c FRICTION 22
4.7 DISC BRAKES 23
4.7.1 TYPES OF DISK BREAKS 23
4.7.1 a OPPOSED PISTON TYPE DISC BRAKES 24
4.7.1 b FLOATING CALIPER TYPE DISC BRAKES 24
4.8 BRAKE PAD 25
4.9 WHEEL ALIGNMENT AND BALANCING 26
5 CONCLUSION 29
CHAPTER 1
INTRODUCTION
1.1 COMPANY PROFILE

Fig 1: Front view

Fig 2: Work shop inside view

Fig 3: Work shop

1.2 COMPANY OVERVIEW
Maruti is India’s most saleable car. There are a variety of Maruti car brands that has
dominated the Indian roads. Maruti cars are buyable from the car dealerships, used car
dealers, car websites and car owners. Maruti car reviews explain the worth of buying Maruti
Car. There are Maruti used car dealer and know more about the car prices.

About Mandovi Motors:

Mandovi Motors Pvt Ltd is one of the leading dealers of Maruti Suzuki cars, in
KUSHALNAGAR. A state of the art showroom, experienced staff, and enviable seller’s
record are a few of the reasons why it makes sense to choose Mandovi Motors was established
in 1963 as a Volkswagen spares and service dealership. There were appointed as dealers for
suvega mopeds at Kushalnagar in 1965. After that, M/s Maruti udyog Ltd appointed Mandovi
Motors as dealers for maruti vehicles in the year 1983. Mr. Ashok Rao is the Managing
director of the company.

Mandovi motors are one of the top maruti dealers in India. They are the 1st authorized dealers
for maruti in Karnataka and commenced our operations at Bangalore on 14th June 1984.
Mandovi also started Maruti Suzuki’s authorized dealership at Mysore in 1986 and later in
1989 at Mangalore. Mandovi Motors Pvt Ltd has over 2200 employees and the company is
certified as ISO-9001/2000 for its quality system by AIB international Ltd., Brussels an
accredited body from Belgium.

Achievements of Mandovi Motors:

 They are N0.1 in corporate sales for 2008-2009.

 Best Dealer in Karnataka in overall performance for 2008-2009.
 Best Dealer in India for Three times in a row for 2008-2009.
 Best Dealer in Sales Growth for 2008-2009.
 Best Dealer for Man Power retention for 2008-2009.
 No.1 in accessories sales for 2006-2007 in Karnataka & No.1 all over India.
Company Culture:

Culture is a pattern of behaviours that is encouraged, developed & incorporated by like-

minded people in a society (in our case, a company). Mandovi is now 35 years old, & their
culture has been developed enough to formalize it. Culture cannot be dictated by heads of
society, leaders, or even directors / owners (as in their company). These are a set of
behaviours / attitudes that are developed by the members of the society, or company.

In order for our company to grow & prosper in these changing times, it is very important that
we identify & respect the culture we live by. It is of utmost importance that ALL members
of their organization agree with & respect their culture that is the only way they can grow in
harmony & happiness.

Respect for all members of the Organization:

They are all working towards the same objective, & every member of our company is as
important as the other. This means respect for everyone, including washers, maintenance staff
etc. is very important. There is a hierarchy and seniority within their organization that must
be respected, however, aside from respecting their seniors, they all must appreciate the
dignity of labour at all levels in their company. They are all part of the organization that
works together to achieve our objective. This attitude brings mutual respect & harmony in
their work environment.

Integrity:
They are all here to achieve our company objectives without compromising on their integrity
& ethics. Honesty is expected & respected amongst us all. They would like all of us to be
100% honest & ethical to all their colleagues & customers. There is no place for unethical
team members, who will lie or cheat their peers for personal gains. This is what creates faith
amongst one another in their organization as well as with their customers.

Loyalty:
They are a very young team, & many of them have started their careers here. The company
respects all team members who work loyally towards the goals of the company. They are
very keen on giving Opportunities for further growth within our organization before doing
external recruiting. This increases opportunity for growth within their organization, along
with reducing attrition.
Positive Teamwork:

They can only succeed if they work positively as a team. Their company should be broken
up into different teams within departments & outlets. This sub classification of teams within
teams will help us manage their organization better, & will increase accountability.
Teamwork at a micro level also helps us identify the managers of the future.

Each team should have a Captain & a Vice Captain. Managers can make this a very interesting
aspect of their company, where teams are interchanged; Captains & vice Captains are
appointed on rotation to give everyone an opportunity. Managers have the flexibility to create
sub teams. This will help us identify successions plans for the future, groom managers for the
future & increase motivation within their organization.

Ownership & Respect for the workplace:

Work is Worship & Mandovi their workplace is our Temple. They think they should not &
cannot let it be abused. All should feel the ownership to keep our workplace clean, respectful
& liveable. This means, bathrooms should be kept clean, lights & fans should be turned off
while leaving the offices, litter should be picked up, etc. It is also their duty to point out to
others who are not respecting their workplace. Managers & senior staff should lead by
example. Damaging company infrastructure should not be accepted.

All here to solve problem:

Every country, society, & organization has problems. There are many who highlight
problems but refuse to participate in finding long term solutions for the same. There are those
who ignore problems with the hope that it will disappear & some who pass problems on to
other Departments / Teams. Mandovi all agree that ‘any company problem is our problem’.
It is their duty to do their very best in ‘solving’ the problem. This will create ownership of
processes within their organization. It will also encourage suggestions & systems that help
us improve.

Transparency & objectivity:

Mandovi think it’s their collective endeavour to be as transparent & as objective as possible.
They have to let everyone know that they are a fair organization that rewards performers.
They must move towards a totally Objective appraisal & incentive system where performance
is the only criteria.
Customer is friend as well as source of live hood:

All the above principles are in vain if we cannot respect our customers. Their utmost
satisfaction is the only way we can secure our future growth. Their convenience, their
satisfaction & their trust is what we must strive for every day. All our trainings, systems &
processes have to be made keeping the Customer as a focal point.

Mandovi not only strive to keep our customers happy, but strive in creating a friendship with
them. All members of Mandovi must have these guidelines at the back of their mind during
any interaction or work. This must be the cornerstones on which we base our growth. All
policies, objectives, & decisions must be made keeping our culture in mind.

Objectives:

 Putting the new employee at ease

 Briefing them of the nature of work

 Creating interest in his/her job and the company

 Providing basic information about working arrangements

 Indicating the standards of performance and behaviour expected of him/her.

 Informing him/her about training facilities

 Creating the feeling of social security.

ABOUT MARUTI SUZUKI:

In the early 1980s, the Indian Government decided to produce a small car, which would be
within the buying reach of the Indian middle class. Maruti Udyog was incorporated in1981.
Suzuki Motor Corporation and the government reached an agreement under which Maruti
Suzuki Automobile was floated as a 70:30 Joint venture Company between Maruti Udyog
and Suzuki Motor Corporation. On 17 September, 2001, Maruti Udyog was renamed to
Maruti Suzuki India Limited. It is subsidiary of Suzuki Motor Corporation of Japan. Suzuki
Motor Corporation Japan is the world Leader in Compact Cars. Suzuki cars are
manufactured in 22 countries, sold in 190 countries. They 6 production plants in Japan
alone. Annual car production of 30 Lakhs. General motors, the biggest car manufacturer has
borrowed the Small car technology from Suzuki. They have 25 Years of trust Over 7720
employees in 4 plants.

Chairman: Mr R C Bhargava

CEO: Mr. Kenichi Ayukawa

Maruti has more than 5 million satisfied customers in India Maruti have a network of 391
sales outlets across 230 cities all over India. The service network covers 1,113 towns and
cities. Bolstered by 2,142 authorized service outlets Maruti produces one car in every 36
seconds. Last year Maruti sold 578,000 cars. Maruti exported 32,000 cars. Maruti has 56%
market share in India. Maruti is No.1 in customer satisfaction, product quality, market share,
service network and performance, economy (total ownership cost), spares (availability and
low cost), and one-stop shop convenience.

Market:

Sales & Growth:

 “The first Indian company to cross this milestone”.

 Maruti Suzuki, has sold 1, 60,598 vehicles in 2017-2018, an increase of 13.4% compared
to 1, 39,763 vehicles sold in 2016-2017. This includes the company’s exports.

 Maruti ranked second highest in customer satisfaction with after-sales service in J.D.
Power 2017 India Customer Service Index.

Competitors:
Tata Motors
Hyundai
Ford
General Motors
Honda
Recent Development

1.04-FEB-16
Looking to hit back at competitors with the new version of its premium hatchback Brezza,
Maruti Suzuki India said it will drastically cut exports of diesel engines to Hungary to
concentrate on the Indian market.

2.01-JAN-18
Car market leader Maruti Suzuki India sold a total of 119,286 vehicles in Dec 2017. This
includes 10,780 units for export. The company had sold a total of 117,908 vehicles in Dec
2017. It registered a growth of 10.3% over the same period of last fiscal.

Future Plan:
 Maruti forecasts low single digit growth rate in FY12

 The New Maruti Swift Launch to Revive the Drop in July Sales of MSIL

 Eyeing Future, Maruti Suzuki geared up to invest Rs 3,000 cr in next fiscal

 Maruti to take annual production capacity to 17.5 lakh units by 2013

 Maruti Opens new workshop at Kaza at an altitude of 3,740 meters

CHAPTER 2

WORKSHOP & SHOWROOM

2.1 WORKSHOP

I have done my internship in the workshop of Mandovi Motors Pvt Ltd. 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 4: Workshop

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.
 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 expert’s team.
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.
3.1 BODY SHOP

In the body shop of 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 5: 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.

Fig 6: Denting
3.2 PAINT SHOP
In the paint shop following processes are carried out: -

There are five plants/units that provide a uniform painting over the white body coming from
the weld shop. In paint shop all the models are painted on the same line. The five units are:

a) Pre-treatment (PT): The body is thoroughly washed to remove the dirt and oil scales.
Then the body is treated with ZnPO4 (phosphating) to prevent corroding of the body.
b) ED coat: This is done by electric deposition method, at 240V-dc supply. After applying
the ED coat the body is baked in oven.
c) Sol-sealer and under coat: Here the left in the body (due to welding) are filled with
sol-sealer to provide waterproofing. Under coat is done on the surface above wheels to
prevent damage of body in that portion.
d) Intermediate coat: This is done by spray-painting method using 10 Kawasaki Robots.
After applying the coat, the body is dried in the oven. Painting done is basically an
intermediate coating to provide base for the final coat.
e) Top coat: This is done by spray-painting method using 20 Kawasaki Robots. For
Metallic coating, double coats are applied and aluminum flakes are provided to shine the
metallic paints.
Fig 7: 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

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.

Fig 8: Gear mechanism

Fig 9: Chain mechanism

 Fig 10: Engine

Fig 11: 4 Stroke engine

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.

Fig 12: Washing

CHAPTER 4

WORKING IN DURING SERVICE 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 ratchet.
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 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.

Fig 13: Air filter

4.3 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.

Fig 14: Engine oil

4.4 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
stationary, 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.
 Fig 15: Clutch plate

4.5 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

Fig 16: Brake

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.

4.6.1 BRAKE BASICS

When you depress your brake pedal, your car transmits the force from your foot to its brakes
through a fluid. Since the actual brakes require a much greater force than you could apply with
your leg, your car must also multiply the force of your foot. It does this in two ways:
 Mechanical advantage (leverage)
 Hydraulic force multiplication

The brakes transmit the force to the tires using friction, and the tires transmit that force to the
road using friction also. Before we begin our discussion on the components of the brake system,
let's cover these three principles:
 Leverage
 Hydraulics
 Friction

Fig 17: Internal view of disk brakes

4.6.1 a LEVERAGE

The pedal is designed in such a way that it can multiply the force from your leg several times
before any force is even transmitted to the brake fluid.

Fig 18: Leverage

In the figure above, a force F is being applied to the left end of the lever. The left end of the
lever is twice as long (2X) as the right end (X). Therefore, on the right end of the lever a
force of 2F is available, but it acts through half of the distance (Y) that the left end moves
(2Y). Changing the relative lengths of the left and right ends of the lever changes the
multipliers.

4.6.1 b HYDRAULIC SYSTEMS

The basic idea behind any hydraulic system is very simple: Force applied at one point is
transmitted to another point using an incompressible fluid, almost always an oil of some sort.
Most brake systems also multiply the force in the process.

4.6.1 c FRICTION

Friction is a measure of how hard it is to slide one object over another. Take a look at the figure
below. Both of the blocks are made from the same material, but one is heavier. I think we all
know which one will be harder for the bulldozer to push.
4.7 DISC BRAKES:

Fig 19: Disc brakes

This type of brake consists of a disc rotor that is rotating together with the wheel and a
stationary brake caliper assembly equipped with brake pads. When pads are forced against the
rotor from both sides, friction that is generated converts kinetic energy into heat, which causes
the rotor and attached wheel to slow or stop.
Since major disc brake components are exposed to air, heat generated during braking can
dissipate efficiently, which offers high resistance to brake fade (heat-induced degradation of
braking performance). In addition, since water is flung off the rotor due to its rotation, the
phenomenon of water fade (significant loss of braking performance caused by buildup of water
on the disc) becomes less likely to occur, which in turn provides safer and more stable braking
performance.

4.7.1 TYPES OF DISK BREAKS:

Opposed Piston Type
Floating Caliper Type
4.7.1 a OPPOSED PISTON TYPE DISC BRAKES

Fig 20: Opposed piston type disc brakes

This type of disc brake has pistons on both sides of the brake rotor, and there are no moving
parts in the caliper assembly other than the pistons themselves. This type of caliper provides
very even pressure distribution between pads and rotor providing better braking performance,
especially under severe braking conditions.
To further improve the performance of opposed piston type brakes, it is possible to increase
the number of pistons (often referred to as the number of "pots") - there exist, for example 4-
pot or 6-pot models. Apart from the regular passenger cars, Akebono also supplies opposed-
piston disc brakes for high-performance vehicles.

4.7.1 b FLOATING CALIPER TYPE DISC BRAKES

FOR PASSENGER CARS

Fig 21: Floating caliper type disc brakes

Floating caliper type disc brakes have a piston (or pistons) only on the inner side of the rotor.
When the brake is engaged, a piston pushes the inner brake pad against the rotor. This generates
a reaction force that moves the caliper itself along the slide pin, pushing the outer pad against
the rotor to clamp it from both sides and achieve braking action.
Many passenger car disc brakes use the floating caliper design, since its simplicity and low
weight result in low manufacturing cost.

FOR COMMERCIAL VEHICLES

Fig 22: Floating caliper type disc brakes

Disc brakes are used mainly in passenger cars, but due to their stable performance at higher
speeds and resistance to brake fade, they are gradually spreading into the commercial vehicle
segment, where drum brakes were traditionally chosen for their long lining life.

4.8 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.
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 calliper, while up to six are installed
on each racing caliper, with varying frictional properties in a staggered pattern for optimum
performance.

Fig 23: Brake pad

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.
4.9 WHEEL ALIGNMENT AND 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

Fig 24: Wheel alignment

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 25: Wheel alignment and balancing

4.9.1 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 26: Engine setup

CHAPTER 5

CONCLUSION

It was a great internship in Mandovi Motors Pvt Ltd, 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
got an in-hand experience apart from theoretical subjects.

Overall it was a good experience and it increases my interest in the Mechanical engineering,
now I am planning to enhance my skills in this field.