INTERNSHIP

REPORT
2021

SEPTEMBER 8

AGRIAUTO INDUSTRIES LIMITED (AIL)

B.E. Mechatronics Engineering
Khawaja Moez-Ur-Rehman-1845110 (Summer-2021)
30th September 2021
04/08/21 – 11/09/21 (06 weeks)
Plant Maintenance Department, Syed Hasan
Humayun, Assistant Manager (AM).

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 Table of Contents

I. Acknowledgement.............................................................................3
II. Overview..........................................................................................
Introduction……………………………………………………………………………….4
i. Parting Cell………………………………………………………………………4
ii. Two Wheeler Plant …………………………………………………….5-6
iii. Yamaha Shocks Plant ………………………………………………….7
iv. Shocks & Struts Plant ………………………………………………….8-10
v. Camshaft Plant……………………………………………………………11-12
vi. Shiroki Plant……………………………………………………………….13-14
vii. Steering Box Plant………………………………………………………15-16
viii. Press Shop………………………………………………………………….17-18
III. Internship Objective........................................................................19
IV. A Little about compressed air system and its room.....................20-22
V. Piping design of compressor room...................................................23
VI. Calculation of orifice flow rate, leakage and its cost ...................24-26
VII. Common leakage Causes and Solutions in Compressed Air System…27
VIII. Air Leakages in Different departments (identification and solution)28-30
IX. Conclusion........................................................................................31
X. Recommendations............................................................................31

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Acknowledgement
First of all I would like to thank
Allah for bestowing me with great
blessings.
Man’s effort does matter in the
way to achieve success in any
field of the world. So I are
heartily
thankful to our teacher Sir
Hamza Ahmed Qazi (Assistant
Professor - DSU) and
Engr. Kalim Ullah (General
Manager Technical - AIL) for
helping me in getting such a
cherished learning
opportunity. Our supervisor in-
charge was Engr. Abdul Wasay

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 (Assistant Manager PE – AIL). He
guided
me about all the ways to get
information of the general processes
happening in the plant and
preliminary
information of every department
was also provided by him. He is
indeed a learned person. I learned
about numerome manufacturing
processes and phenomenon and
literally Ire able to relate the things
that I have been learning in our
theoretical courses in the degree
program. There might be few things
left for me to learn in there but
overall it was a full-fledged learning
experience. Fortunately, I Ire
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surrounded by intelligent problem
solvers like Engr. Danish, Engr.
Jalees and Engr. Bilal who
always
provided tIaks to bridge the
learning gap I Ire having as
interns. The managers of other
departments including Mr. Ali Abid,
Mr. Abdul Qadir, Mr. Zahid and Mr
Irshad also assisted me. In this
widespread learning period, I Ire not
only facilitated by the executive
engineers of our department
but also the engineers of other
departments as Ill as the store
keepers and machine workers.

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Mr. Jahanzaib helped me a lot in
the determination of manageable
material handling issues. Store
keepers like Mr. Sana Ullah, Mr
Farrukh also aided me in the
data collection as it was the most
challenging task for me. There are
many other names that deserve to
be mentioned here but I can
simply sum up the support from
the Employees as a fundamental
part in the completion of our
designated assignments.
At the end of the day, all that
matters is our own performance.
The performance of this intern trio
is

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 nearly up to the mark as per
supervisor’s remarks.
First and foremost, I want to express my gratitude to Allah for the many gifts he has
bestowed upon me.
In order to attain success in any sector of the world, a person's work is critical. So I owe a
huge debt of gratitude to MR. Syed Waqas Talib (Deputy General Manager-PM AIL) and my
boss Engr. Hasan Humayun (Assistant Manager PM-AIL) for assisting me in studying and
understanding the industrial environment. He sent me to Engr. Shahzaib, a plant worker
who works in the facility's powerhouse. He walked me through all of the options for
gathering information on the plant's basic procedures, as well as providing preliminary
information on each department. He is, without a doubt, a well-educated worker. I learnt
about a variety of industrial processes and phenomena, and I can now practically use what
I've studied in my degree program's theoretical courses. There may be a few things
remaining for me to learn, but it was a full-fledged learning experience overall. Fortunately,
I was surrounded by intelligent problem solvers like senior manager Engr. Mr. Zahid, Engr.
Aleem and manager Engr. Mohib who always provided tweaks to bridge the learning gap I
was having as intern. During this extended learning period, I was assisted not only by my
department's executive engineers, but also by engineers from other departments, as well as
storekeepers and machine operators. Mr. Shahzaib, together with engineers Mr. Fayyaz and
Mr. Imran, were extremely helpful in teaching me about the compressed air system, its
losses, how many compressors are needed for the entire facility, and what air pressure is
necessary. There are many other names that deserve to be mentioned here, but I can
simply summarize the Employees' assistance as a critical component in the accomplishment
of my assigned task.
All that mattered at the end of the day was my performance. According to the supervisor's
comments, this intern's performance was practically perfect .

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Overview
Introduction:
Agriauto Industries Limited is a public limited company incorporated in 1981 and quoted on
the stock exchange. The company is one of the leading automotive components
manufacturers in the private sector and the first company in Pakistan to acquire TS16949
certification. The firm is well-known for producing a wide range of integrated automobile
parts for Pakistani automakers such as Indus Motors and Pak Suzuki Motors, AL-Ghazi tractors
and Millat tractors. To keep up with the quick production rates at Indus Motors and Pak
Suzuki, AIL's manufacturing department works tirelessly while maintaining high quality
standards. Yamaha Shocks are also assembled in AIL. AIL's mission is to be a world-class
manufacturer and supplier of high-barrier-to-entry automotive components that provides
competitive returns to all stakeholders. Within the main compound of AIL, there are a few
sub-manufacturing units such as:

Shocks and Struts Plant

 Press Shop
 Camshaft Plant
 Two Wheeler Plant
 Steering Box Plant
 Yamaha Shocks Plant
 Shiroki Plant
i. Parting Cell
ii. Two Wheeler Plant (pipe fork)
iii. Yamaha Shocks Plant
iv. Shocks & Struts Plant
v. Camshaft Plant
vi. Shiroki Plant
vii. Steering Box Plant
viii. Press Shop

I. Parting Cell:
This department is a designated section in AIL. Its purpose is the parting of inner and
outer tubes and piston rods for all the models of shocks and struts that are
manufactured in AIL. The pipe rods used for shocks in 2 wheels and 4 wheel vehicles
are cut and send to shocks and struts department for further processes.

8
II. Two Wheeler Plant (pipe fork):
In this department, rods, which came from parting cell after cutting, are shaped which
are then used in two wheel vehicles’ jumps. Piston rods are also assembled here.

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III. Yamaha Shocks Plant:
In this department, shocks are assembled for which parts were manufactured in two-
wheeler (pipe fork) department. Shocks of Yamaha YBR especially.

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IV. Shocks & Struts Plant:
This department is the busiest section of the AIL Plant which manufactures shocks and
struts that generate 70% revenue of the company. This plant has several machinery and
cells that are a part of the whole process by which shocks and struts are manufactured.
Buffing, rods are buffed, threaded and grinded, which are cut in the parting cell
department first. Tempering of car parts is also done while final assembling and quality
inspection of struts and shocks of front and back of a car are also done in this
department. The ED paint known as electroplating paint is also a part of this plant and
it is done on struts of cars in this department.

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13
14
V. Camshaft Plant:
In this department camshaft of engines are shaped by drilling, grinding and threading.
Gears are made on the shaft. It is one of the most important part of engine converting
rotational motion to reciprocal motion.

15
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VI. Shiroki Plant:
In this plant door, hinges or cars and window regulator mechanisms are
manufactured and assembled.

17
18
VII. Steering Box Plant:
In this department, steering boxes of tractors are manufactured and assembled.

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VIII. Press Shop:
AIL has a purpose-built and well equipped press shop. The sheet metal parts and dies
are manufactured in this plant. It has heavy press machines ranging from 15 tons to as
high as 400 tons. The hydraulic press was ranging from 15-200 tons while the 300-400
tons pressing was achieved by mechanical press. The selection of press strength is
based on the thickness and type of sheet. The common processes observed at the press
shop were Shearing, Blanking, Piercing, Drawing, Chamfering, Embossing, Forming,
Collar Bending, Restriking, Trimming, etc.Pressing dyes makes some of the smallest
components of different parts. Press fitting of items is done here too. Making of
instrumentation panels is also done here.

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 Agriauto Industries Limited was
established in 1981 by House of
Habib. The company is one of the

22
 leading automotive components
manufacturers in the private sector
and the first company in Pakistan
to acquire TS16949 certification. The
company is well-known for the
manufacture of variety of integral
automotive part for automotive
giants in Pakistan like Indus
Motors and Pak Suzuki Motors.
To get
synchronized with the fast production
rates at Indus Motors and Pak
Suzuki, the production department
at AIL works diligently without
compromising the quality
requirements.
The vision of AIL is to be a
world class manufacturer and
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 supplier of high entry barrier
automotive
components providing competitive
returns to all stakeholders. AIL
consists of few sub-manufacturing
units within main compound such as

Internship Objective
Before graduating from a course of study, i.e. before entering the profession, every student
must have practical experience in the job. This was the emphasis of my internship. I was
pursuing Bachelors of Mechatronics Engineering from SZABIST Karachi campus. The internship
lasted six weeks, during which time I was assigned to the Plant Maintenance Department and
given a variety of responsibilities and case studies. My major concern was to enhance the
plant's compressed air system by identifying air leaks, determining their causes, and proposing
fixes. I worked in the compressor room and studied its theory as well as the plant's scattered
pipeline connections. Making a 2D orthographic projection of the compressor chamber was
the first task. Following that, data regarding air leakages was gathered by visiting all
departments. This internship turned out to be a great opportunity for hands-on professional
development. It developed a professional mindset for dealing with a variety of industrial
issues. Throughout my internship, I was exposed to a variety of job settings, ranging from

24
white-collar office work to storage and aggressive machining. I was criticized for my lack of
technical knowledge in comparison to the company's current requirements. This inspired me
to prepare myself for tough job environments.

Compressed Air System and Its Room

The working of compressor can be explained through the above flowchart as the compressor
stores the air from the environment let it be dirty or damp. AS molecules collide it creates
heat. The air receiver stores the compressed air and releases it when the pressure in the
compressor arises from the set pressure with help of safety valve placed above the air
receiver. In air receiver water condenses and drops to the bottom of the tank therefore less
air stores in the space. Three factors determine the presence of water in the air. Geography,
season of temperature and air. The condensate drain allows this drain to be switched ON &

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OFF. The isolating valve allows the supply of the air to be disconnected from ring main. The
distribution pipe allows all the energy in the air to circulate through the system.

The compressor room is the biggest of the compressed air system. It might be a room that was
constructed specifically for the compressor or one that could be built with the compressor in
mind. Five things should be considered thoroughly while designing a compressor according to
the standard.
1. The compressor room should be situated in a centralized location near to the faculty as
it will benefit in the improvement of operating it, it will be easy for greater user-
friendliness, better opportunities for controlled ventilation and noise levels and lastly
protection against unauthorized access. The compressors should be placed somewhere
that allows a minimum of a three-foot radius around the unit and air receivers must be
placed in a coolest place but not to or below freezing point.
2. The room should have enough space in order to install new compressors for backup or
future expansion. It should be enough open ensuring easy service and maintenance.
The height should be enough so that the lifting material could be handle properly
without any damage.
3. The air intake of the compressor must be clean free from solid and gaseous
contamination for trouble-free and efficient-operation. Dust and dirty particles can
cause wear and corrosive gases particularly damage it.
4. Proper room ventilation one of the main aspect as it can improve the efficiency and life
expectancy of compressors and dryers as compressors produce a lot of heat in their
surroundings. Proper ducting should be ensured with the passage of cool air because
poor design of ducting could cause hot air being recirculated to the cooling air duct
causing serious risk of malfunctioning and failure of the equipment. Exhaust fans must
be installed at the highest points of the wall within the room to circulate and cool the
air down in the room.
5. Health and safety regulations should be kept in mind while selecting the location of the
compressor room. If it is near to a building or department where staff member carries
out other tasks, then their health and safety should also be taken into consideration.
Ideal compressor room should be like this as shown in pictures below.

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Here in AIL the compressor room is not according to the standards. It is not equally distributed
from all the walls. The maintenance and service of compressors is not easily done while there
is no proper ventilation too. No exhaust fans installed in the room to keep the room cool
down. The ducting system of two compressors (L55 & GA90) is not correct. It bends in the
initial stage without going a little bit linearly up. It can cause malfunctioning and short life
expectancy of the compressor and compressor to overheat making it less efficient for working

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properly. If the duct itself is damaged it can cause up to 20%-40% air leakage. There are two
types of air receivers which are not placed in the cold area and are not placed according to
their placement. The wet air receiver should be placed before the dryer and the dry air
receiver should be placed after the dryer as it can benefit in the storage of wet and dry air.
Both the air receivers are important as they are the core components of compressed air
systems, providing storage, condensate drop out and pressure modulation.

Piping Design of Compressor Room

The piping technique for the compressor room depends on three factors as discussed below;
Pipe Sizing: Properly piping air compressors to the header is critical, since poorly plumbing air
compressors can result in leaks, pressure decreases, and machine failure. The velocity of the
air will rise if the pipe is too small. Increased velocity produces more turbulence in valves and
tees, making pressure measurements more difficult to read correctly. Minimizing elbows, tees,
and fast disconnect fittings, in addition to correct pipe size, all assist to decrease pressure drop
and possible leak sites, saving users time and money.
Piping Layout: When it comes to maximizing airflow and avoiding possible issues, piping
architecture is equally as essential as pipe diameter. Equalizing pressure across the whole
plant is important for stable usage and monitoring in any system design with several drops.
Using a single pipe run with numerous airdrops will result in a considerable reduction in
airflow for consumers at the end of the line. Furthermore, depending on where they are
placed, pressure transducers put in the system may incorrectly read various pressures. To
counteract these difficulties, users should arrange their pipes in a ring, ensuring that airflow is
evenly dispersed throughout the whole plant.
Compressor Plumbing: Lastly, water that has condensed in the pipe may be present in the
compressed air. The supply line should always be connected into the top of the header to

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prevent this water from draining back down into the compressor. This will prevent water or
pollutants from draining into another compressor that is now turned off.

Calculation of Orifice Flow Rate of Air,

Leakage and Its Cost
There are two ways to calculate the orifice flow rate of air according to the conditions.

 When ( p1−p 1p2 )< F ( r ) . X ( t );

( )( )
p 1− p 2 √ p 1− p 2
( )
2
1 d ( o ) p1 p1
Q( a)= ( 4.17 )∗C∗ . p 1. 1− .
60 4.654 3. F ( r ) . X ( T ) T ( a ) +273.15

 When ( p1−p 1p2 )≥ F ( r ) . X ( t );

( ) ( √ F ( r ) . X (t )
)
2
1 d (o )
Q ( a)= ( 0.667 ) . ( 4.17 ) . C∗ . p 1.
60 4.654 T ( a ) +273.15

Since,
T(a)= Room(Air) temperature (°C)

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p1= Primary Pressure (absolute kPa)

p2 = Secondary Pressure (absolute kPA)

d (o) = Diameter of Orifice (mm)

C= Discharge Coefficient

Q (a) = Air flow rate (Nm^3 /min)

F(r) = Specific heat ratio

X(t) = Pressure differential ratio factor

1) Considering for the orifice having d(o)=1mm, T(a)=28°C, p1=7 bar & p2=6 bar, C= 0.61 of
air, F(r) (specific heat of air) = 1 kJ/kg & X(t)=0.72.

First check if ( p1−p 1p2 )< F ( r ) . X ( t )= 7−6

7
=0.142 kPa<1 ( 0.72 )=0.72

Hence, ( p1−p 1p2 )< F ( r ) . X ( t )therefore, first equation will be used.

Put values in eq. 1, we get,

( ) ( )( √ 0.142
)
2
1 1 0.142
Q ( a) = ( 4.17 )∗( 0.61 )∗ .(7) . 1− .
60 4.654 3.(0.72) 28+ 273.15

3
Q( a)=0.166∗4.17∗0.61∗0.457 ( 7 )∗0.3972∗0.0012=0.000643 m
From m3 to CFM,
Q( a)=0.000643∗35.3=0.0226CFM

In CFH from CFM,

0.0226∗60=1.356CFH

In order to calculate the ideal leakage costing,

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Electricity per unite rate (Kw/hr) = 28 Pkr

Compressor capacity = 110 Kw/hr

Discharge of compressor = 690 CFM*60 = 41400 CFH

For per CFH,

41400
CFH = =13.441 Pkr
28∗110

1 CFH = 1.356*13.441 = 18.225 Pkr

Therefore, on ideal condition of 15hrs of running of compressor by combining all the 3 shifts in
a day the leakage through 1 mm diameter costs around,

18.225*15 = 273.375 Pkr

For monthly cost through 1mm of hole,

273.37*30 = 8201 Pkr.

Similarly, for yearly leakage costing through 1mm of hole,

8201*365.5 = 2,997,502.05 Pkr

2) Similarly, for 4mm diameter hole having rest data same as above.

( p1−p 1p2 )< F ( r ) . X ( t )= 7−6

7
=0.285 kPa<1 ( 0.72 )=0.72

Leakage Cost per month=8201∗4=32,804 Pkr

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 3) Similarly, for 6mm diameter hole having rest data same as above.

Leakage Cost per month=8201∗6=49,206 Pkr

Common leakage Causes and Solutions in

Compressed Air System
1) Air losses occurs in pneumatic bellows like 15 CFM≈90psi. It can be solved by installing
¾’’ ball valve on air supply & should be closed at the end of the shift by the operator.
2) Quick disconnected fitting causes around 3,00,000 Pkr per year. It can be replaced with
a good Q-D fitting.
3) Flexible plastic tubing and ferrule connections work and loose overtime, can be easily
hidden by machinery. It should be repair as soon as possible as it could annually cost
approx. 1,00,000 Pkr.
4) CNC routers of pneumatic cylinder bleeds air continuously. Ultrasonic leak detector can
be used to locate it. It is better to install 1’’ ball values on air supply line 7 operators
should close the valve after the shift.
5) Actuated switch leaks a lot. It should be repaired or replaced with new efficient switch.
6) It is wasteful to use compressed air for cooling or cleaning a boiler. Instead a large
electric fan should be installed & would be efficient, hence saving a lot of money
annually.

Air Leakages in Different departments

(identification and solution)

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In this picture air is leaking from elbow connector.
it can be solved by replacing it or it may be loose so
it should be tighten to ensure no leakage is
occurring from it.

In this picture pneumatic pipe is leaking

which can only be replaced to stop the
air leakage or before replacing the pipe, clamp
should be checked if it is loose then it should
be tighten to overcome the leakage.

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In this picture leakage is occurring
from pneumatic elbow which can only
be replaced to stop the air leakage
occurring from it. Before replacing it
should be checked if the nut or
pipe
is correctly fit or not then those
things
should be fitted first.

In this picture air is leaking from

FRL drain connectors.
These connectors should be repaired like washed
and cleaned from inside before installing
again. Dust in the connectors
causes this type of leakage

In this picture ferrule fitting is leaking which is

ultimately replaced in order to stop the leakage.

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 In this picture leakage is occurring from the silencer
of pneumatic switch ON & OFF. It will be repaired to
overcome the leakage as air only discharges from the
silencer part when switch is turned off.

Conclusion
This internship turned out to be a hands-on professional learning experience in general. I
developed a professional approach to problem-solving. Throughout my internship, I was
exposed to a variety of job settings, ranging from white-collar office work to storage
departments and high-volume machining operations. I learned a lot in this industrial
environment and two of main thing which I learned was time management and verbal
communication to your workers and higher authorities as I lacked in time management &
have less confidence through this internship I learned these two skills. I was able to develop
confidence of presenting in front of CEO and other officers also when I presented my
internship report. I learned how daily tasks are highlighted and completed within the
allotted time. I was also scolded for my lack of technical knowledge in comparison to the
company's current requirements. This inspired me to prepare myself for tough job
environments.

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Recommendations
The components of the machine that are easy to replace should be replaced by the
operator as he is the one who is constantly working on it and does know how the machine
is working. If workers resist in doing small work related to them then awareness sessions of
minimum 10 minutes should be organized for realization of assistance and contribution in
work.
The leakages should be considered in the first place as it contributes in a huge loss for the
company to bear.
There should be amendments to the compressor room according to ISO certification as it is
not according to the standard currently. There should be a proper ventilation system in
compressor room for achieving good efficiency and ducting system should be improved for
good efficiency and for longer life expectancy of the compressors. Workers should also take
internees to the field work so that internees could learn and gain knowledge regarding the
field that how daily problems are solved.

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