PUNJAB - TIANJIN UNIVERSITY OF TECHNOLOGY

2019-2023

SUPERVISED INDUSTRIAL
TRAINING REPORT

Presented By: Majid Mushtaq

Roll Number: 19AU038

BSc Automotive Engineering & Technology

Punjab Tianjin University of Technology Lahore

Department of Automobile

Submitted by: Majid Mushtaq

Registration no: 19AU038

Training Organization Punjab Forest workshop, Lahore

Final Report: Industrial training report

Semester: 8th

Email ID: majid4243144@gmail.com

 DECLARATION

I'm here to declare that this internship report is submitted by me under the guidance of my
supervisor MR. Tahir. I assure you that the report contains actual events and facts that
were observed and performed during my internship practice program.
All the contents are my and have not been submitted to any other institute.

Signature: _____________

Name of Student: Majid Mushtaq

Registration No: 19AU038

 ABSTRACT

This Industrial training report presents the experience garnered during my 16

weeks of industrial training undertaken at Forest Workshop Lahore. I crossed his
workshop because it’s a pilot dealership in central region of Regal Automobile
Industries.my training was on the diagnosis, repairs, maintenance in automobile vehicles
ranging from cars. I also cover all the departments of workshop (Mechanical Workshop,
Body& Paint shop, warranty department, customer relationship department and parts
department).

During this period, I acquired practical knowledge on how to repair, replace and
install mechanical parts and systems also assisted in providing the units the functionality
they need. I learned how to diagnose the faults in vehicles. During this period, I also
acquired the knowledge of 3S aftersales workshop management system. In which I
learned how to control the flow of vehicles in workshop, training of technician,
enhancement of customer retention, necessities of workshop, handling of warranty cases
and its procedure and parts department working. In management system I learned how to
receive a customer, how to talk with him and customer dealing. I get detail learning and
practice on DMS (Dealer Management System) in which I came to know that how to
make different types of job cards. Like (FFS, SFS, Periodic maintains, General repair
etc.)This report discusses the technical skills gained during the training period and
justifying the relevance of the scheme in equipping students with needed technical
competence to thrive in the real world. I get all these above trainings from certified Forest
Workshop Management and technical staff and include hands on skills with theoretical
knowledge on it.
ACKNOWLEDGEMENTS
All glory to Allah for a successful Industrial Training exercise. Special thanks to
the management and staff of Forest workshop for giving me a chance to see first-hand,
and engage in the practical aspects of my course of study.my profound gratitude goes to
my parents, and my siblings for believing in me, for the love, care and support given in
cash a kind. Even though it has not been easy on your finances, still you have decided to
give me a chance at every necessary junction of my life. May Allah bless you and cause
you to increase on every side. Also, my heartfelt appreciation goes to the Head of
Department (past and present), Lecturers, Technologists, Technicians, and the non-
academic staff of the Automotive Engineering & Technology Department of the Punjab
Tianjin University of Technology, Mr. Ghilman Haider. The immense man-hours
invested into us, in and out of class as students, shall yield wonderful fruits to the benefit
of humanity. I pray that the Almighty Allah increase you in all directions. Allah bless
you. I say a big thank you to my dearie, Sir Irfan, for standing by me through the trying
times. I won’t fail to appreciate my colleagues at trainee, Tousif & Tahir and to the
countless others I won’t be able to mention due to time and space constraints. My
heartfelt prayer for us is that Allah will lift us all to the peak points in our lives in Allah’s
name. Finally, I want to say thank you to all the numerous people who supported me even
when it was difficult but are not listed here because to time and space constraints, not
because they are unimportant. I hope you will always be important where it counts.
Ameen.
Table of Contents
ABSTRACT ......................................................................................................................... 3
ACKNOWLEDGEMENTS ................................................................................................. 4
Chapter #1 .......................................................................................................................... 13
Backgrounds of Training Organization ............................................................................. 13
Abstract .............................................................................................................................. 13
Backgrounds ...................................................................................................................... 14
Forest.............................................................................................................................. 14
Wildlife .......................................................................................................................... 14
Fisheries ......................................................................................................................... 14
Importance of Forests .................................................................................................... 15
Company Profile: ........................................................................................................... 16
Company Logo: ............................................................................................................. 17
Development History ..................................................................................................... 17
Biodiversity Conservation: ............................................................................................ 17
Afforestation and Reforestation: .................................................................................... 18
Community Engagement: .............................................................................................. 18
Wildlife Protection:........................................................................................................ 18
Ecosystem Services:....................................................................................................... 18
Research and Monitoring ............................................................................................... 18
Technology Integration: ................................................................................................. 18
International Collaboration: ........................................................................................... 19
Public Awareness and Education: .................................................................................. 19
Capacity Building: ......................................................................................................... 19
Work Globally ............................................................................................................... 19
Buses .......................................................................................................................... 20
Special Vehicles ......................................................................................................... 20
Vision Statement ............................................................................................................ 21
Mission Statement.......................................................................................................... 21
Core Values .................................................................................................................... 21
 Forest Workshop ............................................................................................................ 21
........................................................................................................................................ 22
Company Organogram ................................................................................................... 22
Chapter # 2 ......................................................................................................................... 23
Schedule of Training and Duties, as a Trainee .................................................................. 23
Duties as a Trainee in Service Department .................................................................... 23
Duties as a Trainee in Warranty Department. ................................................................ 24
Duties as a Trainee in Mechanical Workshop. .............................................................. 25
Duties as a Trainee in Parts Department. ....................................................................... 26
Duties as a Trainee in Body and Paint Department. ...................................................... 26
Body Shop .................................................................................................................. 27
Paint Shop .................................................................................................................. 28
Duties as a Trainee in Account Department .................................................................. 29
Chapter # 3 ......................................................................................................................... 30
Industrial Training ............................................................................................................. 30
Training week 01 ........................................................................................................... 30
Training week 02 ........................................................................................................... 30
Training week 03 ........................................................................................................... 31
Training week 04 ........................................................................................................... 31
Training week 05 ........................................................................................................... 32
Training week 06 ........................................................................................................... 32
Training week 07 ........................................................................................................... 33
Training week 08 ........................................................................................................... 33
Training week 09 ........................................................................................................... 34
Training week 10 ........................................................................................................... 34
Training week 11 ........................................................................................................... 35
Training week 12 ........................................................................................................... 35
Training week 13 ........................................................................................................... 36
Training week 14 ........................................................................................................... 36
Training week 15 ........................................................................................................... 37
Training week 16 ........................................................................................................... 37
Chapter # 4 ......................................................................................................................... 38
Working Experiences ......................................................................................................... 38
Project Carried Out ............................................................................................................ 38
 How to Replace V-Tech Sensor In Isuzu D-Ma ................................................. 38
 How to Replace Clutch & Pressure Plate ............................................................ 38
 How to do Engine Overhauling ........................................................................... 38
 How to Replace a Rear Axel Tube of a Vehicle ................................................. 38
 How to Replace Fuel Tank of Isuzu D-Max ....................................................... 38
Clean V-Tech Sensor In Isuzu D-Max........................................................................... 39
Voice of Customer ..................................................................................................... 39
Fault Diagnosing ........................................................................................................ 39
Corrective Action Taken / Working Procedure ............................................................. 40
Replace Clutch & Pressure Plate ................................................................................... 41
Voice of Customer ..................................................................................................... 41
Fault Diagnosing ........................................................................................................ 41
Corrective Action Taken. ........................................................................................... 41
Estimate...................................................................................................................... 42
Working Procedure Steps .......................................................................................... 43
Bill.............................................................................................................................. 45
Engine Overhauling ....................................................................................................... 46
Voice of Customer ......................................................................................................... 46
Diagnosing ................................................................................................................. 46
Corrective Action Taken. ........................................................................................... 47
Replace a Rear Axle Tube of a Vehicle ......................................................................... 47
Customer Complaint: ................................................................................................. 48
Diagnosing: ................................................................................................................ 48
Corrective Action Taken: ........................................................................................... 48
Replace Fuel Tank of Isuzu D-Max ............................................................................... 49
Customer Complaint: ................................................................................................. 49
 Diagnosing: ......................................................................................................... 49
Corrective Action Taken: ........................................................................................... 49
Hands on Skill Acquired ................................................................................................ 51
Mechanical Tool List: ................................................................................................ 52
Special Service Tool List: .......................................................................................... 52
 Electrical Tool List: ................................................................................................... 53
Body & Paint Shop Tool List: ................................................................................... 53
Pictures of Workshop Tools in” Appendix” .................................................................. 54
Inspection of Isuzu D-Max ............................................................................................ 54
FFS (First Free Service) ................................................................................................. 55
SFS (Second Free Service) ............................................................................................ 57
TFS (Third Free Service) ............................................................................................... 58
Periodic Maintenance..................................................................................................... 59
How to Generate DTR on DMS Portal .......................................................................... 61
Login Window ........................................................................................................... 61
DTR Main Portal........................................................................................................ 61
DTR Data FormHow to Place Parts Order on DMS Portal ....................................... 62
Login Window ........................................................................................................... 63
Parts Order Window .................................................................................................. 63
Part Selection Window .................................................................................................. 64
Parts OrderPaint Process: ........................................................................................... 64
Paint Making and Matching ........................................................................................... 65
Fault Diagnosing ............................................................................................................ 66
Troubleshooting: ............................................................................................................ 66
Suspect Area: ............................................................................................................. 66
Remedy: ..................................................................................................................... 66
Troubleshooting ......................................................................................................... 66
Suspect Area: ............................................................................................................. 66
Remedy: ..................................................................................................................... 67
Problems encountered ................................................................................................ 67
Supervisory works ..................................................................................................... 67
Supervisor on Service Advisor: ................................................................................. 67
Workshop controller: ................................................................................................. 68
Warranty Administrator: ............................................................................................ 69
Quality Management System in place ........................................................................... 70
PDCA ......................................................................................................................... 70
PLAN: ........................................................................................................................ 70
DO: ............................................................................................................................. 70
 CHECK: ..................................................................................................................... 70
ACT: .......................................................................................................................... 70
Project Carried Out Chassis Assembly .............................................................................. 71
CAP (CHASSIS ASSEMBLY PLANT) ....................................................................... 71
BMP (BODY MANUFACTURING PLANT): ............................................................. 71
ISO CERTIFICATION: ................................................................................................. 71
CHASSIS ASSEMBLY ................................................................................................. 72
STAGE #01 .................................................................................................................... 72
Axle and Wheel Mounting ......................................................................................... 72
STAGE #02 .................................................................................................................... 72
Air and Oil Piping ...................................................................................................... 72
STAGE #03 .................................................................................................................... 72
Engine Mounting ....................................................................................................... 72
STAGE #04 .................................................................................................................... 73
Cabin/Floor Mounting ............................................................................................... 73
STAGE # 05 ................................................................................................................... 73
Control Setting ........................................................................................................... 73
ENGINE ASSEMBLY .................................................................................................. 73
STAGE # 01 ................................................................................................................... 73
STAGE # 02 ................................................................................................................... 74
STAGE # 03 ................................................................................................................... 74
STAGE # 04 ................................................................................................................... 74
STAGE # 05 ................................................................................................................... 74
STAGE # 06 ................................................................................................................... 75
STAGE # 07 ................................................................................................................... 75
ENGINE TESTING: ...................................................................................................... 75
ASSIGNMENTS............................................................................................................ 76
PROJECT 230 DRAWINGS INVENTORY ................................................................. 76
COSTING OF PARTS:.................................................................................................. 77
Registrations: ............................................................................................................. 77
Vision: ........................................................................................................................ 77
Reach: ........................................................................................................................ 77
Clientele: .................................................................................................................... 77
 SUBDIVISIONS: ........................................................................................................... 78
AUTO INJECTION MOLDING AREA: .................................................................. 78
Horizontal Injection Molding: ................................................................................... 78
Vertical Injection Molding:........................................................................................ 78
SHEET METAL AND TOOL SHOP: ........................................................................... 79
Press Machine: ........................................................................................................... 79
Lathe Machine: .......................................................................................................... 79
Shaper: ....................................................................................................................... 80
Hobbing machine: ...................................................................................................... 80
QUALITY CHECK: .................................................................................................. 81
Checking Fixtures. ..................................................................................................... 81
PARTS PRODUCED: ................................................................................................... 81
WHEEL HUB PRODUCTION: ................................................................................ 82
PARTS PRODUCED: ............................................................................................... 82
Project CONCLUSION ............................................................................................. 83
Chapter # 5 ......................................................................................................................... 84
Conclusion: ........................................................................................................................ 84
Recommendations: ......................................................................................................... 85
Chapter # 6 ......................................................................................................................... 86
References: ..................................................................................................................... 86
Table of Figure
Figure.1 Company Profile .................................................................................................. 16
Figure.2 Company Logo .................................................................................................... 17
Figure.3 Work Globally ..................................................................................................... 19
Figure.4 Work Globally ..................................................................................................... 20
Figure.5 Buses.................................................................................................................... 20
Figure.6 Forest Special Vehicles ....................................................................................... 20
Figure.7 Forest Workshop ................................................................................................. 22
Figure.8 Company Organogram ........................................................................................ 22
Figure.9 Warranty Department. ......................................................................................... 24
Figure.10 Mechanical Workshop ....................................................................................... 25
Figure.11 Parts Department ............................................................................................... 26
Figure.12 Body Shop ......................................................................................................... 27
Figure.13 Paint Shop .......................................................................................................... 28
Figure. 14 Account Department ......................................................................................... 29
Figure.15 Account Department .......................................................................................... 29
Figure.16 Fault Diagnosing ............................................................................................... 39
Figure 17 V-Tech Intake & Exhaust Sensor ...................................................................... 40
Figure.18 Clutch & Pressure Plate ..................................................................................... 41
Figure.19 Estimate ............................................................................................................. 42
Figure 20 Clutch & Pressure Plate ..................................................................................... 44
Figure.21 Clutch ................................................................................................................ 44
Figure.22 Pressure Plate..................................................................................................... 44
Figure.23 Bill ..................................................................................................................... 45
Figure.24 piston ................................................................................................................. 46
Figure.25 •Engine Block .................................................................................................... 46
Figure.26 Connecting Rod ................................................................................................. 47
Figure.27 Engine Block ..................................................................................................... 47
Figure.28 Rear axel ............................................................................................................ 48
Figure.29 Rear Axel Angle ............................................................................................... 48
Figure 30 Diagnosing Fuel tank ......................................................................................... 49
Figure.31 Fuel Tank ........................................................................................................... 49
Figure.32 Replace Fuel Tank ............................................................................................. 50
Figure.33 New Fuel Tank .................................................................................................. 50
Figure.34 Pre-Inspection .................................................................................................... 54
Figure.35 Pre-Inspection .................................................................................................... 55
Figure.36 First Free Service ............................................................................................... 56
Figure. 37 Second Free Service ......................................................................................... 57
Figure.38 Third Free Service ............................................................................................. 58
Figure.39 Periodic Maintenance ........................................................................................ 59
Figure.40 Suspension ......................................................................................................... 60
Figure.41 Login Window ................................................................................................... 61
Figure.42 DTR Portal......................................................................................................... 61
Figure 43 DTR Data........................................................................................................... 62
Figure.44 Login Window ................................................................................................... 63
Figure.45 Parts Order Window .......................................................................................... 63
Figure.46 Selection Window ............................................................................................. 64
Figure.47 Parts Order ......................................................................................................... 64
Figure.48 PDCA ................................................................................................................ 70
Figure.49 Auto Injection molding...................................................................................... 78
Figure.50 Press Machine:................................................................................................... 79
Figure.51 Lathe Machine ................................................................................................... 79
Figure.52 Shaper: ............................................................................................................... 80
Figure 53 Hobbing machine............................................................................................... 80
Figure.54 Wheel Hub Production ...................................................................................... 82
Chapter #1

Backgrounds of Training Organization

Abstract

Pakistan's remaining forests are both fragile and unique. They are also extremely
important for the ecological services that they provide to society. Despite the government's
ongoing recognition of the need to increase forest cover since 1955, very little substantive
progress has been made. Indeed, deforestation levels have been continuing at an alarming rate,
making Pakistan one of the most vulnerable countries in the world to losing its forest resources
in the next thirty years. This paper highlights the impact of political and government actions on
the forest sector in Pakistan. It describes how the rapid rate of deforestation in the past has
been linked to government and administrative failures and discusses the possible impact of
forest land transfers on forest loss. It then presents the case of the proposed Patriata Reserved
Forest development in 2004 as an example of a situation where provincial governments and
institutions attempted to usurp established forest policy and legislation to transfer ecologically
endangered forestland for a resort development
Backgrounds
On the grounds that its beginning, the department has targeted at helping conserve
and guard the herbal resources of Punjab. We have labored now not simplest to defend
the plant and animal species but also helped it multiply.

Forest

The department become created in 1886 underneath British rule as imperial

woodland provider. After independence, in 1947, the department started functioning as
Pakistan woodland service. In 1969, after the dismemberment of one unit, Punjab wooded
area provider became created. The branch inherited its laws and manuals from the British.
The wooded area branch proceeds underneath forest Act 1927 amended in 2016.

Wildlife

Punjab natural world and Parks department is the custodian of Wildlife sources of
the province and ensures the safety, renovation, conservation and management of
Wildlife and the resources. The branch has a checkered records from 1934 – 1973. In
1934 it changed into sport department and sprouted out as Punjab natural world & Parks
department in 1973. Punjab natural world Act was promulgated in 1974 which stands
amended up to 2007. The Punjab protected areas Act, 2020 has been enacted to bolster
the powerful control of procted regions in Punjab

Fisheries
The information of fish and fisheries is very old and has been recorded nearly five
thousand years returned through old relics in Baluchistan. Over the past four many years
the technological know-how of fish and fish lifestyle within the international has emerged
with a promising position to clear up food hassle each quantitatively and qualitatively, as
nutritionally fish meat can offer the pleasant sort of animal protein which consists of vast
spectrum amino acids which are easily digestible by the belly. Additionally, the chicken
of fish is sort of ldl cholesterol unfastened and anti-cancerous.
Importance of Forests

It is hard to overstate the importance of forests. Forests contribute to agricultural

production by protecting water, controlling erosion, and providing habitat for wild
pollinators and predators of agricultural pests, like bats. America’s forests create fertile
soils that support timber and forage, food and fiber. Forests store vast quantities of
carbon, thereby mitigating the effects of a changing climate. Forests take up about 12
percent of the carbon dioxide that Americans emit each year. And forests furnish much of
the water we drink.
Company Profile:

Figure.1 Company Profile

Forest workshop was founded in Lahore, Pakistan, in 1958, and it began operating
in 1978. We take great pleasure in offering engineered special application vehicles,
equipment, and pumps that are effective, affordable, and have years of experience. Our
primary goal is to foster mobility while coming up with responses to regional and global
problems. We were established out of a passion for engineering and innovation; hence we
aim to execute proactive diagnostics and take preventive measures to deliver user-centric
vehicles that are designed to perform. Forest workshop is continuously incorporating
dependability, societal responsibility, economic awareness, and responsibility throughout
our value chain.
Company Logo:

Figure.2 Company Logo

Development History
It seems like I interested in the development of forest departments. Forest
departments play a crucial role in the conservation, management, and sustainable
utilization of forest resources. They are responsible for a wide range of activities aimed at
maintaining the ecological balance of forests and ensuring their long-term health and
vitality. Here are some aspects of forest department development:

Biodiversity Conservation:
Forest departments work to protect and preserve the diverse plant and animal
species that inhabit forests. This involves creating and implementing strategies to prevent
habitat destruction, illegal logging, poaching, and other threats to biodiversity.
Afforestation and Reforestation:

Forest departments often engage in afforestation (planting trees in non-forest

areas) and reforestation (replanting trees in deforested areas) initiatives to increase forest
cover and combat deforestation.

Community Engagement:

Many forest departments involve local communities in forest management and

conservation efforts. This can include providing training, resources, and incentives for
sustainable practices such as agroforestry and non-timber forest product harvesting.

Wildlife Protection:
Forest departments work to protect and manage wildlife populations within
forested areas. This includes creating and maintaining protected areas, establishing
wildlife corridors, and implementing anti-poaching measures.

Ecosystem Services:
Forests provide essential ecosystem services such as carbon sequestration, water
regulation, and soil conservation. Forest departments focus on maintaining these services
to support both the environment and human communities.

Research and Monitoring:

Developing forest departments often invest in research to better understand forest

ecosystems, track changes over time, and inform conservation and management
decisions. Policy and Legislation: Forest departments play a role in developing and
implementing policies and regulations related to forest management, land use, and
conservation.

Technology Integration:

Advancements in technology, such as Geographic Information Systems (GIS) and

remote sensing, are increasingly being utilized by forest departments for improved
monitoring, planning, and decision-making.
International Collaboration:

Many countries collaborate with international organizations and other nations to

share knowledge, best practices, and resources for forest conservation and sustainable
management.

Public Awareness and Education:

Forest departments often engage in public awareness campaigns and educational

programs to inform the public about the importance of forests, biodiversity, and
sustainable forest management practices.

Capacity Building:
Developing the skills and capacity of forest department staff is crucial for
effective management and conservation. Training programs and professional
development opportunities are often provided.

Work Globally
Adhering to independent R&D and innovation based on the formulation and
implementation of its strategy of globalization, Forest has led a development path of
continuous breakthroughs. At present, Forest overseas business covers more than 30
countries and regions in Asia, Africa, South America, as well as Central and Eastern
Europe. While expanding its overseas market, Forest has been shaping an internationally
famous brand by virtue of its advanced management concepts, technology and top design
to support its brand globalization. Located in China, Sweden and Germany, our domestic
and overseas bases are committed to technological innovation and application in
automotive industry through joint research and development.

Forest Globally

Figure.3 Work Globally

 Figure.4 Work Globally

Buses

Figure.5 Buses

Special Vehicles

Figure.6 Forest Special Vehicles

Vision Statement

To be the most valued and respected automobile company in Pakistan, making

people’s lives better by making mobility accessible and affordable with innovative people
and technology.

Mission Statement
Foremost in providing, high-quality products, exceptional service and unparalleled
customer support ultimate to achieve customer delight and building customers for
generations.

Core Values

 Passion & Excellence

 Fostering Team Work
 Best Quality Product
 Integrity
 Accountability
 Customer Satisfaction

Forest Workshop
Forest Workshop is the pilot workshop of AUTOMOBILES in Central region of
Pakistan. It was established in 1978 in Lahore. It is a 3s workshop which provides
following service to customers.

 Maintenance
 After sales service
 Sales
 Parts
 Figure.7 Forest Workshop

Company Organogram

Figure.8 Company Organogram

Chapter # 2

Schedule of Training and Duties, as a Trainee

Duties as a Trainee in Service Department

I have following duties to perform in service department.

 Attending the customer & inspection of the vehicle along with him before
opening the job card.
 Open the job card, prepare estimate of repair after necessary road test /
inspection.
 Get signature of customer on the estimate, preferably.
 Explain jobs to be done on the vehicle to the customer.
 Close the job card after checking the completion of requested jobs and
conducting road test, preferably with customer.
 Inform to the customer in case of any delay in promised time or cost
overrun due to more work.
 Take feedback from the customer through instant feedback card and take
necessary action along with CRO.
 Check cleanliness and safety procedure in the workshop.
 Be present at the time of delivery of vehicle and explain the work done to
the customer with defective parts.
 Update progress of under repair vehicles on tracking sheet, after
consultation with supervisor.
 Maintain History Card.
Duties as a Trainee in Warranty Department.

I have following duties to perform in warranty department.

 Processes warranty claims on a timely.

 Processes all warranty paper work to ensure proper documentation.
 Verifies criteria required by Forest Workshop parts shop.
 Reconciles all warranty receivables with payments through the appropriate
accounting schedule.
 Posts credits on computer.
 Resubmits all rejected laims promptly or receives authorization to write
them off.
 Follows up on payment of out standing claims.
 Tracks warranty parts by tagging with repair order number, date of
replacement and date on which part maybe disposed of.
 Arranges for parts to be shipped to the factory or distributor or to be
scrapped.
 Files and maintains all service records as required by the warrantor.
 Keeps informed of all factory recalls and bulletins.
 Assists with body shop warranty claims as needed.

Figure.9 Warranty Department.

Duties as a Trainee in Mechanical Workshop.

I have following duties to perform in Mechanical Workshop

 Inspect vehicle engine and mechanical/electrical components to diagnose

issues accurately
 Periodic maintenance and general repair work done.
 Inspect vehicle computer and electronic systems to repair, maintain and up
grade
 Conduct routine maintenance work (replacing fluids, lubricating parts etc.)
aiming to vehicle functionality and longevity
 Schedule future maintenance sessions and advise motorists on good
vehicle use
 Repair or replace broken or dysfunctional parts and fix issues (e.g.leaks)
 Provide accurate estimates (cost, time, effort) for a repair or maintenance job
 Keep logs on work and issues
 Maintain equipment and tools in good condition

Figure.10 Mechanical Workshop

Duties as a Trainee in Parts Department.
I have following duties to perform in parts department.

 Parts orderings and receiving from company and other vendors.

 Maintain proper stock through inventory management system.
 Parts tagging and location checking
 Maintain stock report and generate reorder list of all product Ipos operation how
to add items in inventory management system how to generate purchase voucher
 Check the quality of local parts and create strong relationship with vendors
 Maintain stock & ledger with the account department.
 Guide customers to use always genuine OEM parts for your vehicle
 Make Monthly parts discount offers for the customers
 Monthly sales report.
 Monthly purchase report.
 Service rate of parts department.
 Handling part payment collection and making sure all parts are billed properly
through the service department.

Figure.11 Parts Department

Duties as a Trainee in Body and Paint Department.
I have following duties to perform with workshop controller.

 Attending the customer & inspection of the vehicle along with him
before opening the job card.
 Open the job card, prepare estimate of repair after inspection.
 Get signature of customer on the estimate, preferably.
 Explain jobs to be done on the vehicle to the customer.
 Monitoring the body and paint work.
 Insure the vehicle get ready with in providing time.

Body Shop

Figure.12 Body Shop

Paint Shop

Figure.13 Paint Shop

Figure.14 Paint Shop

Duties as a Trainee in Account Department
I have following duties to perform with workshop controller

 Generate Daily Sale & Expanse reports.

 How to update monthly quarterly and yearly closing reports
 Maintain all corporate account ledger & recovery outstanding on time
 Maintain All Local vendors account ledger & cross check for
satisfaction
 How to create tax report & submission in the FBR
 Today I learn how to create salary slips of all employees.

Figure. 14 Account Department

Figure.15 Account Department

Chapter # 3

Industrial Training

Daily Training Logbook

Introduction and workshop visit.

Guideline about safety precaution

Training week 01 Visit warranty department

Visit mechanical workshop

Visit parts department

Industrial Training

Daily Training Logbook

Visit body and paint department

Visit accounts department

Training week 02 Replace v-tech sensor in Isuzu D-Max

Replace clutch and pressure plate in vehicle and

diagnose

Engine overhauling in Isuzu D-Max and diagnose

Industrial Training

Daily Training Logbook

Replace rear Axel tube in Isuzu D-Max forest

vehicle

Check vehicle fuel tank and replace a fuel tank

Guideline how to mechanical and electrical

Training week 03 maintenance

Enter workshop and understand tools

Guideline how to use electrical and Special service

tools

Industrial Training

Daily Training Logbook

Check vehicle PDS (Pre Delivery Service)

Today learn about FFS ( First Free Service)

Training week 04 Check Vehicle SFS (Second Fire Service)

Maintain Isuzu D-Max TFS ( Third Free Service)

Check vehicle periodic maintenance

Industrial Training

Daily Training Logbook

Inspection Suspension and study of Suspension

General repair Suspension and overhauling

Training week 05 Study of Generate DTR pm DMS portal

Study about how to place parts order on DMS

portal
Learn about how to Parts order

Industrial Training

Daily Training Logbook

Visit to Paints & Body shops

Learn about paints process & paint making

machine
Training week 06 Fault diagnosing Troubleshooting for Engine

Diagnosing fault electronic parking brake.

Supervisory works about workshop controller.

Industrial Training

Daily Training Logbook

Study about Warranty Administrator.

Learn About Pakistan ISO system.

Training week 07 Inspection of vehicle exhaust emission

Inspection of Tail pipe extraction and replace

Isuzu D-Max Exhaust emission inspection and

replace

Industrial Training

Daily Training Logbook

Project about Carried out Chassis Assembly.

Visit Chassis Assembly Plant.

Training week 08 Visit Body Manufacturing Plant

Chassis assembly assemble axle and wheel

mounting
Chassis assembly assemble stage two air and oil
piping
Industrial Training

Daily Training Logbook

Chassis assembly assemble stage three engine

mounting

Chassis assembly assemble stage four Cabin/ Floor

& and Control steering
Training week 09 Hino Buss Engine assembly overall.

Inspection Hino Buss engine assembly and watch

damage parts
Inspection Hino Buss crank shaft and bearing
installation

Industrial Training

Daily Training Logbook

Installation of flywheel housing, oil seal clutch,

disk and cover timing gear, water pump in Hino
Buss Engine
Installation of piston and intake system Hino Buss

Training week 10 Installation of Hino Buss Exhaust system

Assemble all component chassis and engine

assembly

Engine Testing Hino Buss

Industrial Training

Daily Training Logbook

Introduction of Tariq auto industries

Visit to Tariq auto industries

Make a assignment about project 230 drawing

Training week 11 inventory.
Complete to assignment parts development process
flow
Study about how costing of parts

Industrial Training

Daily Training Logbook

Visit to mechanical workshop

Learn about Molding Machine.

Operate to molding machine and performed to

Training week 12 Horizontal and Vertical injection molding

Study the process of Sheet Metal machine

Study the process and working of sheet metal

machine
Industrial Training

Daily Training Logbook

Study the process of lathe machine

Practical operation of lathe machine & its type

Training week 13 Study of grinding machine

Study of working process of grinding machine

Review the process of grinding machine

Industrial Training

Daily Training Logbook

Visit and introduction of welding shop

Study about of to operation performed to welding

machine
Training week 14 Practical performed to welding machine

Learn about to hobbing machine how to operate the

machine

Practical operation of hobbing machine

Industrial Training

Daily Training Logbook

Study about projection spot welding machine

Operate the practical in projecting spot welding

Training week 15 Study of shaper machine

Operate the practical in shaper machine

Study about quality check and checking fixtures

Industrial Training

Daily Training Logbook

Inspection Suspension and study of Suspension

General repair Suspension and overhauling

Training week 16
Study about how to place parts order on DMS
portal
Chapter # 4

Working Experiences

During my 16 weeks of industrial training I have got some projects by industrial

trainer. According to my training schedule, my duties are to go through dedicated after
sale service department and workshop site or workshops and get knowledge about the
working nature and equipment used in these workshop and get myself familiar with the
usage of multiple equipment and machines used in these workshops. The following
projects assigned by the trainer.

Project Carried Out

 How to Replace V-Tech Sensor In Isuzu D-Ma

 How to Replace Clutch & Pressure Plate

 How to do Engine Overhauling

 How to Replace a Rear Axel Tube of a Vehicle

 How to Replace Fuel Tank of Isuzu D-Max

 How to Replace Hino Buss Chassis Assembly

Clean V-Tech Sensor In Isuzu D-Max
This is my 1st project in this project I have learn how VVTI system work. How to
diagnose and cleaning of V-Tech Sensor.

Voice of Customer
Customer complaint that my vehicle missing at high speed continuously.

Fault Diagnosing
 1st we connect vehicle with Forest workshop Scanner & Scan the vehicle
 P0010 Code appear in the scanner
 Check grip / connector of the V-Tech Sensor

Figure.16 Fault Diagnosing

Corrective Action Taken / Working Procedure

 Vehicle Engine Stop & Open the bonnet

 Remove V-Tech intake & exhaust Sensor Bolts
 Clean V-Tech Sensor by using Engine Lubricants
 Check strainer of Sensors
 Fix bolt with given torque from the workshop manual

Figure 17 V-Tech Intake & Exhaust Sensor

Figure. 18 V-Tech Sensor Figure.19 V-Tech Sensor

 Replace Clutch & Pressure Plate

This is my 2nd task but it is very technical task for me. In this task I have to
replace a clutch & pressure plate set with clutch and pilot bearing. In this problem vehicle
cannot move anywhere.

Voice of Customer
Customer complaint that my vehicle not move even I start engine shift gear and release
clutch paddle.

Fault Diagnosing
 1st Visual inspection of Clutch & Pressure Plate as well as Gear Cables
 Check clutch master & release cylinder and fluid level

Corrective Action Taken.

1. Open Clutch Box assembly and clutch & Pressure Plate Set need to be replaced.

Figure.18 Clutch & Pressure Plate

Estimate

Figure.19 Estimate
Working Procedure Steps
 Remove Bolts from engine housing
 Remove front two wheels
 Remove both axel shafts from transaxle & drain the transmission fluid.
 Remove gear shifting cables
 Remove clutch release cylinder
 Remove bolts of pressure plate and separate Clutch and Pressure Plate
 Remove fly wheel bearing
 Fit new fly wheel bearing
 Turning of fly wheel from lathe work shop
 Check quality and built proper pressure of pressure plate
 Fit new clutch & pressure plate
 Attached gearbox assembly with engine
 Install drive shafts in the transaxle
 Proper tyre fitting
 Fit gear cables & clutch release paddle
 Tight all the nut &bolt with given torque.
 Start engine & test drive the vehicle
 Figure 20 Clutch & Pressure Plate

Figure.22 Pressure Plate Figure.21 Clutch

Bill

Figure.23 Bill
 Engine Overhauling
Voice of Customer
Customer complaint that my vehicle is overheated in the long route & I hear a blast noise
after sometime from Engine. Customer Stop vehicle and check engine physically. Engine
Oil Leaked.

Diagnosing

 Visual Inspection accrued

 Engine Block Damage and its need to be replaced
 After dismantling we found that engine connecting rod broken due to engine

overheating Figure.25 •Engine Block

Figure.24 piston
Corrective Action Taken.

1. Engine connecting rod and engine block assembly was replaced

Figure.26 Connecting Rod

Figure.27 Engine Block

 Replace a Rear Axle Tube of a Vehicle
Customer Complaint:
Customer Compliant that my vehicle rear tires condition not good one tire is
wearing a lot then other axel

Diagnosing:
 Rear tires visual inspection
 Check rear tube with level gauge
 Tire damage due to improper wheel camber
 At the end we found that the rear tube of the vehicle were misaligned & damage
 Rear axel tube need to be replaced.

Corrective Action Taken:

 Rear axel tube was replaced.
 Check angle after replacement
 All things were okay

Figure.28 Rear axel Figure.29 Rear Axel Angle

 Replace Fuel Tank of Isuzu D-Max
Customer Complaint:

Customer compliant that my vehicle fuel tank is damaged.

 Diagnosing:
 Visual Inspection
 Check & found that vehicle fuel tank damaged due to stone hitting.

Corrective Action Taken:

1. Fuel tank was replaced.

Figure 30 Diagnosing Fuel tank

Figure.31 Fuel Tank

Figure.33 New Fuel Tank

Figure.32 Replace Fuel Tank

 Hands on Skill Acquired

I learn complete mechanical & Electrical maintenance skill during this internship
program. I have acquired following skill during this period.

 Use of all workshop tools

 Engine oil replacement.
 PDS (Pre-Delivery Service)
 FFS (First Free Service)
 SFS (Second Free Service)
 TFS (Third Free Service)
 Periodic maintenance
 General repair
 Suspension overhauling
 How to generate DTR on DMS portal
 How to generate parts order on DMS portal
 Engine overhauling
 Faults diagnosing
 Inventory management system
 Point of sale system
 Daily & monthly account closing
 Solving employees account problem
 Audit & account
 Paint processing
 Paint matching
 This is my first project, which is assigned by my trainer in this project I have a
task to learn complete usage of Mechanical, Electrical, Body & Paint Shop tools, which
are used in the workshop for rapier, and maintenance of vehicle.

Mechanical Tool List:

 Breaker bar  Oil filter wrench

 Pick set  Pry bar

 Retches and sockets  Screwdriver set

 Tire pressure gauge  Torque wrench

 Wrench set  Air compressor

 Tool box  Safety glasses

 Safety helmet  Flashlights

 Jack and jack stands  Funnels

Special Service Tool List:

 Vernier caliper  Portable crane scale

 Micro meter  Oil filter wrench

 Dial gauge  Ball joint puller

 Torque angle adapter  Fuel pump cover remover

 Expander-Piston  Oil pan remover

 Rachet  Fuel pressure gauge

 Oil seal installer  Oxygen sensor socket

Electrical Tool List:

 Pliers  Screwdriver

 Multi meters  Insulated Screwdrivers

 Stubby screwdriver  Hacksaw

 Electrician's hammer  Cut resistant gloves

 Digital circuit breaker finder  Cable cutter - klein high-leverage

 Conduit bender  Conduit cutter

 Battery charger  Battery tester

Body & Paint Shop Tool List:

 Angle grinder  Corded drill

 Dust mask  Hearing protection

 Hydraulic puller  Safety glasses

 Sanding block  Dent puller

 Chain puller  Jack Puller

 Spot welding machine  Mig welding machine

 Gas welding  Electric arc welding.

 Filler applicator  Paint gun

 Air compressor  Dry sanding machine

 Heat gun  Air gun

 Pictures of Workshop Tools in” Appendix”
Inspection of Isuzu D-Max

Figure.34 Pre-Inspection
Figure.35 Pre-Inspection
FFS (First Free Service)
 Lift up on bay
 Check and tighten the nut & bolts of front suspension, rear suspension,
and complete underbody.
 Check the complete auxiliaries of vehicle.
 Check the electrical instruments
 Check the AC & Heater operations.

Figure.36 First Free Service

SFS (Second Free Service)
 Lift up on bay
 Check and tighten the nut & bolts of front suspension, rear suspension,
and complete underbody.
 Check the complete auxiliaries of vehicle.
 Check the electrical instruments
 Check the AC & Heater operations.

Figure. 37 Second Free Service

TFS (Third Free Service)
 Lift up on bay
 Check and tighten the nut & bolts of front suspension, rear suspension,
and complete underbody.
 Check the complete auxiliaries of vehicle.
 Check the electrical instruments
 Check the AC & Heater operations.

Figure.38 Third Free Service

Periodic Maintenance
Periodic Maintenance Schedule- Normal Conditions

ISUZU D-MAX

Figure.39 Periodic Maintenance

General Repair / Suspension Overhauling

In this type of mechanical job we have to face different individual parts replacement. I
have skill to replace following parts.

• Wheel hub replacement

• Shock absorber replacement

• Lower arm replacement.

• Engine head gasket replacement.

• Injectors and coils replacement.

All above mentioned and more vehicle parts replacement skill I got during this internship
period.

Figure.40 Suspension
How to Generate DTR on DMS Portal
In this project we learn about how to generate a DTR on dealer management system

Login Window

Figure.41 Login Window

DTR Main Portal

Figure.42 DTR Portal

DTR Data Form

Figure 43 DTR Data

Figure.45 DTR Management System

 How to Place Parts Order on DMS Portal

In this project I will learn about how to place a required part order on DMS

Login Window

Figure.44 Login Window

Parts Order Window

Figure.45 Parts Order Window

Part Selection Window

Figure.46 Selection Window

Parts Order

Figure.47 Parts Order

Paint Process:

Today I learn about paint process of a car in paint shop which includes
following steps.

 Apply P80 sand paper by sanding machine on the surface of body

 According to denting results we apply P120 to remove P80 lines scratches oral so
if denting is good than direct apply P120
 Than we use pole gate and its hardness poteen on surface
 According to poteen condition we use sand paper of P120 for good condition and
P80 for rough.
 Than P180 use after P120 and P240 use after P120.
 Apply surface primer 2k with hardener 4:1
 Primer sanding.
 P320, P400, P600 AND P800 use respectively for finishing.
 Do masking around the paint area.
 Apply color in paint both.
 Heat the paint properly.
 Compound and max the paint.

Paint Making and Matching.

Today I learn how to match and make a paint for a car.

 The paint making and matching depends on following process.

 Check the colour number on VIN plate.
 Use the formula of colour to make the exact colour.
 If the colour metallic than use lacquer, hardener 2:1 and 1:1 respectively.
 If colouris none metallic 2k than hardener and lacquer mixed in paint.

Than do eye matching because computer matching is not 100% fine.

 Fault Diagnosing
Troubleshooting:
Engine is not cranked. Crankshaft does not rotate.

Suspect Area:
 Hydraulically locked cylinder
 Coolant /antifreeze in cylinder
 Oil in cylinder
 Fuel in cylinder
 Broken timing chain and/or timing chain gears
 Material in cylinder
 Seized crankshaft or connecting rod bearings
 Bent or broken connecting rod
 Broken crankshaft

Remedy:
 Remove spark plugs and check for fluid
 Inspect for broken head gasket
 Inspect for cracked engine block or cylinder head
 Inspect for a sticking fuel injector and/or leaking fuel regulator.
 Inspect timing chain and gears. Repair as required
 Inspect cylinder for damaged components foreign materials.
 Inspect crankshaft and connecting rod bearing

Troubleshooting
The electronic parking brake does not operate.

Suspect Area:
 We check the EPB Lamp was illustrated
 Then we try to operate the EPB switch physically but the brake does not operate.
 We install the KDs and Found DTC EPB Switch Malfunction
 We replaced the new part ( EPB Switch ASSY) for confirmation

Results. EPBS witch ASSY Need to be replaced.

Remedy:
 Remove the center console.
 Dismantle the complete EPB switch assembly.
 Install a new EPB switch assembly.
 Reinstall the center console.
 Calibrate the EPB switch.

Problems encountered
 Time Management
 Communication gap with technicians
 Communication gap with customers
 Leak of Technical Trainings in Labor

Supervisory works

During my industrial training I done following supervisory work in Forest

workshop.

 Supervisor in service department

 Workshop controller
 Warranty administrator

Supervisor on Service Advisor:

As a supervisor in service department I perform following duties.
 Focusing on customer retention by building relationships
 Monitoring the service advisors works.
 On job trainings for service advisor.
 Cross checking of advisors jobs card and do corrections.
 Managing and controlling costs
 Keeping track of service and inventory records
  Ordering parts and supplies as needed
 Forecasting goals and objectives for the department
 Implementing a marketing plan to promote business
 Maintaining relations with executives and factory representatives
 Contacting clients regarding the status of vehicles
 Overseeing post-repair services (vehicle delivery, test driving, etc.)

Workshop controller:
I have following duties to perform with workshop controller.
 Receive the vehicle form workshop entrance from service advisor.
 Maintain vehicle tracking board on daily basis.
 Fault Diagnosing of warranty claim vehicles.
 Allocate vehicle to technician as per skill matrix sheet
 Maintain daily tracking sheet
 Assist technician in case of any abnormality.
 Maintain5S in overhaul workshop
 Check final inspection sheet before delivery
 Perform work as per VOC and R/O job description
 Check Technician work is he perform his work as per LMCSOP.
 Ensure that all technician use PPE. (helmet, Gloved and Safety Shoes
E.T.C)
 Check Technician Tool trolley on weekly basis.
 Check mechanical workshop equipment on daily basis.
 Ensure that we delivered all vehicle on promise time, in case of any
vehicle is delay give there as on of service manager.
 Check repeat job.
Warranty Administrator:

I have following duties to perform in as a warranty administrator.

 Processes warranty claims on a timely.
 Crosscheck and approve all warranty paperwork ensure
proper documentation.
 Verifies criteria required by Forest workshop.
 Reconciles all warranty receivables with payments through the appropriate
accounting schedule.
 Posts credits on computer.
 Resubmits all rejected claims promptly or receives authorization to write
them off.
 Follows up on payment of outstanding claims.
 Tracks warranty parts by tagging with repair order number, date of
replacement and date on which part may be disposed of.
 Arranges for parts to be shipped to the factory or distributor or to be
scrapped.
 Files and maintains all service records as required by the warrantor.
 Keeps informed of all factory recalls and bulletins.
Quality Management System in place
The Pakistan automobile industry using the important quality management system
which is ISO/TS1 6949 includes special requirements for organizations supplying the
automotive sector. These supplement standard quality management requirements for
companies that produce parts or spares for automobiles. ISO/TS 16949 certification is
frequently a requirement for companies wishing to trade within the automotive industry.

PDCA
The PDCA cycle is used as a work philosophy and is the core principle of ISO TS.
This methodology is inherent to the sector on a daily basis and it sets the steps to be
followed to undertake any improvement

PLAN: Assortment of problems and planning of improvement actions → to know the

problem that is tried to be improved

DO: Realization of concrete actions to solve the problem → to put the necessary means
for improvement.

CHECK: Validation of results and controlling of aims → to measure the obtained results,
to see if the aims are reached

ACT: Improvement of actions, of the situation, etc. → to extend the solutions to other
similar problems, families of pieces

Figure.48 PDCA
 Project Carried Out Chassis Assembly
CAP (CHASSIS ASSEMBLY PLANT)
The chassis assembly plant is equipped with the latest technologies for vehicle
assemblies. It also comprises of Chassis Assembly Line, Engine and Axle Shops, Vehicle
Inspection Facility, Paint Booths and Ovens as well as other components manufacturing
facilities.

BMP (BODY MANUFACTURING PLANT):

HPML is the only commercial vehicle assembler in the country which has its own state of
art body fabrication plant. The Body Operation Plant team is dedicated for the production
of various bus and trucks bodies for city and requirements. Both operation plants of
HINOPAK MOTORS LIMITED is provided with the quality assurance department which
is responsible for providing good finished AND reliable products of the customers.

ISO CERTIFICATION:
 QMS-9001: 2008
 EMS-14001: 2004
 OHSAS-18001: 2007
CHASSIS ASSEMBLY
Chassis Assembly plant where different components are assembled at the chassis step by
step. Workers were found efficiently busy in their work comprising of the following
steps:

STAGE #01
Axle and Wheel Mounting
 Front and Rear Axle
 Steering Box
 Front and Rear Wheel
 Shock Absorber and Stabilizer
 U-Bolt and Leaf spring
 Carry time

STAGE #02
Air and Oil Piping
 Air and Oil Piping
 Control Cables
 Air tank sub assembly
 Fuel tank sub assembly
 Brake Boosters
 Carry time

STAGE #03
Engine Mounting
 Engine Mounting
 Exhaust Pipe and Muffler
 Radiator and Intercooler
 Power Steering Oil Pipe
 Cables
 Carry time
STAGE #04
Cabin/Floor Mounting
 Air Cleaner
 Arch Member
 Cabin/Floor
 Propeller Shaft
 Trailer Brake
 Carry time

STAGE # 05
Control Setting
 Lubricant/Fluid filling
 Batteries and Electric Box
 Fluid Bleeding
 Head Lamp and Bumper
 Greasing
 Carry time

ENGINE ASSEMBLY
STAGE # 01
 Crank shaft sub assembly
 Washing, degreasing
 Cam, crankshaft, flywheel, connecting rod, cylinder head, head cover, intake
manifold, cam and crank gear, pump & idle gear, oil strainer.
 Washing and painting : cylinder head , block , flywheel housing , timing gear
cover
STAGE # 02
 Bearing installation
 Crank installation
 Oil pump installation
 Engine no. punching
 Sub assy. Of cylinder head.

STAGE # 03
Installation of flywheel housing, oil seal , clutch disk and cover timing gear , timing gear
cover , water pump.

STAGE # 04
 Piston sub assy.
 Connecting rod sub assy.
 Piston installation
 Oil strainer installation
 Oil panel installation

STAGE # 05
 Sub assy. Installation of ion
 cylinder head
 Cam housing sub assy. And installation
 Sub assy. And installation of injection nozzle
 Tappet adjustment
 Sub assy. And installation of cylinder head
 Cover
STAGE # 06
 Intake manifold and air intake installation
 Installation of fuel injection pump
 Fuel filter installation
 Fuel and oil piping
 Thermostat sub assy. And installation
 Starter and motor installation

STAGE # 07
 Exhaust manifold sub assy. and installation
 Air and water piping
 Alternator installation
 Fan belt installation
 Bracket engine mounting

ENGINE TESTING:
Engine is tested by means of a hydraulic dynamometer in engine testing cell
where the testing of engine is carried out in the conditions same as it is mounted on the
vehicle. It is then tested with varying load and no load conditions. The load is given by
pressurized water through turbine.
At a certain load, the torque and RPM are measured and fuel consumption per
cubic cm is noted down in the smoke test. The sample of smoke is coming out of exhaust
is taking on a carbon paper and then tested on a smoke testing machine which determines
the amount of carbon present which should be less than 20%.
ASSIGNMENTS
PROJECT 230 DRAWINGS INVENTORY
Internship at Forest workshop has proven to be beneficial for us in numerous ways. Not
only has it taught us how the management of such a huge system works but also how the
office environment should be to get optimum output. Hino Bus is among the top notch
Bus of Pakistan and the office environment and plant management serve as a staircase to
the success. We learned that there are 11 processes that the parts are made through which
include:
 C1-Big Casting
 C2-Normal Casting
 F-Forging
 FH-Forging + Heat
 S1-Big Stamping
 S2-Normal Stamping
 P-Pipes
 R-Rubber + Elastic + Resin
 FU-Functional Parts
 WH-Wiring Harness
 K-Small clips/brackets
Furthermore, going through the assembly drawings taught us about the sub-assembly
parts and that their part numbers are also important in the assembly of any part. An
inventory of all parts with all their details including part numbers, prototype numbers,
manufacturing process, sub-assembly part numbers etc is worked upon so that the
drawings of parts and related details can be dealt with, easily. Also, it taught us that
drawings may be hand carried or scanned.
The internship has taught us to deal with paper work and also the complete parts
development process, from the selection of vendors to the storage of vendorized parts.
COSTING OF PARTS:
Estimated costs of different parts to be made were observed from the drawings of the
respective parts in order to enter into the inventory for a later ease in comparison.
Vendor Visit
Tariq Auto industries
CEO: Syed Sarfaraz Ali
Guide: Engr. Furqan Ali
Address: Quid-e-Azam Industrial Area, Lahore.
Tariq Auto Industries started off as a small manufacturing shop and is now a renowned
manufacturer in the market. It consists of a major molding machinery area, and a minor
mild steel press shop. Our guide through the visit, Mr. Furqan Ali demonstrated us about
different departments of the company, as well as their customers, their quality inspection
and safety precautions taken during the manufacturing.

Registrations:
PAAPAM, ISO 9001 2008, Lahore Chamber of Commerce, FBR Pakistan.

Vision:
To become the benchmark manufacturing company of the automotive industry which
provides world class products to its customers with continuous improvement driven by
the integrity, team work and creativity of our people.

Reach:
Karachi, Hyderabad, Lahore, Sadiqabad. Rahim Yar Khan, Dera Ghazi Khan, Multan,
Hub, and even extends borders by reaching China, Canada and South Africa.

Clientele:
Suzuki, Hino Pak, Master, SSGC, Al Haj FAW, N.J Motors, D.S Motors and Super
Power, FIAT etc.
SUBDIVISIONS:
AUTO INJECTION MOLDING AREA:
Auto injection molding sector consists of various injection molding machinery. Old Semi-
manual machinery has now been replaced by advanced Auto Injection molding
machinery which efficiently produces thousands of molded parts. Auto injection molding
machinery includes:

Figure.49 Auto Injection molding

Horizontal Injection Molding:

Huge horizontal auto injection molding machines are worked upon at Tariq Auto
Industries under the supervision of Mr. Jawwad. The major features of these machines
include short weights, pressure in tons, heat, tie bars that decides the mold size that the
respective machine can work upon and a dying plate. The material injection is pushed
forward by application of pressure and heated by heat generators and injected thus into
the respective mold.

Vertical Injection Molding:

Vertical Injection molding is also done on minor basis in the manufacturing shop. It
works the same way, except its vertical and gravity helps in the process.
SHEET METAL AND TOOL SHOP:
Press Machine:
Dies for this purpose are usually imported from China and sheet metal is placed in the
press machine and hence pressed in the required shape. The press machines in the sheet
metal and tool shop of Tariq Auto Industries were of different capacities and sizes i.e.
varied in tons as per requirements of the final products.

Figure.50 Press Machine:

Lathe Machine:
Cosmetic parts are usually fashioned in the lathe machine. The tool shop consists of one
lathe machine and a worker efficiently works. Flash may also be removed by the help of
machining.

Figure.51 Lathe Machine

Shaper:
A shaper is used for making flat surfaces. They may be of two types, one in which the
vice is stationary and the tool moves and one in which the tool is stationary and the vice
moves

Figure.52 Shaper:

Hobbing machine:
Hobbing is done to enhance the threads which are spoiled during the processing of the
parts. When working downward on the part, it works clock wise and for reverse process,
it works counter clockwise in order to not spoil the threads it just enhanced.

Figure 53 Hobbing machine

QUALITY CHECK:
For quality check, a quality inspector named Ali who is a graduate from UET is hired.
The quality maintenance is of huge importance at Tariq Auto Industries. Primitive
method was to check sizes and measurements by means of vernier calipers and screw
gauges. However the modern technique which is implemented in Shah Rubber Products is
the use of.

Checking Fixtures.
These fixtures are perfect templates of the final product; the product produced is placed in
it to check dimensions, if it fits perfectly, the product is considered to be acceptable,
otherwise rejected. Any kind of flashes produced during molding process are also made
sure to be removed by machining.

PARTS PRODUCED:
Some of the parts that are manufactured at Tariq Auto Industries include:
 Holder FR Bumper
 Holder RR Bumper
 Bracket, ignition switch
 Brake Reservoir
 Stay Parking cable bracket
 License lamp
 Side wall handle
 Plate rear Mudguard
 Intake EURO II
WHEEL HUB PRODUCTION:
This process is carried out for the production of the wheel hub for HPML.

Figure.54 Wheel Hub Production

PARTS PRODUCED:
To name a few, the parts produced by NCB include:
 Flywheel
 Wheel Hub
 Oil sump
 Tractor parts
 Brake drums
Project CONCLUSION
Working as an internee at the Supply Chain Division of Tariq Auto Industry
Lahore has been beneficial for us in numerous ways. Not only do we know now how the
office environment is, but also how the production procedure is carried out at the Plant,
HPML, Lahore. Our supervisor, Ms. Yousra Sheikh was kind enough to let us observe the
practical work carried out at the HPML’s Assembly line and also directed us about the
office work. We were also given the opportunity of visiting two vendors under the
supervision of Mr. Muhammad Tahir, and Mr. Shakeel who briefed us about the vendors
and very patiently answered all our queries.
All in all, it was a very healthy working experience; the office environment is very
welcoming and disciplined. Working here gave us exposure to the professional world
which is very useful for us, being students. The internship tenure here at Tariq Auto
Industry, Lahore was worthwhile and we’d certainly like to work here as employees
someday.
Chapter # 5

Conclusion:
My 16 week industrial attachment as a trainee technologist at special gift technical
services was a huge success and a great time of acquisition of knowledge and skills.
Through my training I was able to appreciate my chosen course of study even more,
because I had the opportunity to blend the theoretical knowledge acquired from university
with the practical hands on application of knowledge gained here to perform very
important tasks that contributed in away to my productivity in the company. My training
here has given me a broader view to the importance and relevance of Automobile
engineer technologist in the immediate society and the world as a whole, as I now look
forward to impacting it positively after graduation. I have also been able to improve my
communication and presentation skills and thereby developed good relationship with my
fellow colleagues at work. I have also been able to appreciate the connection between my
course of study and other disciplines in producing a successful result though the industrial
training lasted just for some months, I learned quite a lot. I had the privilege to participate
as an assistant in a sizeable number of repairs and services. The automotive maintenance
industry is a rapidly evolving industry with a lot of potential, especially in a developing
nation like Pakistan due to the fact that a lot of vehicles moving around are based on
technological advancements that are way beyond the reach of the typical road side
mechanics. This poses a threat to the survival of the local mechanic but also opens up a
new world of opportunities should he be willing to try them out.

The overall working experience in each workplace was kind of intellectual and
diversified. I learn how to manage workload in any working site and gain experience
from those who are working along side.I am sure that the practical skills and knowledge
got from this Internship program will definitely help me during my professional life
ahead. Finally, I would like to thank my instructors and all the person of this organization
who had helped me a lot during my internship.
Recommendations:
I use this means to make the following recommendations concerning the
training of students in Industrial Attachments.
1 The University community should invite and encourage corporate bodies
and organizations with seasoned professionals in relevant fields to hold
seminars and workshops that will enlighten the minds of the students to
recent development sand challenges in their discipline.
2. As a way of encouragement, lecturers should be provided with multimedia
teaching aids when and where necessary as this would help this students
get a clearer picture of the topics discussed in the classrooms.
3. Due to the nature of the nation’s economy, the students should be assisted
in securing attachment for their Industrial training periodas this will
eliminate the waste of time encountered in searching for a place of
attachment.
4. More practical classes should be held so as to further reduce the breach
between the classroom and the professional field. Also, more field trips
and excursions should be organized as this would encourage the students
because the link between the classroom and field work would be further
emphasized.
Chapter # 6
References:
[1]. https://forestautomobiles.com/

[2]. http://www.forest.com/portal/index/companyprofile.html

[3]. http://www.forest-global.com/

[4]. http://www.forest-global.com/index.php/marketing/consulting.html

[5]. http://www.forest-global.com/index.php/Aboutus/overview.html
COMPLETION CERTIFICATE