Industrial Attachment Report

Carried Out at
Suzuki Motor Parts: Service Center
BY
The students of Mechanical Engineering Department
Of
TU, IOE PURWANCHAL CAMPUS
Dharan, Nepal
Within the
Training Duration From
15/03/2021 to 15/04/2021
 Acknowledgement
We are grateful to our head of department, Roshan Ghimire,
Department of Mechanical Engineering of Tribhuvan University, for
allowing us to gather practical experience and enrich our knowledge via
the internship program.
We would also like to thank Mr. Saroj Khadka for his constant support
and guidance throughout our work.
We express our deepest thanks to Mr. Pankaj Tiwari (the workshop
manager) to guide us with attention and care and provide us with
insight into the technological world and aiding us to put our theoretical
knowledge into practice.
We appreciate Mr. Narayan Ghimire (the floor supervisor), Mr. Sarun
Bhandari, Mr. Sushil KC, Mr. Khanal (the service Managers) for the
valuable insights they have shared with us.
We would also thank the whole Suzuki Executive Motors team, who
guided us with the hands of experience throughout the journey. They
have provided us with an adequate amount of time and patience to
gain technical knowledge regarding the Automobile industry.
We have tried with our utmost effort to prepare this report. We hope
that our endeavor will be educational for you all.
Table of Contents
1. Abstract
2. Location
3. About Suzuki
4. Suzuki Models in Nepal
5. Workshop layout
6. Management Policies
7. Tools and Equipment
8. Suzuki Training
9. Components
10. Job Flow
11. Tasks Completed
• Engine Oil Change
• Brake Fluid Change
• Brake pad and disc change
• Suspension system
• Ignition coil and spark plug replacement
• Fuel Filter Replacement
• Predelivery Inspection
• Miscellaneous
• Engine Overhauling
12. Technician’s toolbox.
 Abstract
A wide range of companies and multinational organizations who are involved in
the design, development, manufacturing, marketing, selling and distributing
motor vehicles comprises the automotive industry. By size of the revenue, it is one
of the largest industries. Even after selling the vehicle, the companies provide
customers with after sales services through their franchised automotive
workshops.
Within the duration of this industrial attachment program, certain objectives
were observed and dutifully carried out. These are:
1. Observing and assisting with problem identification and troubleshooting
procedure,
2. Automotive component identification and understanding of mechanisms of
each component,
3. Familiarizing with toolbox and tools, understanding of special tools and
operating primary and secondary components required for repairing vehicles,
4. Disassembling and reassembling individual units withing the vehicle,
5. Observing and assisting with basic and special repair packages,
6. Understanding inventory management,
7. Observing and assisting with work documentation and digital data
management,
8. Understanding and abiding by workshop work ethics, code of conduct and
company rules and regulations,
9. Maintaining company quality control procedure.
Withing the short period of the attachment program, it was possible to briefly
observe, assist and understand automotive technology and its trends, workshop
operations and procedures and company policy. This report also has the scope to
portray some of the repair and maintenance procedures which were noted down
during the program. But in-depth discussion of each and every process that goes
down in the workshop is not possible due to very limited time, knowledge and
experience and therefore it is out of the scope of this report.
 Location

Image source: Google Map and Phone Camera.

 About Suzuki:

Suzuki is a Japanese multinational corporation that manufactures a wide

range of products, including automobiles, motorcycles, and marine engines.
Suzuki Motor Corporation was founded by Micho Suzuki in 1909 as Suzuki Loom
works, a company that produces weaving looms form the silk industries.
The company diversified into various products, including motorized bicycles,
before eventually becoming a fully fledged motorcycle and automobile
manufacturer.
Suzuki is known for producing a variety of automobiles, including compact
cars, hatchbacks, SUVs, and motorcycles. The company has a strong presence in
the small car segment and is well regarded for its fuel efficient and affordable
vehicles.
Suzuki has formed various partnerships and alliances with other
automakers. One notable collaboration was with General Motors (GM), where
Suzuki and GM had stakes in each other’s companies for a period.
In addition to automobiles and motorcycles, Suzuki is also involved in the
production of marine engines for boats and other watercraft.
 Suzuki Models in Nepal
Some of the Suzuki car models available in Nepal includes:
1. Suzuki Alto 5. Suzuki Dzire

2. Suzuki Wagon R 6. Suzuki Vitara Breeza

3. Suzuki Celerio 7. Suzuki S-Presso

4. Suzuki Swift 8. Suzuki Baleno

Workshop layout
1. Reception and Lobby
2. Workshop Manager Room
3. Parts Storage
4. Warranty Parts storage
5. Repair and service area
6. Washing Area
7. Engine Room
8. Record Room.
Management Policies
Suzuki service Policies:
1. Wear-and-tear repairs:
2. Front brakes service (Brake pads and/or brake discs when worn)
3. Rear brakes service (Brake pads and/or brake discs when worn)
4. Replacement of clutch (if required)
5. Replacement of wiper blades (if required)

Repair and Care

1. Paintworks Repairs
2. Plastic Repairs
3. Dent Repairs
Tools and Equipment
The Components

Cutaway image of Suzuki Vitara.

Table: General List of Car Components
Main Components Sub-components
1. Car Body and Main Part 1. Body components, including trim,
2. Doors,
3. Windows.
2. Low voltage/auxiliary electrical system 1. Audio/Video Devices,
and electronics 2. Cameras,
3. Low voltage electrical supply,
4. Gauges and Meters,
5. Ignition System,
6. Lighting and signaling systems,
7. Sensors,
8. Starting systems,
9. Electrical Switches,
10. Wiring Harness,
11. Miscellaneous.
3. Interior 1. Floor Components and Parts,
2. Car Seats,
3. Miscellaneous.
4. Powertrain and Chassis 1. Braking System,
2. Electrified Powertrain Components,
3. Engine Components and Parts,
4. Engine Cooling Systems,
5. Engine Oil Systems,
6. Exhaust Systems,
7. Fuel Supply Systems,
8. Suspension and Steering Systems,
9. Transmission Systems.
5. Miscellaneous Parts 1. Air-Conditioning System,
2. Bearings,
3. Hoses,
4. Other miscellaneous parts.
Schematic Diagrams of Some Components:
Engine.
Gear Box Components
Job Flow
Task completed
• Engine oil Change
Engine oil, Lubricants, and motor oils are the important components of engine to
operate properly. Its main functions are to reduce friction and wear, protect from
sludge and varnish formation, protects from oxidation and neutralizes acids and
keeps the engine life span at optimum. Oil change duration varies due to the type
of oil used. Synthetic oils have a longer life thus they are changed once after every
16000 KMs. For conventional oil its around 8000 KMs or 6 months.
If oil and oil filter is not changed on time, there will be difficulty in starting the
vehicle, the life span of engine decreases, the engine consumes more fuel and
engine may get heated quickly.
Oil Change Procedure:
Dipstick is taken out from engine to figure out the level of engine oil and if oil is in
very bad condition, it is changed along with oil filter.
The vehicle is secured to the car lift. The oil cap is opened from where oil is filled
into engine. Then the old oil filter and the rubber ring is taken out and taken out.
The car is then lifted up to a significant height where drain nut is opened from the
oil pan located on the engine and the oil is allowed to drain. An oil/lubricant/fluid
catch can catch all the shopfloor fluid. After draining, the nut is replaced with a
new washer and the nut is tightened and closed.
Oil is refilled back through the top of the engine with a help of a filling cone. Once
that is done the oil cap is closed.

Figure of dip stick and oil filter

 • Brake Fluid Change

Changing brake fluid is an important maintenance task for vehicle's braking

system. Over time, brake fluid can absorb moisture from the air, which can lead to
a decrease in its effectiveness and the potential for corrosion within the braking
system. It's generally recommended to change the brake fluid according to the
manufacturer's specifications, which can vary depending on the vehicle make and
model.
Brake fluid is taken and the reservoir is filled with the new brake fluid to the
recommended level. Brake fuel is used as specified in the vehicle manual.
• Brake Pad and Disc Change
Brake pads are parts which are friction elements that helps with stopping
the car. Usually semi metallic brake pads are made from shavings of copper,
steel and bronze which are glued together using resin. Brake discs are fixed
to the wheel hub and the pads grab on to it to stop the car.
Operation Procedure:
When the driver presses the brake pedal, hydraulic pressure is generated in
master cylinder. This pressure is transmitted through brake lines to brake
calipers.
In disc brakes, the hydraulic pressure causes the brake caliper pistons to
push the brake pads against the rotating brake discs.
The resulting friction between brake pad and disc converts kinetic energy
into heat.
 • Suspension system
The suspension system in a car serves several important functions that contribute
to the overall performance, safety, and comfort of the vehicle. Others functions
are smooth ride, vehicle stability, isolation from vibration and noise, protection of
vehicle components, adaptability to various road condition and enhance the
 • Ignition coil and spark plug replacement;
Procedure to change the spark plug:
Spark plug is located inside the cylinder head. Spark is required for the
combustion of fuel. Three Cylinder internal combustion engine contain three
spark plugs whereas four Cylinder combustion engine contains four spark plugs.
• Engine should become cold before changing spark plug.
• Battery should be disconnected to prevent accidental short circuits.
• Spark plug wires are disconnected carefully simply by pulling motion.
• Now, Spark plug socket is fit over protruding plug ang gently unscrew it by
using counterclockwise motion.
• New spark plug is fitted into the hole and wires are reattached.
• Fuel Filter Replacement
Fuel filter is located along the fuel line between the fuel tank and the
engine. The specific location can vary depending on the make and model of
the vehicle. Some modern vehicles have the fuel filter integrated into the
fuel pump assembly, which is located inside the fuel tank.
The primary function is to filter out impurities and contaminants from the
fuel before it reaches the engine. The filter helps prevent these particles
from entering the engine and causing damage to fuel injectors, carburetors,
and other components.
• Engine Overhauling
A 4-cylinder petrol engine is an internal combustion engine with four cylinders.
Each cylinder contains a piston that moves up and down within it, and the
engine operates on the four-stroke cycle—intake, compression, power, and
exhaust.
4-cylinder engines are often simpler and less complex than larger engines,
which can make them more straightforward to maintain and repair. Routine
maintenance tasks such as changing spark plugs, oil, and air filters are typically
more accessible in 4-cylinder engines due to their compact design.
Now we will go through some descriptive pictures of an overhauling
procedure of a 4- cylinder petrol engine used in Suzuki vehicle.
• Miscellaneous
Here are some miscellaneous pictures from the training period.

Gasket
Timing chain Adjuster
Starting motor
• Technician Toolbox
A toolbox containing all the necessary tools for all types of maintenance work
is the most necessary part for a technician at a workshop.
Suzuki uses toolbox containing all types of tools and toolsets.
A special ‘thank you note’ to the team and Suzuki Group:
We would like to end this report by thanking each and every member of the
Suzuki Service Center of Dhobighat.
Without your constant support, patience and guidance we wouldn’t have been
able to know so many beautiful and mind-boggling aspects of automotive
engineering and technology. We wouldn’t have been able to know the
advancement in engineering and technology that suzuki has made. And we
wouldn’t have been able to create this special bond and lots of memories that we
have made in the past 1 month. It’s something we will always remember.
We would also like to thank AIT Dhobighat Group. We are indeed grateful to the
company. Having been able to see futuristic technology in use, being able to see
the work that goes into making it ergonomic and driver focused, being able to feel
the luxury and appreciating the reason why it’s called the ultimate driving
machine was something really special and important to us.