Industrial Attachment Report

Carried Out at
AIT Dhobighat: Suzuki Service Center
By
The students of Mechanical Engineering Department
Saugat Phuyal (PUR077BME081)
Shyam Kishor Yadav (PUR077BME082)
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, 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, National Service
Manager at for providing us opportunity to learn and gather practical
knowledge about automobile at Suzuki.
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, and Mr.
Sarun Bhandari, Mr. Sushil KC, Mr.Ganesh Khanal (the service
Managers) for the valuable insights they have shared with us.
We would like to thank to 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.
Table of Contents
1. Abstract
2. Location
3. About Suzuki
4. Suzuki Models in Nepal
5. Workshop layout
6. Company Structure
7. Tools and Equipment
8. Job Flow
9. Components
10. 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
11. 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

Dhobighat, Lalitpur

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..
Company Structure
Work flow of company is shown;
Tools and Equipment
1. Impact wrench: Impact wrench, also known as a pneumatic impact wrench,
is a type of power tool commonly used for tightening or loosening nuts and bolts.
It operates on compressed air and is a popular choice in automotive repair,
construction, and industrial applications.

2.Two and four post lifts: Two-post lifts and four-post lifts are types of
automotive lifts used in garages, car repair shops, and auto maintenance facilities.
Two-post lifts provide better access to the vehicle's wheels and suspension
components. This makes them ideal for tasks such as tire changes, brake work and
suspension repairs. Four-post lifts are commonly used for wheel alignments.
3.Air Blow Gun. An air blow gun is a pneumatic tool used for cleaning
surfaces, blowing away debris, and generally applying a stream of compressed air.
JOB FLOW
Vehicle Reception: Service advisor receive the vehicle. Customers
drop off their vehicles for service. During this phase, the service
advisor may discuss the customer's concerns and note any specific
issues the customer wants addressed and fills the job card. They
assess the vehicle, provide cost estimates, and communicate
recommended services or repairs to the customer.

FIG: JOBCARD

Vehicle Inspection: The vehicle is then inspected by technicians who

perform diagnostic tests to identify any issues. This may involve using
computerized diagnostic equipment to pinpoint problems.
Floor Incharge: Floor Incharge is responsible for overseeing and
managing activities on a floor of workshop. Floor Incharge supervise and
manage a team of employees working on the designated floor, Coordinate
workflow and operations on the floor to ensure that tasks are completed in
a timely and organized manner. If the parts are not available on the
workshop, He contacts with other service center for parts.

Parts department: The parts department keeps the record of the parts
with parts number which is suggested by service advisor to be replaced by
looking at job card. The parts are provided to technicians.

Vehicle Repairs: Technicians perform the required repairs or services on

the vehicle. This may involve tasks such as engine repairs, brake
replacements, oil changes, and other maintenance work.

Washing and cleaning: This department washes the exterior of vehicles

to remove dirt, grime, and road debris. This can include hand washing or
automated car wash systems, providing additional services, such as waxing,
polishing, and applying protective coatings to enhance the vehicle's
appearance. They also clean the interior of vehicles. This includes
vacuuming, shampooing carpets and upholstery, cleaning and conditioning
leather surfaces, and ensuring a tidy and fresh interior.

Costumer care: This department calls the costumers by looking the data
from the computer. Here the costumers are informed about the time of
servicing and call them if necessary. Costumer can wait in this section until
their vehicle gets repaired.

Billing: Here the customer settles the payment, and necessary paperwork,
including an invoice and details of the services performed, is provided.
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
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.

Refilling Oil
Dipstick
 Removing oil
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.

Changing Brake Fluid

• 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.

Brake Pad Front Brake

Rear Brake
 • 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 life
span of vehicle.
 • 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.

Spark Plug
New Spark Plugs Are fitted in above holes.
• 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.

Fuel Filter
 Pre delivery Inspection:
The purpose of this inspection is to ensure that the service or repair work
has been completed to a high standard, and the vehicle or equipment is in
proper working condition. Technician conduct a thorough quality control
check to ensure that all work has been done to the service center's
standards. This includes checking for any loose bolts, connections, or
components. Test drive of the vehicle is also done in case of necessity.

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.
 Crank shaft
Cam Shaft
 Rockers

Oil and Compression Ring

• 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.

Tool Box

Figure Source: Google

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 AIT
Dhobighat, Suzuki service center.
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. From the bottom of the heart, thank you Everyone.