A

Report on

INDUSTRIAL TRAINING
Kamu Motors
M.I.D.C, Ahmednagar

Submitted by :

Wagh Sujit Sanjay

Enrollment No: 2001300585

Roll No: 100

Under the Guidance of

Prof. A.G.Joshi Sir,

Lecturer in Mechanical Engineering Department

GOVERNMENT POLYTECHNIC, AHMEDNAGAR

(2022-2023)
 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
Certificate of Completion

of Industrial Training

This is to certify that Mr. Wagh Sujit Sanjay with Enrollment

No.2001300585 has successfully completed Industrial Training
(22049) in Kamu Motors M.I.D.C, Ahmednagar From 05
August 2022 to 14 August 2022 for partial fulfilment towards
completion of Diploma in Mechanical Engineering from
Government Polytechnic, Ahmednagar , Institute Code: 0130

Prof.A.G.Joshi Prof.R.M.Mane Prof.B.M.Kardile sir

(Industrial Training Guide) (Head Of Department) (Principal)

SEAL

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 ACKNOWLEDGMENT
We express our sincere gratitude to our Institute Government Polytechnic, Ahmednagar
for providing us an opportunity to undertake and complete six weeks Industrial training. We
are very thankful to our respected Head of Mechanical Engineering Department Prof. R. M.
Mane for the confidence he had on us regarding the Industrial training. We are very much
obliged to our respected Principal Prof B. M. Kardile Sir for motivating us and providing
industrial platform for performing the industrial Inplant training of six weeks in reputed
industries. We are very grateful to our mentor Mr. A. G. Joshi who was our backbone and our
guide throughout this Industrial training, without his assistance we could not have completed
this Industrial training within a short period of a time. It would be really very unfair without
mentioning of our friends and families.

We are also thankful to Maharashtra state Board Of Technical Education, Mumbai And
Kamu Motors , Ahmednagar for providing this opportunity of industrial training which is very
helpful to us for elaborating our concept of industrial working.

We are thankful to Mr. Akshay Gadekar Director , Mr. Babasaheb Bhingardive ,

General Manager Workshop Section of Kamu Motors Ahmednagar for giving us the
opportunity of 6 weeks Industrial training.

Also we are grateful to all the members of technical and non-technical staff of the Kamu
Motors , M.I.D.C Ahmednagar for their constant support and help.

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 Index

Sr. Content Page No.

No.
1 Introduction of Organization 5

2 Equipment Used in Industry 7

3 Different Systems in Automobiles 12

4 Automobile Components 15

5 Body Shop 20

6 Oil Types and its Grades 22

7 Regular Servicing of Vehicles 23

8 Tools Use in Vehicles 30

9 Car AC System 32

10 Car Scanning 32

11 Vehicle Insurance 33

12 Safety Equipment in Automotive Industry 48

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 1. INTRODUCTION OF ORGANIZATION

❖ Introduction of Kamu Motors , M.I.D.C Ahmednagar

➢ Tata Motors Limited is an Indian multinational automotive manufacturing company,
headquartered in Mumbai, India, which is part of the Tata Group.

➢ Formerly known as Tata Engineering and Locomotive Company (TELCO), the

company was founded in 1945 as a manufacturer of locomotives

➢ Tata Motors Ltd. is an Indian multinational automotive manufacturing company;

headquartered In Mumbai, Maharashtra, India.

➢ Its products include passenger cars, trucks, vans, coaches, buses, construction
equipments and military vehicles.

➢ Tata Motors has auto manufacturing and assembly plants in Jamshedpur, Pant Nagar
etc. in India as well as in Argentina, the United Kingdom. Etc.

❖ Name of the Directors:

1. Mr. Akshay Gadekar (Manager)
2. Mr. Babasaheb Bhingardive (superviser)
3. Mr. Shivraj Sase

❖ Available Vehicles in Industry

Vehicles
ZEST
PUNCH
SAFARI
ALTROZ
HARRIER
ARIA
TATA SUMO
TATA TIGOR
TATA HEXA
TATA NEXON
TATA TIAGO

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 ❖ Departmental Study
There are various departments at Kamu Motors. Ahmednagar like sales department, service
department and management department etc.

• Workshops

The Kamu Motors have big plant structure in which various workshops are there for servicing
its products. The workshops are:

Heavy Vehicle Workshop: In which the servicing and repairing is done for heavy vehicles like
truck, bus, and commercial vehicles.

Light Vehicle Workshop: In which the servicing and maintenance is done for light weight
vehicles like passenger cars, Tiago, Tigor, Bolt etc.

• Body Shop Department:

This is separate department from all other service and repairing departments. In which the
servicing is done for the vehicles which causes the accident. In this workshop, the change of
spares which gets damaged and also the replacing new parts which gets damages in accidents
is done.

• Washing Center:

Also there are separate washing center for each type of vehicle that is washing center for
Passenger Cars and another washing center for Heavy commercial vehicles

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 2. Equipment Used In Industry

❖ Air compressor

• Function:
An air compressor is a pneumatic device that converts power (using an electric motor, diesel
or gasoline engine, etc.) into potential energy stored in pressurized air (i.e., compressed air).
By one of several methods, an air compressor forces more and more air into a storage tank,
increasing the pressure. When the tank's pressure reaches its engineered upper limit, the air
compressor shuts off. The compressed air, then, is held in the tank until called into use.[1] The
kinetic energy provided by the compressed air can be used for a variety of applications such as
pneumatic tool as it is released air and the tank depressurizes. When tank pressure reaches its
lower limit, the air compressor turns on again and re-pressurizes the tank. An air compressor
must be differentiated from a pump because it works for any gas/air, while pumps work on a
liquid.

• Specifications:
-Accessories: Pressure switch, Pressure gauge, Regulator, Safety valve, Manual drain, Sixfoot
power cord

-Capacity: 60 or 120-gallon

-Tank: 30 gal

-Max PSI: 135

-NPT Outlet: 3/8 inch

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-ACFM @ 90 PSI: 5.7

-Voltage: 115 V

- Single Phase

- 60 Hz

-Running HP: 2

-Durability: 2,000 hours or approximately 1 year of operation.

❖ Jack, jack stands, and pole jacks

• Function:

When the vehicle lift temporarily, to support the vehicle once it has been elevated, to support
axles or other components of raised vehicles.

• Specifications:

Holding capacity: 6,000 lbs. / 2,721 kg

Lowered height: 11-1/2" x 292 mm

Maximum height: 17" / 431 mm

Base dimensions: 7" x 7-1/2" / 178 mm x 190 mm

Shipping weight: 22 lbs. / 10 kg

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 ❖ Oil drain

Services like changing oil and transmission fluid requires an oil caddy with enough capacity to
contain the largest fluid volume anticipated. As your services expand and you’re working with
vehicles on lifts, a standing oil caddy that can reach the raised vehicle will make the job easier
and quicker.

Specifications:

-18-gallon red translucent poly tank allows for easy viewing of oil level.

-18" diameter funnels with strainer.

-1/2" heavy-duty casters.

-Evacuation spouts and drain valve.

-Adjusts from 48" to 71".

-Weight 15lbs.

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❖ Engine hoist

Required in doing serious engine work that will require removal of the engine for repairs,
rebuilds, or replacement Lifting capacity: 2 Tons

Jack capacity: 6 Tons

❖ Vehicle lifts

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 Every mechanic needs to get under the vehicles to perform essential inspection and diagnostics.
Vehicle lifts are required to raise the vehicle to the height needed for these services.

Specifications:

MODEL XPR-10AS-168

Lifting Capacity 10,000 Lbs. / 4,536 kg.

Max Capacity / Front Axle 5,000 Lbs. / 2,268 kg.

Max Capacity / Rear Axle 5,000 Lbs. / 2,268 kg.

Screw Pad Adjustment: 2" / 51 mm.

Motor 220 VAC / 60 Hz. 1Ph.

Time of full Rise 45 Seconds

Max Load Per Arm 2,500 Lbs. / 1134 Kg.

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 3. Different Systems in Automobile Vehicles

❖ Engine cooling system

The engine in your car works best at a high temperature. When the engine is cold, components
wear out easily, emits more pollutants, and the engine becomes less efficient. Thus, another
important task of the cooling system is to allow the engine to warm up as quickly as possible,
and then to maintain a constant engine temperature. The main function of a cooling system is
to ensure that the engine runs at its optimum operating temperature. If the cooling system or
any part of it fails, it will overheat the engine, which can lead to many serious issues.

Have you ever imagined what would happen if your engine cooling system did not work
properly? Overheating can cause cylinder head gaskets to explode and even crack engine blocks
if the problem is serious enough. And all this heat must be fought. If the heat cannot beremoved
from the engine, the pistons are literally welded to the inside of the cylinders. Then you just
must throw the engine away and buy a new one. So, you should take care of your engine cooling
system and learn how it works.

❖ Exhaust System
The exhaust system collects the exhaust gases from the cylinders, removes harmful
substances, reduces the level of noise and discharges the purified exhaust gases at a
suitable point of the vehicle away from its occupants. The exhaust system can consist of
one or two channels depending on the engine. The flow resistance must be selected so that
the exhaust backpressure affects engine performance as little as possible. To ensure that
the exhaust system functions perfectly, it must be viewed as a whole and developed
accordingly. This means that its components must be coordinated by the design engineers
in line with the specific vehicle and engine

In addition to all the complex functions which the exhaust system has to perform, it is also
subject to extreme stresses. The fuel-air mixture in the cylinders is abruptly heated to
temperatures up to 2,400 °C. This causes it to expand greatly before escaping into the exhaust
system at supersonic speed. This noise level resembles the crack of an explosion and must be
reduced by approx. 50 dB(A) as it travels from the engine exhaust valve to the end of the
exhaust system.

Apart from temperature and pressure stresses, the exhaust system must also cope with
vibrations from the engine and bodywork as well as vibrations and jolting from the
carriageway. The exhaust system additionally has to resist corrosion attacking from the inside
caused by hot gases and acid, and from the outside in the form of moisture, splashed water
and salt water. There is also the risk that the catalyst may be poisoned through sulphur or lead
present in the fuel

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 ❖ Fuel Supply System
Fuel supply system consists of the following components

1. Fuel tank

2. Fuel lift pump or fuel feed pump

3. Fuel filter

4. Fuel injection pump

5. High pressure pipe

6. over flow valve

7. Fuel injector

Fuel is drawn from fuel tank by fuel feed pump and forced to injection pump through fuel filter.
The injection pump supplies high pressure fuel to injection nozzles through delivery valves and
high pressure pipes.

Fuel is injected into the combustion chamber through injection nozzles. The fuel that leaks out
from the injection nozzles passes out through leakage pipe and returns to the fuel tank through
the over flow pipe.

Over flow valve installed at the top of the filter keeps the feed pressure under specified limit.
If the feed pressure exceeds the specified limit, the over flow valve opens and then the excess
fuel returns to fuel tank through over flow pipe.

❖ COOLING SYSTEM
Fuel is burnt inside the cylinder of an internal combustion engine to produce power. The
temperature produced on the power stroke of an engine can be as high as 1600 ºC and this is
greater than melting point of engine parts. The best operating temperature of IC engines lie
between 140 F and 200 ºF and hence cooling of an IC engine is highly essential. . It is estimated
that about 40% of total heat produced is passed to atmosphere via exhaust, 30% is removed by
cooling and about 30% is used to produce power.

• Purpose of Cooling:
1. To maintain optimum temperature of engine for efficient operation under all
conditions.
2. To dissipate surplus heat for protection of engine components like cylinder,
cylinder head, piston, piston rings, and valves

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 3. To maintain the lubricating property of oil inside engine.

• Methods of Cooling
1. Air cooled system
2. Water cooled system

 Lubrication System
IC engine is made of moving parts. Duo to continuous movement of two metallic surfaces over
each other, there is wearing of moving parts, generation of heat and loss of power in engine.
Lubrication of moving parts is essential to prevent all these harmful effects.
• Purpose of lubrication
1. Reducing frictional effect
2. Cooling effect
3. Sealing effect
4. Cleaning effect
• Types of Lubricants

Lubricants are obtained from animal fat, vegetables and minerals. Vegetable lubricants are
obtained from seeds, fruits and plants. Cotton seed oil, olive oil, linseed oil, castor oil are used
as lubricants. Mineral lubricants are most popular for engines and machines. It is obtained from
crude petroleum found in nature. Petroleum lubricants are less expensive and suitable for
internal combustion engines.

The parts which require lubrication are

1. Cylinder walls and piston

2. Piston pin

3. Crankshaft and connecting rod bearings

4. Camshaft bearings

5. Valve operating mechanism

6. Cooling fan

7. Water pump and

8. Ignition mechanism

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 4 Most Important Automobile Components

❖ Engine

One of the most important components of a vehicle includes the engine. This is the most
important component of an automobile by all accords. The performance of a vehicle depends
on its engine and it is the heart of every car.

Engines require regular oil changes to stay lubricated and prevent wear and tear.

The engine consists of a fixed cylinder and a moving piston. The expanding combustion
gases push the piston, which in turn rotates the crankshaft. Ultimately, through a system of
gears in the powertrain, this motion drives the vehicle’s wheels.

There are two kinds of internal combustion engines currently in production: the spark ignition
gasoline engine and the compression ignition diesel engine. Most of these are four-stroke
cycle engines, meaning four piston strokes are needed to complete a cycle. The cycle includes
four distinct processes: intake, compression, combustion and power stroke, and exhaust.

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 ❖ Gear Box (Transmission)

The Gear Box, or transmission, comes in at a close second to the engine and is what commonly
needs attention when vehicles fail.
The transmission is what contains the different gears that the vehicle needs to shift into
depending on speed. These gears transfer the engine’s power to the wheels of the vehicle. There
are many types of gearbox parts in different cars.

A transmission is available in two types: the manual and the automatic models. As the speed
of the vehicle varies, the gears can be switched from one ratio to another. The power of the
engine is transferred to the wheels of the vehicle with the help of the gears.

Nowadays, most of the vehicles have automatic gears or transmissions. The gear box is one of
the most difficult parts of the vehicle to work on, and when restored can give new life to even
the oldest of vehicles.

In order to propel the vehicle, a particular type of speed and power changing device is required
to transfer the power developed by engine to the driving wheel due to constantly changing
requirement demand on the engine and inherent limitation is called transmission, and this
system is called transmission system.

The transmission allows the gear ratio between the engine and the drive wheels to change as
the car speeds up and slows down. You shift gears so the engine can stay below the redline and
near the rpm band of its best performance.

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 ❖ Brakes

Another extremely important component of a vehicle is the brakes which help reduce and halt
speed of the vehicle. When the brakes are applied, a hydraulic fluid is transmitted through the
steel pipes to the wheels of the vehicles.

Obviously, the failure of this system may lead to some serious accidents. Though previously
the entire system used to work upon human intervention, nowadays sensors are being installed
in cars so that the car itself can sense the necessity of braking and take action. Whether you
have a manual or sensor braking system, it is very important to maintain the brake parts such
as brake pads, which can crack with age.

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 ❖ Oil Filter

Filters are essential in removing dust and abrasive particles from the engine oil. Such particles
can harm the engine and prevent proper functioning. Oil filters are mainly used to segregate
the engine oil from unwanted debris and dust particles. Most of the oil filters are classified as
high efficiency filters as it segregates abrasive materials from the engine oil.

❖ Air Filter

An engine air filter prevents your engine from being damaged with dirt, dust, sand, and other
contaminants, but if it becomes clogged, your engine air filter can start to negatively impact
your vehicle performance. A cabin air filter is used to decontaminate the air that your vehicle
brings into its cabin.

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❖ Clutch Set

Most automotive clutches are a dry single plate clutch with two friction surfaces. No matter
the application, the function and purpose of a clutch is to transmit torque from a rotating
driving motor to a transmission. Clutches require a mode of actuation in order to break the
transmission of torque

5 signs that your clutch needs to be changed

. Difficulty shifting gear.

. Squeaking or grumbling noise when the clutch pedal is pressed.

. Spongy, sticking, vibrating or loose clutch pedal when pressed.

. Ability to rev the engine, but poor acceleration.

. Slipping' clutch, causing a momentary loss of acceleration

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 5 Bodyshop (Denting and Painting)

Denting and Painting is of two components: One is removing dents, scratches on the vehicle
external body are removed and re-made to look like how it looks before deformation. Second
is painting the body with the nearest matching paint. To make you understand furthermore
the process below steps are followed.

In the next step wherever there is a scratch or paint is deformed, that area is scrubbed with a
wax (called coat application in technical terms) is applied on the area.

In the next step after making the dent into the original shape, matched paint is applied on the
area or whole panel depending up on the length of the scratch or dent.

In the last step they do rubbing and buffing on the panel which it is painted. This helps in
smoothing the surface of the body

Factors To Consider Before Buying A Denting And Painting Service

Type Of Paint

As we know there are many types of paint to paint on the external body of a car, it can be
glossy, metallic, pearl, matte etc. Check for the type of paint which they are used while the
painting is done.

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Pick And Drop

Many service providers give a convenience for the customer by providing pick and drop
service when you buy a denting and painting service. So, the customer should be aware of
this thing.

Time Of Completion

It takes 2-3 days to do a denting and painting job completely because the coat application and
the paint must dry completely. So, it is advised to buy the service and schedule it for the
weekend for a hassle-free job.

Removal Of Parts

In case of full body package, the car is painted completely, so the things inside the car like
seats, dashboard and in some cases even the engine is removed. After the re-painting
everything is fitted back in its place. As a buyer it is one of the important things to consider.

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 6 Oil Types and its Grades

Lubricant Grades and Specification

Engine oil SAE 0 W-40 API CH4 and MB 228.3

specifications.

Rear axle oil SAE 85W-140 grade with 7% Anglamol-A

6043 by weight and API GL5 specifications

Gear box oil SYN Gear EP 75 W-90 GL4 Gluf grade

specifications

Power steering oil Automatic transmission fluid ATF Type

ASuffix A or Dextron II D

Brake/clutch fluid SAE J 1703F DOT 3 plus or DOT 4

Coolant Non - Amino Base class II JIS K 2234

specification

Chassis/wheel bearing grease Li base grease NLGI 2 (Consistency No. 3)

Clutch release bearing Sleeve, Clutch disc

Synthetic grease 365 TS 25205 P1
splines,

Brake pneumatic equipment Synthetic grease 365 TS 25205 P1

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 7 Regular Servicing of Vehicles

Sr. No. Servicing Operation Frequency (in KM)

1 Wash vehicle 9000

ENGINE
1 Check oil level in the sump and top up, if necessary. Check DAILY
oil leaks and rectify, if any
2 Check coolant level in auxiliary tank and top up, if DAILY
necessary. Check coolant leakages and rectify, if any
3 Drain water trapped in fuel water separator DAILY
4 Check thermostat for proper functioning and replace if 18000
necessary.
5 Lubricate with oil can : Controls to fuel injection pump and 9000
exhaust brake linkage ball joints. Pinion bush of the starter
motor.
6 Change oil in sump. Drain off while hot. Clean magnetic 18000
drain plug.
7 Clean engine oil filter housing and cover. Replace oil filter 18000
cartridge and 'O' ring.
8 Clean oil bath air filter (Euro I) and fill to correct level with 9000
recommended engine oil. Check condition of sealing rings,
replace if necessary.

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9 Remove drain plugs of fuel filters. Drain off sediments. 9000
Bleed the fuel system.
10 Clean prefilter at feed pump and bleed the fuel system. 9000
11 Check valve clearance (warm-up engine) and adjust, if 18000
necessary.
12 Check and if necessary, tighten the following :- (a) Injector 9000
pressure lines, (b) Leak off fuel line banjo bolts, (c) Heat
exchanger bolts, (d) Oil sump screws, (e) Oil pressure pipe
union at heat exchanger, (f) Exhaust manifold mounting
bolts, (g) Turbocharger mounting fasteners, (h) Flywheel
housing mounting bolts, (i) Clutch housing mounting bolts,
(j) Air cleaner mounting bolts, (k) Delivery valve holders,
(l) Leak off lines (m) Engine mounting bolts, (n) Water
pump, (o) Coolant temperature transducer, (p) Air filter
mounting (q) Exhaust manifold and muffler assembly.
13 Check alternator / fan belt condition and tension. If 9000
necessary replace belt & adjust.
14 Check and if necessary, tighten the following :- (a) Push rod 18000
chamber cover, (b) Timing gear cover, (c) Cylinder head
cover, (d) Radiator mounting (e) Radiator hose
connections, (f) Fuel tank brackets, (g) Fuel filter bracket,
(h) Fuel filter mounting bolts, (i) Air ducting hose
connections, (j) Engine mounting bolts
15 Check air cleaner service indicator on instrument cluster DAILY
(Euro II). If it blinks continuously , clean air filter
housing and replace primary cartridge.
16 Change air filter secondary cartridge. After every 3
replacements of
primary cartridge
17 Check fuel level in fuel tank and secure fuel tank cap. DAILY

18 Remove primary fuel filter bowl, clean and replace 18000

element. Bleed the system.
19 Remove secondary fuel filter bowl, clean and replace 36000
element. Bleed the system.
20 Remove strainer in fuel tank, clean and refit. Bleed the 36000
system.

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21 Remove engine breather cap, clean in kerosene. Blow air 9000
from outlet pipe. Replace gasket, if necessary. Check and
replace rubber hose, if necessary.
22 Remove injection nozzles. Test pressure and spray 36000
characteristics on nozzle testing equipment. Do not
disassemble nozzle, if found correct.
23 Drain cooling system - reverse flush. Refill system with 320000 kms or 2 years
fresh coolant. Add recommended quantity of anti-freeze whichever is earlier.
agent in specified ratio
24 Replace radiator rubber hoses 72000

25 Remove and clean exhaust outlet elbow, exhaust butterfly 72000

valve, shaft and refit. (Do not lubricate)
26 Check engine for trouble-free operation (colour of exhaust 18000
gases and nozzle operation)
27 Check end play of turbo charger shaft & radial clearance 72000
between turbine wheel & housing (Euro II).

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 CLUTCH
1 Check level of clutch fluid in plastic containers. Top up if 9,000
necessary
2 Check clutch pedal free play and adjust if necessary. (For 9,000
highway operation vehicles, this checks to be done more
often).
3 Remove grease cup for lubricating clutch release bearing. 9,000
Replace 3/4 full with grease and tighten by a few turns.
4 Lubricate with oil can-clutch pedal pivot pins 9,000
5 Tighten if necessary. Mounting of clutch master cylinder 9000
and slave cylinder.
6 18,000

7 Dismantle clean, inspect, replace kits and re-assemble 72,000

clutch master cylinder and slave cylinder and bleed the
system.
GEAR BOX
1 Check oil level in gear box, top up if necessary. 9000
2 Change oil in gear box (also at first 9,000 km) 36000
3 Clean breather on gear box. 72000
4 Check & tighten if necessary. Gear box mounting screw. 18000

26
•
8 Tools use in Vehicles

• Jack/Axle Stands

The jack and axle stands should always be used when the car has been raised off the ground.
These additional supports ensure safety is always kept as a priority. Most cars will have factory-
recommended slots underneath the car for the axle stands to be used. Always read the
instructions in your vehicles ownership manual on how and where the stands can be used.
• Wrench/Spanner, HEX Key, Plier and Screwdriver Sets
These sets of tools are not only common to be used on vehicles; they are also common
household tools too. These tools will be able to be used on many areas of the vehicle from the
engine, panels to the interior of the vehicle.
• Oil Pan/Drip Tray and Funnel

Changing your vehicle’s oil is a common task that can be completed at home. Having a drip
tray and funnel, can help avoid any unnecessary mess or spills which can be hard to clean up!
• Trolley Jack
The easiest way to lift your car off the ground at home is with a trolley jack. Jacks can come in
a variety of weights and sizes. Always be sure to check which jack is best suited for your vehicle
before purchasing. Most vehicles will also have “jack points” under the car, this is where the
car should be jacked up from.
• Wheel Chocks
They may seem unnecessary but wheel chocks are an important safety element. When the car
has been raised of the ground, chocks should be used to stop the car rolling dangerously
backwards or forwards (depending on where the car has been raised from).
• Wheel/Lug Wrench (Tyre Iron)
A flat tyre is one of the most common issues drivers will have to face without their mechanic.
Therefore changing a wheel is a job that all drivers should be capable of completing. Using a
wheel wrench is the easiest way to undo the wheel nuts, and can often be found with the spare
tyre in a vehicles boot.
• Jumper Cables
Jumper Cables can get you out of the sticky situation of a flat battery and are quite simple to
use. Jumper cables are available in different sizes and strengths so before purchasing, be sure
to check the cables capacity to ensure it will suit your battery.
• Torch/Work light
Having to work on your vehicle at night or in the dark is also a situation that often cannot be
avoided. Having a work light or flashlight can help rectify these situations.

30
 9 Car AC System

The air-conditioning system in a car works by manipulating refrigerant between a liquid and a gaseous
state. As the refrigerant changes states, it absorbs heat and humidity from the vehicle and allows the
system to give off cool, dry air.
Ac Gas Machine is used to charge the gas into car and refill the gas into the car . The gas use in this
machine is R134A Floron which is fill in the car ac system. This machine is used to vacuum the car ac
system and refill the oil.

10. Car Scanning

While a scanner won't fix your car by itself, it's a useful diagnostic tool that will help you or your
mechanic figure out exactly what's wrong with your car and fix it intelligently, rather than just throwing
parts at the problem, which can get expensive.
Scanner machine is used to scan the car and erase the codes. by this tool we can find the fault and the
fault can be solved with help of this tool.
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 11 Vehicle Insurance
Vehicle insurance (also known as car insurance, motor insurance, or auto insurance) isinsurance
for cars, trucks, motorcycles, and other road vehicles. Its primary use is to provide financial
protection against physical damage or bodily injury resulting from traffic collisions and against
liability that could also arise from incidents in a vehicle.

Vehicle insurance may additionally offer financial protection against theft of the vehicle, and
against damage to the vehicle sustained from events other than traffic collisions such as keying,
weather or natural disasters, and damage sustained by colliding with stationary objects. The
specific terms of vehicle insurance vary with legal regulations in each region. In many cases,
it is compulsory to have vehicle insurance before using or keeping a motor vehicle on public
roads. Most cases relate insurance to both the car and the driver; however, the degree of each
varies greatly.

Depending on the case, the insurance premium can be either mandated by the government or
determined by the insurance company, in accordance with a framework of regulations set by
the government.

• Why is car insurance necessary?

Having car insurance is essential because it covers your expenses in the event of vehicle damage
or injuries to other drivers, passengers or pedestrians. All motorists must be insured against
their liability to other people, as stipulated in the Road Traffic Act 1988.

The main purpose of auto insurance is to provide liability protection in case you injure or kill
someone during a car accident or cause damage to other people's property. All 50 states legally
require you to carry a minimum amount of this liability insurance.

• What Is an Insurance Claim?

An insurance claim is a formal request by a policyholder to an insurance company for coverage

or compensation for a covered loss or policy event. The insurance company validates the claim
and, once approved, issues payment to the insured or an approved interested party on behalf of
the insured.

Insurance claims cover everything from death benefits on life insurance policies to routine and
comprehensive medical exams. In many cases, third-parties file claims on behalf of the insured
person, but usually, only the person(s) listed on the policy is entitled to claim payments.

• Procedure for claiming car insurance

Car insurance claim for damages to your own car, first and foremost, as the policyholder, you
will have to submit a duly filled in claim form along with the requisite documents to the
insurance company and inform the insurance company before you send the car to the garage
for any repairs.

32
The insurance claim process for accident-related policies like auto, home, and liability
insurance usually involves a short window of time for filing a claim Usually, your health
care provider can submit a claim directly to your health insurance company if they provide that
service and have your insurance information.

If your car accident was caused by the other driver, then the liability (bodily injury) coverage
of their car insurance policy should cover your medical expenses, up to policy limits of course.
Your car insurance policy will pay for your medical bills, regardless of who was at fault for the
car accident.

• Types of Insurance Claims

1. Business Insurance Claims. Business Interruption.
2. Fire & Smoke Damage Claims.
3. Hail Damage Claims.
4. Homeowner Insurance Claims.
5. Property Damage Claims.
6. Water & Flood Damage Claims.
7. Wildfire Insurance Claims.
8. Wind Damage Claims.

• What is Third-Party Insurance?

Third-party insurance is an insurance policy purchased for protection against the claims of
another. One of the most common types is third-party insurance is automobile insurance. Third-
party offers coverage against claims of damages and losses incurred by a driver who is not the
insured, the principal, and is therefore not covered under the insurance policy. The driver who
caused damages is the third party.

There are two types of automobile third-party liability coverage. First, bodily injury liability
covers costs resulting from injuries to a person. These injuries' costs could include expenses
like hospital care, lost wages, and pain and suffering due to the accident.

• Comprehensive insurance

The type of insurance policy under which an insured (the first party) is paid by his or her
insurance (the second party) in the event of an accident, injury, or loss whether caused by the
itself or someone else.

• Collision insurance

(1) In comprehensive insurance, the insurer pays for the damage to the insured's vehicle
and (if the insured is at fault) to the other vehicle(s), as well as for personal injury and private
property damage arising out of the collision.

(2) In third-party insurance, only the loss and/or injury sustained by the party other than
the insured are covered.
• What is Depreciation?
Depreciation often refers to the loss in value of an asset over time due to factors such as age,
wear and tear, and obsolescence. Vehicles, in general, are depreciating assets. The insured
person has to pay for the difference between the market value of the new part and the
depreciated part of the car.

Zero depreciation cover, also called 'zero dep' policy, offers complete coverage without
factoring in depreciation. It means, if your car gets damaged following a collision, you will
receive the entire cost from the insurer.

• Four main parts to an auto insurance policy:

1. Bodily Injury and Personal Property Liability: This insurance pays damages for
other people's injuries or deaths caused by an accident that is your fault. It also covers any
damages caused to property. This type of liability coverage is usually presented in a series of
3 numbers such as: 100/300/50.

2. Personal Injury Protection: This coverage pays for your own medical expenses and
lost wages as well as your guest passengers if injured during an accident.

3. Collision and Comprehensive: Collision provides coverage in case your car is

damaged as a result of any kind of accident, such as crashing into another vehicle or into a
utility pole.

4. Uninsured Motorist: Provides protection if you're involved in an accident where the

other party does not have insurance or doesn't have enough to cover your damages.It also
protects you in the event of a hit-and-run accident.

• Basis of premium charges in Insurance policies

Gender

Because male drivers, especially younger ones, are on average often regarded as tending to be
more aggressive, the premiums charged for policies on vehicles whose primary driver is male
are often higher. This discrimination may be dropped if the driver is past a certain age.

Age

Teenage drivers who have no driving record will have higher car insurance premiums.
However, young drivers are often offered discounts if they undertake further driver training on
recognized courses.

Profession

The profession of the driver may be used as a factor to determine premiums. Certain professions
may be deemed more likely to result in damages if they regularly involve more travel or the
carrying of expensive equipment or stock or if they are predominant either among women or
among men.

Vehicle classification
Two of the most important factors that go into determining the underwriting risk on motorized
vehicles are: performance capability and retail cost. Vehicles that are commonly considered
luxury automobiles usually carry more expensive physical damage premiums because they are
more expensive to replace. Vehicles that can be classified as high performance autos will carry
higher premiums generally because there is greater opportunity for risky driving behavior.
Motorcycle insurance may carry lower property-damage premiums because the risk of damage
to other vehicles is minimal, yet have higher liability or personal-injury premiums, because
motorcycle riders face different physical risks while on the road.

Distance

Some car insurance plans do not differentiate in regard to how much the car is used. There are
however low-mileage discounts offered by some insurance providers. Other methods of
differentiation would include: over-road distance between the ordinary residence of a subject
and their ordinary, daily destinations.

• Top 10 Car Insurance Firms in India for 2018-19

1) ICICI Lombard GIC Ltd.

2) TATA AIG GIC Ltd.
3) Bajaj Allianz GIC Ltd.
4) Bharti AXA General Insurance.
5) The New India Assurance co. Ltd.
6) The Oriental Insurance co. Ltd.
7) HDFC ERGO General Insurance co. Ltd.
8) United India insurance co. Ltd.
9) National Insurance Company.
10) Future General India Insurance.
 12. Safety Equipment in Automotive Industry
Industrial safety is important as it safeguards human life, especially in high risk areas such as
nuclear, aircraft, chemical, oil and gases, and mining industries, where a fatal mistake can be
catastrophic. Maintaining a safe and healthy working environment is not only an important
human resources issue, it's the law.

Safety during work is the primary concern in any industrial environment for both employees
and employers. Adequate usage of safety equipment at a workplace provides additional
protection to employees in the presence of a slew of other safety measures.

• Personal Protective Equipment (PPE)

Safety equipment in many workplaces comprise of gloves, safety helmets, glasses/goggles,

safety boots, hearing protectors, respirators and high-visibility clothing like reflector jackets
that are worn usually in construction sites. There are also many special safety items available
for specific workplaces, such as those using UV or infrared rays. PPE refers to the equipment
which protects the user from health hazards or safety risks at work. It includes protective coats,
helmets, gloves, foot wear, goggles etc.

An employee who is new to the company may not know how to use the machinery and
protective equipment. He needs to be told about the precautions to be taken while using
machines/instruments in the workplace. It is important to train workers on how to use safety
gear effectively.

• Storing and maintaining equipment

Safety equipment needs to meet storage constraints correctly when it’s not put in to use. It needs
a constant check on being kept clean and in good working condition, or else it may run the risk
of getting obsolete in no time. One efficient measure would be to nominate individuals who are
assigned responsibility for regularly checking the equipment’s safety. Apart from providing the
right safety equipment to help minimize risks, employees need cohesive and comprehensive
training to ensure that they use safety equipment properly in their respective workplaces. Never
the less, along with proper training, policies and labelling, safety equipmentis the best way to
avoid workplace injury.
 • Types of personal protective equipment

PPE can be considered in the following categories, based on the type of protection afforded by
the equipment:

1. Respiratory protection - for example, disposable, cartridge, air line

2. Eye protection – for example, spectacles/goggles, shields, visors
3. Hearing protection – for example, ear muffs and plugs
4. Hand protection – for example, gloves and barrier creams
5. Foot protection – for example, shoes/boots
6. Head protection – for example, helmets, caps, hoods, hats
7. Working from heights - for example, harness and fall arrest devices
8. Skin protection – for example, hats, sunburn cream, long sleeved clothes

• Main Safety Equipment in Automotive workshop for workers

Safety Goggles or Safety Spectacles: These items are designed to protect employees’ eyes
from dangerous debris or infectious material. There are many types of eye protection available
out there in the market, which includes glasses, goggles, face shields and visors, etc. solely
depending on the varied types of work conditions.

Safety Gloves: These gloves are designed to protect workers from getting in direct contact with
harmful substances through their skin or sustaining a hand injury. Types of work gloves include
industrial safety work gloves, rubber gloves for handling chemicals, and Kevlar gloves for
construction and protection from abrasions.

Any form of PPE that acts as a barrier between the skin and the agent of exposure can be
considered skin protection. Because much work is done with the hands, gloves are an essential
item in providing skin protection. Some examples of gloves commonly used as PPE include
rubber gloves, cut-resistant gloves, chainsaw gloves and heat-resistant gloves.

Safety Shoes: Shoes with appropriate traction can help prevent falls on the same level in
slippery environments. They can also prevent falls from ladders, which are all too common
when people don’t wear shoes with proper treads. Footwear that fits well and feels comfortable
can also improve balance, which will help prevent slips, trips and falls, too.

For workers who stand all day, especially on hard surfaces like concrete, fatigue can be a real
problem. Muscles in the feet as well as the legs, back and other parts of the body grow tired,
and the situation can be worsened when employees don’t wear appropriate footwear. Shoes that
provide adequate cushioning and arch support can make people more comfortable, which
alleviate strain on muscles. This means employees will grow fatigued less quickly. Employees
who are less fatigued will be more alert, so they will likely do their jobs more safely and more
efficiently.

Protective, safety footwear is essential to ensure safe and healthy feet. Steel toe boots and shoes
protect feet, help prevent injuries to them, and reduce the severity of injuries that may occur in
the workplace. The foot is the most valuable part of our body subjected to injury in industry

Safety Helmet: Finally, wearing helmet helps you to protect your life. While you are
controlling your vehicle on the roads you would face a lot of problems especially accident by
wearing helmet can protect your head from danger. Head is the most important part for
everyone. Safety helmets are also important in automotive workshop for workers because
heavy duty commercial vehicles are present in it for repairing and other work.

Welding Helmets: Shielding your face and neck from sparks and radiation, a welding helmet
is as essential to welding as a welding machine and torch. Without a helmet (or hood or mask),
the powerful radiation emitted by the arc can quickly damage your skin and eyes.
Protective Clothing:-It includes items like safety jackets, safety shoes, etc. that is made from
material that offers protection against chemical splashes, asbestos, grease, etc.. This sort of
clothing is designed for auto workers, construction workers and any other industry that exposes
you to potential hazards.

Aprons and Sleeves: When worn beneath a jacket, a welding apron can offer additional
protection for a welder’s legs and chest. Pair it with a flame-resistant shirt and leather sleeves
for protection during light-duty welding.

Personal Protective Equipment and Dress

Employee attire should consist of long sleeve shirts and long pants that help protect arms and
legs from cuts, scrapes and burns. Avoid loose clothing that could get caught in machines or
equipment. Require that employees tie back any long hair and remove body jewelry before
working with machinery. Make all appropriate protective equipment available to employees,
including safety glasses, goggles, chemical-resistant gloves and kneepads. Ensure that
employees use safety equipment when it is required.

Safety Dust Mask: A dust mask is a flexible pad held over the nose and mouth by elastic or
rubber straps to protect against dusts encountered during construction or cleaning activities,
Dust masks are a cheaper, lighter, and possibly more comfortable alternative to respirators, but
may not provide as much protection

Fire Extinguisher: Fire extinguishers are needed to put out small fires; they also have an
amazing benefit towards the environment. By having the ability to control fires, fire
extinguishers limit the amount of pollution that is caused by smoke and burning debris. Car
repair workshops pose a range of fire risks, from flammable liquids to high tech equipment,
plus a potentially combustible mix of dust, sward and lubricants. So, we should always equip
your workshop with at least two different types of fire extinguisher.

Fire Extinguisher Training

As part of your fire safety requirements, all workshop staff should be trained in the correct use
of all types of fire extinguisher, and be aware of the different fire extinguisher colours, so they
can quickly access the right extinguisher in the event of a fire.

Hopefully this information clarifies the wide world of Personal Protective Equipment. The most
important thing is to stay protected from head-to-toe. Look for PPE that keeps the fine balance
of comfort without sacrificing safety. With comfort and security, welders can make the most
of their work without concern.

Conclusion
➢ The industrial training to Automobile Industry was a very informative training. The
training provided in depth information about Automobile Industry.

➢ The training provides an insight of the various technologies that Automobile works on
and also gave the students an overview of the company.

➢ The manager provided a brief note on agile methodologies adopted by the company.
 ANNEXURE

Evaluation Sheet for the Industrial Report

Name of Programme: Mechanical Engineering Semester:

ME4I Name of Mentor: Mr. A. G. Joshi Academic Year:

2022-23 Course: Industrial Training Course Code:

22049Name of Industry: Kamu Motors (Tata Motors)

Course Outcomes Achieved

………………………………………………………………………………………
………………………………………………………………………………………
……………………………………………………………………………………...…
………………………………………………………………………………………..

oral
Marks
Report (25 Presentation Viva(25
Enroll. No. Student Name (75mark)
marks) (25 marks) marks)

2001300407 Bapkar Vivek Gorakh

2001300565 Satav Vaibhav Sudam
2001300572 Shirsath Jayraj Sunil
2001300584 Wagh Akshay Dadabhau
2001300585 Wagh Sujit Sanjay
2001300586 Waghmare Tejas Dattatray
2001300587 Waghmode Krushna Bhaskar
2001300588 Warke Mayur Sunil
2001300590 Zirpe Niranjan Yashwant
Comments/suggestions about teamwork/leadership/inter-personal communications (if any):
…………………………………………………………………………………………………
………………………………………………………………………………………................

Signature Signature

Mr. A.G.Joshi

Mentor of Training External Examiner