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S. NO.

#
1. 2.

NAME #
Muhammad Ehsan Muhammad Owais

ROLL NO. #
08-Dcet-Ind-314 08-Dcet-Ind-336

Date of Submission: 24-01-2010

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S. No. #
1. 2. 3. 4. 5. 6. 7. 8.

Department #
Engineering Works (Plant) Maintenance (plant) Service PR&D P&D Parts GNL Plant Visit REMARKS

Time Spent #
09/12 to 16/12 17/12 to 18/12 21/12 to 24/12 28/12 to 01/01 04/01 to 06/01 07/01 08/01 ------

Page No. #
3 to 10 11 to 13 14 to 16 17 to 19 20 to 22 23 to 25 26 to 28 29

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In the plant the work, which is done on a large scale, is of Body Fabrication. Fabrication: The act of making something (a product) from raw materials or The act of constructing something as a piece of machinery. The body is fabricated for different types of vehicle. It is classified in two groups. Truck body Fabrication Bus body Fabrication

1. Truck Body Fabrication:


In the truck body fabrication the body is fabricated for different models (of trucks), including:

FTS 33 Truck

FTR 33 Truck

FTR 33 (Heavy Duty Truck)

NPS Truck

NPR Truck

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Steps Involve in Truck Body Fabrication:


o Material Preparation:
In this step material is selected and cut in the required shape and length as given in the drawings from Isuzu Japan, also some parts are modified here as well using the standard CAD technology, the machines used for this purposes are:

Shearing Machine (For cutting):


This the machine used for cutting metal sheet. The machine works by first clamping the material with a ram. A moving blade then comes down across a fixed blade to shear the material. For larger shears the moving blade may be set on an angle or "rocked" in order to shear the material progressively from one side to the other; this angle is referred to as the shear angle. This decreases the amount of force required, but increases the stroke.

Press Machine (For Bending):


This machine is used for bending the metal sheets in the required size and shape. Bending is a manufacturing process that produces a V-shape, U-shape, or channel shape along a straight axis in ductile materials, most commonly sheet metal. Usually bending has to overcome both tensile stresses as well as compressive stresses. When bending is done, the residual stresses make it spring back towards its original position, so the sheet must be over-bent to achieve the proper bend angle. When sheet metal is bent, it stretches in length. The bend deduction is the amount the sheet metal will stretch when bent as measured from the outside. The bend radius refers to the inside radius. The bend radius depends upon the dies used, the metal properties, and the metal thickness.

Machine Shop:
Machine shop consists of the following machine, which are also being utilized as required. Lathe Machine Shaper machine Milling machine Planner machine Surface grinding machine Machine shop also provides certain dies and tools used in the machines.

Galvanizing:
Some material is galvanized before using in the process of fabrication. Galvanizing is the practice of immersing clean, oxide-free iron or steel into molten zinc in order to form a zinc coating that is metallurgically bonded to the iron or steel's surface. The zinc coating protects the surface against corrosion by providing protection to the iron or steel The process consists of the following steps. Surface preparation Prefluxing Galvanizing Finishing

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The preparation steps consist of cleaning and pickling operations that free the surface of dirt, grease, rust and scale. The preflux step serves to dissolve any oxide that may have formed on the iron or steel surface after pickling and prevents further rust from forming. Clean, oxide-free work is galvanized by immersion into molten zinc. Finishing operations include quenching, removing excess zinc and inspection. After material preparation the process of fabrication is started.

o Fabrication Process For FTS 33 Truck:


The process consists of the following main steps.

Flooring:
For the floor of the FTS 33 truck 14 cross member and 2 long members is used. Length of the long members = 5100 mm, and Length of the cross members = 2440 mm. Sheet for both long members and cross members is M S Sheet of Thickness = 4 mm Sheet used for floor is of thickness 3 mm and also two types of sheet is used like: Plane sheet: It is used at the sides of the floor, and Chukker sheet: It is used in the middle of the floor, which provides much more stability and gripped for walking on it or prevent from being slipped on the floor. Then welding is done on it, to join it permanently. The welding mostly used is arc welding. Arc welding uses a welding power supply to create an electric arc between an electrode and the base material to melt the metals at the welding point. They can use either direct (DC) or alternating (AC) current, and consumable or non-consumable electrodes. The welding region is sometimes protected by some type of inert or semiinert gas, known as a shielding gas, and/or an evaporating filler material. The process of arc welding is widely used because of its low capital and running costs.

Panelling:
In panelling the side walls or sections are attached to the floor of the body. Panelling consists of: Side panels Front panel Tale gate panel Panels consists of a metal sheet and pillar usually made from the sheet metal by bending the sheet metal. The thickness of the sheet metal usued for side panels is about 2 mm and for the pillar, the thickness of the sheet is 2 mm. The pillar and the sheet metal is joined by Spot welding. Spot welding is a process in which contacting metal surfaces are joined by the heat obtained from resistance to electric current flow. Work-pieces are held together under pressure exerted by electrodes. Typically the sheets are in the 0.5-3.0 mm thickness range. The process uses two shaped copper alloy electrodes to concentrate welding current into a small "spot" and to simultaneously clamp the sheets together. Forcing a large current through the spot will melt the metal and form the weld. The attractive feature of spot welding is a lot of energy can be delivered to the spot in a very short time (ten to one hundred milliseconds. That permits the welding to occur without

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excessive heating to the rest of the sheet.After preparing the panels, then it attached with the floor. From out side pillar is welded with the floor, and inside the panel sheet is welded with the floor, to strongly held the panels with the floor. The welding used here is CO2 welding. CO2 welding is used for the welding of carbon and low alloy steels from 16 gage (0.059 inch) to 1/4 inch (6 mm) or heavier. CO2 welding overcomes the restriction of using small lengths of electrodes as in manual metal arc welding (SMAW) and over comes the inability of the submerged arc welding process to weld in various positions. CO2 is basically a semi automatic process, in which the arc length and the feeding of the electrode wire into the arc are automatically controlled. CO2 welding can be done in any weld position, it is easy to weld in the down hand position. For making butt welds, the root run is laid by moving the electrode, back and forth along the seam. For the filler runs of the multipass weld, the electrode is moved. The finishing run is deposited by weaving the electrode. Fillet, Vertical, horizontal and overhead welds can also be made using CO2 welding. After the weld is complete, the end crater should be filled. Through the process of welding the side panel and front panel is attached with floor, but the tale gate is attached with the floor through hinges. Hinge is a type of bearing that connects two solid objects, typically allowing only a limited angle of rotation between them. Here bow pipes is also attached with the piller of the panels.

Painting:
As the body fabrication is nearly completed, then it is sent into paint shop, painting is done through the following steps: Decreasing is done by washing the body by hydro-chloric acid, which reduce various oxides formed on the surface othe body, then it is cleaned by hot water and dryed up through air pressure. Then if something (i-e decreased material) is present on the surface of the body is cleaned by steel wool. Filling is done on the rough surface, (i-e joints, welds, spots formed by spot welding). The material used for filling is usually polykote, which is fast body filling material. After filling polykote is appllied then the surface is finished bu rubbing the surface through hands or machines. Priming ensures better adhesion of paint to the surface, increases paint durability, and provides additional protection for the material being painted. A primer is a preparatory coating put on materials before painting. Final Paint is done after all the above processes. The paint used is a mixture of an air dry paint and thinner, after painting the body, then it is allowd to dry out as required and also when to produce large amount of vehicles, it is smply kept for some time in an oven depending upon the temperature of the oven, as it is set. In the oven the paint is dryed up quickly.

Body Drop:
After painting, the whole fabricated body is drop over the chassis, which is assembled in the GNL Plant (Chassis is a skeleton of vehicle consisting of a steel frame supported on springs that holds the fabricated body and engine). It consist of a 6 cylinder, 4 stroke direct injection, water cooled OHC diesel engine.

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As the fabrication process of the FTS 33 truck is completed. After completing the process, then several persons of quality controll department check the body and other things as required. In the quality chech they manually checks all the parts, joints and several other things. They check and remove any problem, if they found. Then after proper documentation,then it is supplied as per demanded

2. Bus Body Fabrication:


In the bus body fabrication the body is fabricated for different models (of busses), including:

MT 133 Bus

NPR Bus LT 132 Bus CNG Bus

Steps Involve in Bus Body Fabrication:


o Material Preparation: The procedure adopted for the truck material preparation is also used for bus material preparaiton but the change is in the size and shape of the parts used.

o Fabrication Process For MT 133 Bus:


The process consists of the following main steps. Flooring: Number of cross member used in the floor = 13, sheet used for cross members is M S Sheet, having thickness = 4 mm, and length of the cross member is 2388 mm. The cross members are attached with the chasses (consisting of a 6 cylinder, 4 stroke water cooled In line OHC direct injection diesel engine) through mounding brackets, and some support pipes or tube are placed with the cross members, in order to provide sufficient support to the floor sheet placed on the cross members. They all are joined through arc welding. Finally fiber board/wood is used for flooring. Panelling: In the bus body fabrication,the panelling is of much more importance and is also much more complex. It is done on jigs and fixture. Jigs and fixtures are production tools used to accurately manufacture duplicate and interchangeable parts. Jigs and fixtures are specially designed so that large numbers of components can be machined or assembled identically, and to ensure interchangeability of components.

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The economical production of engineering components is greatly facilitated by the provision of jigs and fixtures. The use of a jig or fixture makes a fairly simple operation out of one which would otherwise require a lot of skill and time. Both jigs and fixtures position components accurately; and hold components rigid and prevent movement during working in order to impart greater productivity and part accuracy. Jigs and fixtures hold or grip a work piece in the predetermined manner of firmness and location, to perform on the work piece a manufacturing operation. A jig or fixture is designed and built to hold, support and locate every component (part) to ensure that each is drilled or machined within the specified limits. The correct relationship and alignment between the tool and the work piece is maintained. Jigs and fixtures may be large (air plane fuselages are built on picture frame fixtures) or very small (as in watch making). Their use is limited only by job requirements and the imagination of the designer. The jigs and fixtures must. be accurately made and the material used must' be able to withstand wear and the operational (cutting) forces experienced during metal cutting. Jigs and fixtures must be clean, undamaged and free from swarf and grit Components must not be forced into a jig or fixture. Jigs and fixtures are precision tools. They are expensive to produce because they are made to fine limits from materials with good resistance to wear. They must be properly stored or isolated to prevent accidental damage, and they must be numbered for identification for future use. Panelling is done in the following steps: Side Panelling: It consist of pillar tube of 2.5 mm thickness, the plane surface of the tube is 70 mm and the width of the tube is 50 mm. And the outer panel is of 1.6 mm thickness.
support tube (50 x 50 x2 mm)

pillar tube (70 x 50 x2.5 mm) support tube (50 x 30 x 1.6 mm)

Also a curvature is given to the outer panel and then All the tubes and pillars are joined through arc welding, and between the outer panel and inner panel thermopore is fitted. And also the outer zone A and B is attached to the structure. Front and Rare Panelling: The front and rare panels are made from fiber by moulding the fiber material in the mould to get the desired shape and structure. Roof Panelling: Roof panelling is done by the same process as adopted for the side panelling, but here only the difference is curvature given to the side panels and also the size.

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Painting:
Painting is done through the following steps: a. Dents are removed ,either by heating the area and then working on it or by simple working on it. b. Polykote is applied on the rough surface and the joints area. c. Then the surface is finished bu rubbing the surface. d. Primer is applied on the surface, which ensures better adhesion of paint to the surface, increases paint durability, and provides additional protection for the material being painted. e. Again the surface is check to find if there is any dent still present or any other problem. f. Then the surface is again finished by rubbing the surface. g. At last the final paint is applied to the surface, the paint is usually a mixture of an air dry paint and thinner.

Trimming:
As trimming is the process or act of adding decoration, therefore in trimming process the interior and exterior decorative work is done. It consists of: a. b. c. d. Fitting window Door Seats And Some electrical work (like indicators, lights, horn, and other connections). e. If the bus is an AC bus, then the ducts and other requirements for an AC is fulfilled here. Final Finishing: In the last the whole bus body is finally finished, Fianl finishing consists of: Buffing (to remove buffs i-e dust particle, if present any). Polishing (to polish the surface). The AC work in the bus if demanded by the customer is carried out by Nihon Engineering Company, they use high performance products imported from Itsly, Turkey, etc. and also provides tools for wniter season as well, like certain heaters. As the fabrication process of the MT 133 bus is completed. After completing the process, several persons of quality controll department check the body, roof and other things as required. In the quality chech they manually checks all the parts, joints and several other things. They check and remove any problem, if they found. Then after proper documentation,then it is supplied as per demanded

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Maintenance, repair, and operations (MRO) involves fixing any sort of mechanical or electrical device should it become out of order or broken (known as repair, unscheduled or casualty maintenance). It also includes performing routine actions which keep the device in working order (known as scheduled maintenance) or prevent trouble from arising (preventive maintenance). MRO may be defined as, "All actions which have the objective of retaining or restoring an item in or to a state in which it can perform its required function. The actions include the combination of all technical and corresponding administrative, managerial, and supervision actions". MRO operations can be categorised by whether the product remains the property of the customer, i.e., a service is being offered or whether the product is brought by the reprocessing organisation and sold to any customer wishing to make the purchase.

In Engineering or In general, the term maintenance has the following meanings: a) Any activity Such as tests, measurements, replacements, adjustments and repairs (intended to retain or restore a functional unit in or to a specified state in which the unit can perform its required functions). b) For material All action taken to retain material in a serviceable condition or to restore it to serviceability. It includes inspection, testing, servicing, classification as to serviceability, repair, rebuilding, and reclamation. c) For material all supply and repair action taken to keep a force in condition to carry out its mission. d) For material the routine recurring work required to keep a facility (plant, building, structure, ground facility, utility system, or other real property) in such condition that it may be continuously used, at its original or designed capacity and efficiency for its intended purpose. Manufacturers and Industrial Supply Companies often refer to MRO as opposed to Original Equipment Manufacture (OEM). OEM includes any activity related to the direct manufacture of goods, where MRO refers to any maintenance and repair activity to keep a manufacturing plant running. Industrial supply companies can generally be sorted into two types: a) The ones who cater to the MRO market generally carry a broad range of items such as fasteners, conveyors, cleaning goods, plumbing, and tools to keep a plant running. b) OEM supply companies generally provide a smaller range of goods in much larger quantities with much lower prices, selling materials that will be regularly consumed in the manufacturing process to create the finished item.

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In Isuzu GIL the following types of maintenance work is carried out or planned. Preventive maintenance Corrective maintenance In the Preventive maintenance, they work or simply analyze that how they might prevent an error, it may be a human error or fault of a machine as well. Whereas in the Corrective maintenance, they work and finds the different alternatives to get rid of the problems which they are facing. Preventive maintenance (PM) has the following meanings: a) The care and servicing by personnel for the purpose of maintaining equipment and facilities in satisfactory operating condition by providing for systematic inspection, detection, and correction of incipient failures either before they occur or before they develop into major defects. b) Maintenance, including tests, measurements, adjustments, and parts replacement, performed specifically to prevent faults from occurring. While preventive maintenance is generally considered to be worthwhile, there are risks such as equipment failure or human error involved when performing Preventive maintenance, just as in any maintenance operation. Preventive maintenance as scheduled overhaul or scheduled replacement provides two of the three proactive failure management policies available to the maintenance engineer. To make it simple: a) Preventive maintenance: is conducted to keep equipment working and/or extend the life of the equipment. b) Corrective maintenance: is sometimes called "repair", is conducted to get equipment working again. In Isuzu GIL maintenance department, the most Corrective maintenance work carried out is in there own Plant like generators, engines, and other machines used in the production plant. The basic problems a machine might have are: Mechanical problem or error. Electrical problem or error. To overcome all the above problems the Isuzu GIL maintenance department is divided in two sections, to overcome all sorts/types of probems properly and quickly to decrease the break-down time of both the worker and the machine.

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A vehicle service is a series of maintenance procedures carried out at a set time interval or after the vehicle has travelled a certain distance. The service intervals are specified by the vehicle manufacturer in a service schedule and some modern cars display the due date for the next service electronically on the instrument panel. The completed services are usually recorded in a service book which is rubber stamped by the service centre upon completion of each service. However at least one manufacturer (Mazda) now records services electronically on a database and prints them out for vehicle owners on request, so that it is not necessary for them to retain a stamped service book. A complete service history usually adds to the resale value of a vehicle. Services like DriverSide in the United States and Drive Archivein the United Kingdom are trying to create tools to help car owners track this service information.

Mechanics at Service Center. The Service department of the Isuzu GIL is basically an after sale service department but during a cetain period the different parameters of the service may be free of cost like labour cost, and other products like engine oil, oil filter, etc but to the vehicles not in the certain range of warrenty, they are fully cahrged but due to the high performance of there workers, customers still wants to tune up there vehicles from the department. The range of warrenty is of two types either complete one year or 100,000 kilometers. All the products which they changed in a vehicle is mention in the service book and is collected from the warehouse or parts department of the GIL. They also have a mobile workshop team, which provides services to the door step of a customer. In an service the following things are checked and also changed if necessary. Change the engine oil Replace the oil filter Replace the air filter Replace the fuel filter Replace the spark plugs Tune the engine Check level and refill brake fluid Check level and refill power steering fluid Check level and refill Automatic Transmission Fluid

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Grease and lubricate components Inspect and replace the timing belt if needed Check condition of the tires Clutch Gearbox Car Battery Engine components (further inspections than MOT)

Mechanical parts that may cause the vehicle to cease transmission or prove unsafe for the road are also noted and advised upon. Mechanical parts of the vehicle which deteriorated below pass standard since testing are inspected and advised accordingly.

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The phrase Product Research and Development (also P R and D or, more often, R&D), according to the Organization for Economic Co-operation and Development, refers to: "Creative work undertaken on a systematic basis in order to increase the stock of knowledge, including knowledge of man, culture and society, and the use of this stock of knowledge to devise new applications". New product design and development is more often than not a crucial factor in the survival of a company. In an industry that is fast changing, firms must continually revise their design and range of products. This is necessary due to continuous technology change and development as well as other competitors and the changing preference of customers. A system driven by marketing is one that puts the customer needs first, and only produces goods that are known to sell. Market research is carried out, which establishes what is needed. If the development is technology driven then it is a matter of selling what it is possible to make. The product range is developed so that production processes are as efficient as possible and the products are technically superior, hence possessing a natural advantage in the market place. R&D has a special economic significance apart from its conventional association with scientific and technological development. R&D investment generally reflects a government's or organization's willingness to forgo current operations or profit to improve future performance or returns, and its abilities to conduct research and development.

Research:
Research can be defined as the search for knowledge or any systematic investigation to establish facts. The primary purpose for applied research (as opposed to basic research) is discovering, interpreting, and the development of methods and systems for the advancement of human knowledge on a wide variety of scientific matters of our world and the universe. Generally, research is understood to follow a certain structural process. Though step order may vary depending on the subject matter and researcher, the following steps are usually part of most formal research, both basic and applied: Formation of the topic Hypothesis Conceptual definitions Operational definition Gathering of data Analysis of data Test, revising of hypothesis Conclusion, iteration if necessary

Innovation is a new way of doing something or "new stuff that is made useful". It may refer to incremental and emergent or radical and revolutionary changes in thinking, products, processes, or organizations. In the organizational context,

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innovation may be linked to performance and growth through improvements in efficiency, productivity, quality, competitive positioning, market share, etc. All organizations can innovate, including for example hospitals, universities, and local governments. In economics the change must increase value, customer value, or producer value. The goal of innovation is positive change, to make someone or something better. Innovation leading to increased productivity is the fundamental source of increasing wealth in an economy. Innovation is the most important thing for the human survival. Innovation is an important topic in the study of economics, business, design, technology, sociology, and engineering. Colloquially, the word "innovation" is often synonymous with the output of the process. However, economists tend to focus on the process itself, from the origination of an idea to its transformation into something useful, to its implementation; and on the system within which the process of innovation unfolds. Since innovation is also considered a major driver of the economy, especially when it leads to increasing productivity, the factors that lead to innovation are also considered to be critical to policy makers. As from the above information it is easy to understand the purpose of the P R & D Department of GIL. The department work continuously and effectively for the improvement of there products, to make it much more suitable for customers and also they try to modify there products according to the customers demand and from the recent results or data gattered from the market and from the popularity of recent released models of the company. The department work on the new models as well and also study about the modification of the models, like for the FTS truck, 200 liters capacity of oil tank was designed but according to there customer demand they modify it to 400 liters. Also they work that how to decrease the price of a model to make there model much more economical.

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The phrase Procurement and Develpoment (Also known as P & D) is the acquisition of goods and/or services at the best possible total cost of ownership, in the right quality and quantity, at the right time, in the right place and from the right source for the direct benefit or use of corporations, individuals, or even governments, generally via contract, or it can be the same way selection for human resource. Simple procurement may involve nothing more than repeat purchasing. Complex procurement could involve finding long term partners or even 'co-destiny' suppliers that might fundamentally commit one organization to another. Almost all purchasing decisions include factors such as delivery and handling, marginal benefit, and price fluctuations. Procurement generally involves making buying decisions under conditions of scarcity. If good data is available, it is good practice to make use of economic analysis methods such as cost-benefit analysis or cost-utility analysis. Based on the consumption purposes of the acquired goods and services, procurement activities are often split into two distinct categories. The first category being direct, production-related procurement And The second being indirect, non-production-related procurement. Direct procurement occurs in manufacturing settings only. It encompasses all items that are part of finished products, such as raw material, components and parts. Direct procurement, which is the focus in supply chain management, directly affects the production process of manufacturing firms. In contrast, Indirect procurement activities concern operating resources that a company purchases to enable its operations. It comprises awide variety of goods and services, from standardised low value items like office supplies and machine lubricants to complex and costly products and services like heavy equipment and consulting services. An important distinction is made between analysis without risk and those with risk. Where risk is involved, either in the costs or the benefits, the concept of expected value may be employed. As from the above, it is cleared to understand the scope and purpose of the P & D department of the GIL. The department have to manage different parts and materials (which is to produce locally) from different vendors in a certain time period, not to delay the manufacturing process. They also have to manage the different parts being imported from Japan.

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They get the different parts or products from the different vendors, but normaly they take the product from the one, who ensure the best quality and deliver the good in the given time frame and also form the one, whoes product is ecnomical compared to the other vendors, if the vendor have some problems and unable to provide the product in time then they have to response to other vendors as well.

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A warehouse is a commercial building for storage of goods. Warehouses are used by manufacturers, importers, exporters, wholesalers, transport businesses, customs, etc. They are usually large plain buildings in industrial areas of cities and towns. They usually have loading docks to load and unload goods from trucks. Sometimes warehouses load and unload goods directly from railways, airports, or seaports. They often have cranes and forklifts for moving goods, which are usually placed on ISO standard pallets loaded into pallet racks. Stored goods can include any raw materials, components, or finished goods associated with agriculture, manufacturing, or commerce. Some warehouses are completely automated, and require no workers inside. Pallets and product move on a system of automated conveyors, cranes and automated storage and retrieval systems coordinated by programmable logic controllers and computers running logistics automation software. These systems are often installed in refrigerated warehouses where temperatures are kept very cold to keep product from spoiling, and also where land is expensive, as automated storage systems can use vertical spacee fficiently.

Automatic storage warehouse for small parts

Aisle with pallets on storage racks

For a warehouse to function efficiently, the facility must be properly slotted. Slotting addresses which storage medium a product is picked from (pallet rack or carton flow), and how they are picked (pick-to-light, pick-to-voice, or pick-to-paper)

Some of the most common warehouse storage systems are:


Pallet rack including selective, drive-in, drive-thru, doubledeep, pushback, and gravity flow Mezzanine including structural, roll formed, rack supported, and shelf supported Cantilever Rack including structural and roll formed

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Industrial Shelving including metal, steel, wire, and catwalk Automated Storage and Retrieval System (ASRS) including: vertical carousels, vertical lift modules, horizontal carousels, robotics, mini loads, and compact 3D. Traditional warehousing has declined since the last decades of the 20th century, with the gradual introduction of Just In Time (JIT) techniques. The JIT system promotes product delivery directly from suppliers to consumer without the use of warehouses. However, with the gradual implementation of offshore outsourcing and offshoring in about the same time period, the distance between the manufacturer and the retailer (or the parts manufacturer and the industrial plant) grew considerably in many domains, necessitating at least one warehouse per country or per region in any typical supply chain for a given range of products. Large exporters/manufacturers use warehouses as distribution points for developing retail outlets in a particular region or country. This concept reduces end cost to the consumer and enhances the production sale ratio. Due to the importance of a warehouse, the warehouse or parts deparrtment of the GIL is specially designed to fulfill all the needs of there customers in the countryor simply in the region. In the department all the products are IN through a proper process and also it is utilize (i-e being used) through proper OUT process, i-e the IN & OUT of the products or parts is clearly describe in the warehouse book. Also this book contain all the information about the parts either it is present or it is used.

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In the GNL Plant, chassis of assembling for different vehicals is carried out. The various steps involve in the process are the following:

Step no # 1:
In the first step the drilling and rivitting is done in the chasses long member, and chasses number is also punched here.

Step no # 2:
Here the leaf spring and axial is attached with the chasses, and battery and fuel tank is also attached here.

Step no # 3:
In this step tubes and pipes are attached for fuel and for air brack system.

Step no # 4
This step is most important one, here engine is drop on the chasses, and the radiator and exhaust assembly is also done here.

Step no # 5:
Here cabin is drop on the chasses.

Step no # 6:
Air cleaner assembly is attached to the chasses and connected with the engine and with brake system.

Step no # 7:
This is almost the last and final step of the assembly, here different types of oiling is done as required like engine oil, brake oil, and clutch oil. During the assembling process engine is drop on the chasses, but the engine is also assembled in the GNL Plant. Different parts, which is used during the assembling process of the engine are:

Cylinder Head Rocker Arm Valve Cover Cylinder Block Flywheel Housing Timing Case Crankshaft Camshaft Flywheel Piston
Oil Cleaner Oil Filler Oil Filter

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Oil Sensor Exhaust Manifold Turbocharger Intake Manifold Air Intake Air Filter Engine Suspension Engine Gasket Kits

Filter Kits In the assembling of the engine, first crankshaft and camshaft is attached with cylinder block, then cylinder head is attached. After thes things piston is attached to the crankshaft with help of the connecting rods, then housing is done, after which fly wheel is attached. Now the engine starts to get shape, as fuel injection pump and starter morte is attached with the engine, then compressor is attached. Now the engine assembling is almost completed and then the engine test is carried ou before droping the engine on the chasses. The engine test is done in specailly desinged environment providing fuel and air directly form the cylinder. Very rarely they get problems here but if the gets any, they quickly tries to satisfy or remove the problem. The engine is sent to the chasses assembling line, where it is drop on the chasses. The other department which we visit in the GNL is the warehouse. The warehouse of the GNL is similar to the warehouse of the GIL in several aspects, like the managing of the parts in the warehouse but there is also some difference, like here the products which are imported are tested properly and then sent to the department where it is utilized as required.

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We have completed our Internship in the GIL. We observed that GIL is a well organized automobile Industry. Each of its department is connected with each other by formally and working in very good coordination. Official documentation system is also very organized. Coordination between workers and management is also very strong so that there is continuous manufacturing as required. Each kind of facility for production/body fabrication is available in GIL. Management policy of GIL is effective but required some variation to increase the productivity by applying time study and material handling processes for manufacturing to gain more profit. There workers also requires some sort of benefits/incentives to work much more effectively, these sorts of things will motivate the workers towards work. As for trainees, we dont think that any organization is better than GIL because each person from worker to management is too much trained and cooperative. We gain a lot of technical knowledge form GIL which we will never forget and also this will help us alot in our professional life. So we are too much thankful to GIL Staff for great cooperation with us during our internship

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