summer internship report.coloured

2013

SHOAIB HASSAN KHAN

BE (MECHANICAL), 3RD YEAR

PNEC (NUST)

HINO PAK MOTORS LIMITED

8/5/2013

SUMMER INTERNSHIP REPORT

2

SUMMER INTERNSHIP REPORT

NATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY

SUBMITTED TO: MR.MISBAHUDDIN AKOZAI

SUBMITTED BY: SHOAIB HASSAN KHAN

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TABLE OF CONTENTS

Sr.NO Contents Page #

1 TABLE OF CONTENTS 3

2 ACKNOWLEDGEMENT 4

3 INTERNSHIP OBJECTIVE 5

4 COMPANY HISTORY 6

5 MISSION AND VISION 13

6 FIRST DAY AT HINO 14

7 ENGINE ASSEMBLY SHOP 14

8 INTRODUCTION OF MAIN HINO LINE 19

9 MAINTENANCE DEPARTMENT 34

10 ASSIGNMENT 36

11 CONCLUSION 38

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ACKNWLODGEMENT

First of all, I would like to express my gratefulness to Almighty ALLAH who has always

blessed Humanity infinitely and provided us with this opportunity to explore our multifarious

talent and Competence in the practical genre. Secondly, my parents deserve a lot of praise

who cherished and supported me through thick and thin of our bout of life. This experience

wouldn’t have been possible without their approval and support. It was a very challenging

and enjoyable Experience with HINO PAK MOTORS. I had been fortunate in having many

able and congenial colleagues during my stay at HINO PAK. Without their assistance and the

contributions, it was difficult for me to understand the Professional ethics. The personnel

were very cooperative and cordial. Here I take this Opportunity to show appreciation to their

conductive, welcome and pedagogical attitude.

I wish to articulate my deepest thankfulness to SIR MISBAHUDDIN AKOZAI

Who played a pivotal role in my placement of the internship program and oriented my

schedule so intelligently that I cover much more in the given time.

The contributions of the Primary team are acknowledged and special thanks to Mr

ALEEM UDDIN and their team for their interest and support.

Thanks are due to the Secondary Team for their support and the associations

ESPECIALLY with Mr MUJTABA have been most valuable.

Special thanks to our supervisor Mr JMAL QAMAR for their cooperation throughout

the internship and their guidance through which I was able to learn much more.

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INTERNSHIP OBJECTIVE

The objective of the internship is to develop professional skills and broaden the scope on

future work by participation in a professional multinational organization.so that after studying

theoretically I could see that process practically and I should make myself able on primary

level that how an industry works. And all I would be able to relate my theoretical work with

practical work.

HINO PAK MOTORS LIMITED

Hinopak Motors Limited assembles, manufactures and markets world renowned Hino diesel

trucks and buses in Pakistan. The Company has held the top position in the domestic market

for medium and heavy-duty vehicles for 17 consecutive years and is highly acclaimed for

quality and technological excellence.

Backed by Hino's expertise Hinopak has achieved standard of quality and excellence that

rival the best in the region. With over 60,000 vehicles on road, Hinopak has gained 50%

market share making it the largest manufacturer in medium and heavy-duty truck and bus

industry in Pakistan.

HinoPak's product range has been designed and built in Hino's traditions of automotive

excellence to be the leader in its category and the main emphasis has been given to

passengers' safety & comfort.

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THE COMPANY’S HISTORY

“Hino Motors Japan and Toyota Tsusho Corporation in collaboration with Al-Futtaim

Group of UAE and PACO Pakistan formed Hinopak Motors Limited in 1986.In 1998,

Hino Motors Ltd., and Toyota Tsusho Corporation obtained majority shareholding in the

company after disinvestments by the other two founding sponsors. This decision to invest

in Hinopak at a time when the country's economy was passing through a depression and the

sale of commercial vehicles was at an all-time low reflects the confidence our Principals

have in our company and their commitment to the Pakistani market. Hinopak is the trusted

market leader with over 50% share in the Pakistani Truck and Bus industry. Hinopak a

vital contributor in saving of foreign exchange is also providing jobs and plays a pivotal

role for the development of the local industry through its progressive manufacturing.

By continuing to move forward and staying alert to the ever-changing market & social

needs, Hinopak will continue to be a successful and respected corporate citizen of Pakistan,

reflecting their commitment and belief in the Hinopak corporate philosophy to "contribute

to the development of a more prosperous and comfortable society by providing the world

with a new set of values".

STAKE HOLDERS AND PARTNERS

HINO MOTORS LTD., JAPAN

Hino Motors Ltd., JapanHino Motors Limited was founded in 1910 and remains Japan’s

pioneer motor vehicle manufacturer. Hino Motors Limited is part of the Toyota Group and

has been leading the Japanese commercial vehicle market for decades. Hino’s renowned

quality and superior technology paved the way for Hino to becoming the trusted market

leader in Japan as well as one of the largest in world.

In this age of high technology, globalization and advanced data communication, individual

values are diversifying. Hino is dedicated to putting the customers first and maintaining high

standards of quality.

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Toyota Tsusho Corporation (TTC)

Established in 1948, Toyota Tsusho Corporation (TTC) is a trading company within the

Toyota Group. TTC has an extensive network of representative offices all over the world and

offers a vast variety of goods and services to its customers.

As a leading player in the automotive business TTC provides additional support to Hinopak

with its expert advice and knowledge of world markets.

CORPORATE FEATURES

Building on more than 2 decades of success, Hinopak continues to play a leading role in

marketing commercial vehicles with superior and advanced Japanese technology.

Market Leader in Pakistan, holding over 50% of the truck and bus market share.

First Pakistani automobile company and Hino affiliate to receive ISO-9001 certificate.

First Pakistani automobile company and Hino affiliate to receive ISO-14000

certificate.

First company to export buses from Pakistan.

Recipient of Quality Excellence Awards.

First automotive company to introduce "3S" concept in heavy-duty commercial

vehicles market.

First company to supply busses under "Urban Transport Scheme" in Pakistan.

Recipient of Employers' Federation of Pakistan's Golden Jubilee Award for Human

Resource and Industrial Relations.

Recipient of Corporate Excellence Award from Management Association of Pakistan.

Recipient of Employers' Federation of Pakistan's Golden Jubilee Award for

"Excellence in Productivity".

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It prepares

1-buses

2-trucks

3-specializes vehicles

1-BUSES

The largest Manufacturer of Buses in Pakistan, Hinopak is fully-equipped to design and

manufacture a wide range of Bus Chassis and all types of Bus Bodies. Hinopak’s Bus Line

Up includes the Road liner Supreme Luxury Bus for long journeys, Citiliner Intercity Buses,

Citiliner Urban Buses, luxury Senator Coach and Rapid liner Deluxe Coach.

Hinopak delivers only the safest most reliable products and remains the pioneer in supplying

the largest number of Urban Buses that are successfully facilitating the commuters in Punjab

and Sindh.Hinopak is fully-equipped to design and manufacture a wide range of Bus Chassis

and all types of Bus Body.

Road liner supreme GB rapidliner

GB senator City Bus

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TRUCKS AND PRIME MOVERS

Hino 500 Series:

The 500 series consist of vehicles that are in line with global Euro emission standards making

Hinopak the first Pakistani commercial vehicle manufacturer to introduce a complete range of

environment friendly vehicles. It has been especially developed and designed keeping in

mind the rugged terrain in order to meet the requirements of the diverse Pakistani automobile

market.

DUTRO – Light Duty Truck

Hino 300 Series:

Dutro is Hino’s globally renowned light duty truck with high-performance direct-injection

engine that delivers power with high-fuel economy and lower and cleaner emissions for

minimum impact on the environment. The Euro1 emission standards are adhered to through

employment of electronically controlled common rail fuel injection device.

CNG Bus Urban Bus

CitiLiner Clasics Citi Liner Exclusive

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Hino 300 Series:

Hino 500 series:

Hino Dutro WU-600

4x2 Truck

Hino WU-640

4x2 Truck

Hino Dutro WU-720

4x2 Truck

FG1J 4x2 FL1J 6x2

FM1J 6x4

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Prime Movers:

SPECIALIZED VEHICLES:

Our versatile range of special purpose vehicles play an important role in meeting the

transportation needs of our customers. These vehicles are engaged in prompt and safe hauling

of a variety of supplies like food, equipment and machinery, virtually from any location to

any destination. Hinopak has been able to successfully develop and market various buses and

super structures satisfying the needs of different customers.

FG1J PM 4x2 Prime Mover SG1J 4x2 Prime Mover

FMIJ PM 6x4 Prime Mover FM2P 6x4 Prime Mover

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PRODUCT SUPPORT NETWORK

Hinopak is first in commercial vehicles sector to start the establishment of 3S Dealership

network, which offers Sales, Service and Spare parts facilities all under one roof. This

comprehensive network of offices, 3S Service Dealers and Spare parts Dealers are

strategically located throughout the country.

Hinopak also maintains a fleet of mobile workshops, which provide prompt and efficient

back-up service to Hino consumers even at remotest of locations. Hinopak also maintains an

inventory at its own warehouses to ensure that genuine spare parts are readily available

throughout the country.

Hinopak has also established a state of the art product support training centre which is largest

of its kind in the country which is fully equipped with all relevant Training Aids to conduct a

wide range of highly professional training courses for Mechanics, Drivers and Supervisory

Technical Personal, such as Foremen, Workshop Supervisors/ Managers etc. engage with

customers and fleet operator.

Network Support

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Mission and Vision

The mission of Hinopak Motors Motor Limited is to provide the society with safe,

economical, comfortable and environment friendly means of transportation by

manufacturing and supplying commercial vehicles and services”.

To achieve this mission, Hinopak commits itself,

To our individual institutional and in international customers: to deliver high

quality, safe, durable, reliable, comfortable, environment-friendly and

economical products and services to their total satisfaction.

To our employees: to foster corporate culture of mutual trust; respect for

fundamental human rights at work; opportunities for professional growth and

personal welfare so that they are proud of being a member of “HINOPAK

Family”.

To the community and our nation: to contribute in economic and social

development by providing means of transportation and by progress

localization of the vehicles.

To the shareholders: to act in compliance with the norms expected of a

subsidiary of the Toyota group of companies and make a meaningful financial

return to the shareholders.

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FIRST DAY AT HINO

First day we go in the supervision of the sir Umar Afaq who given us complete introduction

of engine shop. And there we were assigned different department there. We were fortunate to

have time with sir Umar Afaq.Further on we will discuss in detail the engine assembly shop.

We have also learned and seen engine testing by dynamometer, smok test, paint shop, spot

welding and IMV section but we will discuss limited department here.

ENGINE ASSEMBLY SHOP:

STAGE # 1:

Stage 1 consists of following steps.

Sub Assembly crank and cam shaft.

Washing.

Cam & cam shaft, fly wheel, connecting rod, cylinder head cover, Intake manifold,

cam and cam gear, pump and idle gear oil, strainer.

Water gallery covers installation.

Washing and painting cylinder head and block fly wheel housing, T/G cover

STAGE # 2:


Crank and crank shaft installation.

Injection pumps gear sub assembly and installation.

Water drain plugs installation.

Oil gallery installation.

Idle gear shaft installation.

Thrust washer installation.

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Engine number punching.

Cam shaft and plate installation.

Engine shafting on conveyor trolley.

Cylinder head sub assembly.

STAGE # 3:


Installation of oil retainer.

Fly wheel housing.

Fly wheel.

Clutch disc.

Clutch cover.

Timing gear cover.

Oil pump.

Compressor idle gear.

Water pump.

Water pipe.

Crank pulley,

STAGE # 4:


Piston sub assembly.

Connecting rod sub assembly.

Piston installation.

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Connecting rod installation.

Dust cover installation.

Oil strainer installation.

Oil pan installation.

Engine tilting.

STAGE # 5:


Tappet installation.

Tappet covers installation.

Oil Filter.

Oil Cooler.

Installation of water flange and studs in cylinder head.

Cylinder head installation.

Push rod and rocker arm sub assembly installation

Sub assembly and installation of injection nozzles.

STAGE # 6:


Installation of fuel injection pump.

Piping of fuel and oil pipe.

Water pumps pulley installation.

Thermo state body sub assembly.

Hose Pipe installation between water pump and thermostat body.

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Intake manifold and air intake pipe installation.

Breather hose pipe installation.

Self starter installation.

STAGE # 7:


Air compressor sub assembly and installation.

Air compressor fuel, Air and water piping.

Exhaust manifold sub assembly and installation.

Alternator installation.

Fan belt installation.

Engine mounting bracket installation.

STAGE # 8:

Stage 8 consists of following steps.In this stage we start the engine and check all faults.

Engine heating (up to 80oC)

Tappets clearance adjustment.

Cylinder head bolt torque rechecking.

Horse power measurement.

Torque measurement.

Fuel consumption measurement.

Exhaust smoke analysis.

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Oil pressure measurement.

Water inlet and outlet temperature.

Maximum (r.p.m.)

Minimum (r.p.m.)

Washing.

STAGE # 9:


Foundation bracket installation

Injections pump seal installation.

Cooling fan installation.

Clear lacquer touchup.

Final Checking

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INTRODUCTION OF MAIN HINO LINE

DRILL AREA:

STAGE # 1:


FRAME PREPARATION:

Un Packing.

De-rusting/cleaning.

Imprinting LH, RH, /FR, RR

STAGE # 2:


WEB:

Setting the rail S/A

Clamping & setting of jigs.

Drilling 09 to 18mm.

Burs cleaning.

Removing the jigs.

Cleaning the rail S/A.

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STAGE # 3:


DRILLING:

Frame rail drilling.

Web drilling.

Frame turning.

Jig setting.

Clamping

Drilling 09 to 25

Self inspection.

STAGE # 4:


TOP BOTTOM:

Setting the rail S/A

Jig setting on bottom flange.


Jig removing.

Turn rail from bottom to top.


Jig removing.

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STAGE # 5:


Turn the rail S/A on web.

Position.

Jigs setting.


Bur cleaning.

Removing the jigs.

Cleaning the rail S/A...

STUDY OF MAIN LINE

STAGE # 0:


Chassis Engraving

Ladder riveting

Grunion sub assembly

Trunnion installation

Chassis no. engineering.

Ladder Riveting.

Trunion sub assembling.

Trunion installation.

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LINE 1:

Tightening of bolts and nuts in frame process of riveting.

LINE 2:

Mounting of cross member on frame.

Riveting:

In riveting, a head is formed on the shank end of a fastener to permanently join sheets or

plates of material. Riveting is applied to avoid to twisting effect of vehicle during motion.

Process of riveting is done by means of hydraulic riveting tool (in which pressure of approx

1000 ton is utilize).

STAGE # 1:


Installation of fuel filter along wiring of nylon

Installation of wiring and pipes which is come from wire and pipe shop.

Fitment of brackets

Installation of light charger, reverse light brake light (red in colour) and indicator light

(orange in colour)

FR spring assembly.

FR U-bolt.

FR stabilizer.

FR greasing nipple.

FR shock absorber bracket.

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FR shock absorber.

Bracket torque rod.

Torque rod.

RR leaf spring

RR U-bolt

RR shock absorber.

RR greasing nipple.

Power Steering assembly.

Drag link.

Spare wheel.

Wheel tightening. Nut & bolt.

WIRE AND PIPE SHOP:

Cutting of wire is performed on bending of pipe is done at various angle. Flaring a bending

operation in which at one side of the pipe the diameter is increase for adjustment of nut.

AXLE:

It allows the transmission of motion towards wheel. Axle should be properly suspended

because working parts of vehicle is breakdown due to continued stresses on the engine and

transmission.

TYPES OF AXLE:

Front Axle

Rear Axle

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FRONT AXLE:

The front axle is fitted with wheels at its end. A part of the weight of vehicle is transmitted to

the wheels through this axle

It Consists of:

Hub Assembly

I-Beam

Knuckle

Knuckle Arm

Tie Rod

Tie Rod Arm

Hub Cap

Drum

REAR AXLE:

Rear Axle is used for transmitted power from differential to the driving wheels

It consists of:

Axle housing

Axle Shaft

Hub Assembly

Drum

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AXLE SHOP:

It is divided into 4 following stages.

STAGE I:

Stage (i) consists of the following steps.

Degreasing (remove oil and sticky components)

Rinsing

Antirsting.

Air blowing.

STAGE ii:

Stage (ii) consists of the following steps.

Knuckle hub assembly

Tie rod installation

Brake assembly install

Differential assembly mounting

Chamber bracket mounting

Camshaft adjuster fitting.

SUB ASSEMBLY:

Drum/Hub sub assembly.

Through shaft sub assembly.

Run out testing.

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DIFFERENTIAL:

The differential unit allows different speeds to the right and left wheels

KNUCKLE:

Steering knuckle is fitted to the front axle with the help of king pin for steering

MECHANISM:

It moves to and fro, moving the wheels to the right or left.

TIE ROD:

It is a straight rod, connected with knuckle from both side of wheels.

Sub assembly

Drum / Hub sub assembly (by fitment of studs, nuts and apply sealer)

Run out testing

Through shaft sub assembly

DRUM AND HUB:

In Drum brake, a drum is attached to hub and revolves

STAGE iii:

Stage (iii) consists of the following steps.

Drum / Hub Mounting

Bearing Installation

Axle Shaft Installation

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Toe-in adjustment

Through shaft \installation

Pre Load adjustment

Chamber Installation

TOE-IN:

The toe-in ensures parallel rolling of front wheels. It stabilizes steering and prevents slide

slipping and excessive wear of the tire. The distance between the front wheels at the front end

is less than the distance between the rears.

The front wheels point inward.

The actual amount of toe-in is only a few millimetres.

BEARING:

There are many rotation and moving parts in vehicle. E.g. axles, rods, shafts. They produce

tremendous hest, thus not being able to operate further. This defect is remedied by the device

called bearing.

STAGE IV:

Stage (IV) consists of the following steps.

Axle Painting

Leaf Spring Installation

U-Bolt pre-tightening Axle painting.

Axle brake piping.

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REAR AXLE:

Brake assembly installation

Differential oil supply.

Liquid gasket application.

Differential carrier installation.

Axle Brake Piping

SUSPENSION SYSTEM:

The working parts of vehicle may develop fracture or break down. This part should be

safeguarded against such fracture. For this purpose the suspension system is used.

SPRING:

When a vehicle is moving on rough roads, shock is developed. The purpose of spring is to

absorb this shock.

LEAF SPRING:

A number of leaf springs are placed one on top of the other and then clamped at the centre. A

nut and bolt arrangement binds all these leaf springs together. These springs are used in

vehicle for suspension purposes

Leaf Spring is originally in semi elliptic form.

When load is applied, friction is developed between the leaf plates. At the same time, one

plate can slide against another. This sliding effect helps in bending and springing.

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U-BOLT:

Leaf spring connected to the axles casing by mean of U-bolt.

STAGE # 2:


Axle mount

Steering box installation

Wheel mount

Shock absorber installation

U-Bolt tightening

SHOCK ABSORBER:

After a car has hit a bump and pot holes, the oscillations of the spring are restricted, thereby,

restricting the vibration through shock absorber.

STEERING BOX:

The main part of steering box is power cylinder. Most of the force required to move the tie

rod in the steering linkage, and steer the car, is furnished by the power cylinder

STAGE # 3:


Harness installation

Rr Lampe horn installation

Fuel tank piping and installation

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Air and oil piping

Air tank sub assembly and mounting

Fuel tank.

Air tank assembly.

Bracket booster assembly.

Nylon tube & steel pipe installation.

FUEL TANK:

Fuel tank holds the fuel for the engine and it is made of steel.

HARNESS:

Harness provides the electricity at required part. It is consists of copper wire and around

which polymer coating is applied.

STAGE # 4:


Engine mounting

Exhaust installation

Radiator sub assembly and mounting

Arch sub assembly and mounting

Propeller shaft installation

Engine mounting nut

Self starter harness.

Parking brake cable.

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Transmission rod.

Transmission cable.

Muffler assembly & exhaust pipe.

Power Steering (P.S) piping.

Hose.

Hose air tank/radiator.

Floor bracket

ENGINE:

Main parts of vehicle generate power to drive.

EXHAUST:

Exhaust gases release from exhaust manifold (it is a set of pipes comes from cylinder)

producing noise because it release at high pressure. To avoid this noise a MUFFLER or

SILENCER is used in the exhaust system. The muffler is fitted between the exhaust pipe and

the tail.

RADIATOR:

The radiator is responsible for cooling the circulating water which gets heated after removing

heat from cylinder block. At the same time, the outer side of these parts is also cooled by

means of the incoming air.

PROPELLER SHAFT:

The propeller shafts transmit the power from the gear box to the differential.

ARCH is basically U in shape and help in supporting of cabin

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STAGE # 5:


Splash board mounting

Anchor lever mounting

Air cleaner installation

Cab mounting

Air cleaner assembly.

Hose.

Fender assembly. Cab tilt.

Anchor le

vel.

Dash indicator.

Electric system.

SPLASH BOARD:

Splash Board is mounting nearby wheels. It works as a shield or covers for various parts of

vehicle, so parts are not destroy earlier due to dust or humidity.

STAGE # 6:


P.S Oil Fillings

Head lamp sub assembly

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Bumper installation

Control Setting

Air cleaner.

Air intake system.

Air tank & air clearers piping.

LH head lamp bracket.

Under floor brake pipe.

Electrical panel.

Floor drop.

STAGE # 7:


Air bleeding.

Control setting.

Cooling radiator.

Brake fluid.

Power steering oil.

Grease.

Propeller shaft.

Bumper assembly.

Head lamp.

Chassis plate.

Electrical system.

Trailer brake assembly..

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Maintenance Department

Maintenance is very important for every thing to keep things or machines in good and

running condition. So the Hinopak has well equipped its maintenance department and

if there is problem regarding any machine within the Hinopak area they have the

capability to repair that and even workers here can make some machines with in

certain limitation.

Areas in maintenance Department:

Electrical repair area

Tools repairing area

Plumbring area

Carpentry area

Machining area

Mechanical repairing area

Compressor room

Tools and machines used by maintenance department and their areas enclosed in

brackets,

Lathe machine,4 feet in length(machines)

Lathe machine,5.5 feet in length, controlled by belts(machines)

Lathe machine,8 feet in length, gear operated made in Pakistan(machines)

Shaper machine(machines)

Surface grinder(machines)

Milling machine(machines)

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Welding machine (tools)

Plasma cutter(tools)

Pneumatic gun(mechanical)

Planer and saw (carpentry)

Multimeter, soldering iron (electrical)

PROJECT DESCRIPTION

Our project was to make the safety kaizan sheet and observe the different task done by

maintenance department.

KAIZAN SHEET

Before doing KAIZEN activity it should be clear that;

What is KAIZEN?

Reason to make KAIZEN?

What is KAIZEN?

Kaizen was created in Japan. The word Kaizen means "continuous improvement".

It comes from the Japanese words

Kai - Take apart and make new

Zen - Think about so as to help others

Kaizen is a system of continuous improvement in quality, technology, processes,

workmanship, company culture, productivity, safety and leadership.

Kaizen expects the workers to work toward standards and the managers to maintain

and improve standards.

Why Use KAIZEN?

To solve problems (without already knowing the solution)

To eliminate waste.

Transportation, Inventory, Motion, Waiting, Over-production, Over-

processing, Defects

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Create ownership and empowerment

Support lean thinking

TYPES OF KAIZEN:

There are different types of kaizen because improvement can be done in many areas.

1-safety

2-quality

3-productivity

4-energy saving

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Assignment:

Our assignment was to make kaizan of switches that were replaced in cargo lift behind the

IMV section.

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CONCLUSION

At the end it can be concluded that working at hinopak was indeed a great experience for me.

I have learned much more thing here and also seen the practical application of the different

phenomenon here which previously I have learned theoretically. These 4 weeks will lead me

to understand the mechanism of multinational companies. Further on I am thankful to

hinopak motors limited’s executive for their cooperation, interest and giving me the

opportunity to learn here. I am lucky to work with these people.

summer internship report.coloured

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