Beruflich Dokumente
Kultur Dokumente
Table of Contents
Acknowledgement ........................................................................................................................... 3 Executive summary.......................................................................................................................... 4 CHAPTER ONE .................................................................................................................................. 5 Introduction ..................................................................................................................................... 5 CHAPTER TWO ................................................................................................................................. 6 Background of the company ........................................................................................................... 6 Mission and Vision Statements. ...................................................................................................... 7 Mission ............................................................................................................................................ 7 Vision ............................................................................................................................................... 7 Values .............................................................................................................................................. 7 Services of the company (organization) .......................................................................................... 8 The sale service provide those machines and Vehicles................................................................. 10 Customer of the product (service) ................................................................................................ 11 Staffing and facility ........................................................................................................................ 14 Product range ................................................................................................................................ 15 Work flow ...................................................................................................................................... 16 CHAPTER THREE............................................................................................................................. 17 Internship experience .................................................................................................................... 17 Auto- service department maintenance schedule for periodic service ........................................ 18 Power transmission ....................................................................................................................... 18 Auto Electricity .............................................................................................................................. 19 Engine maintenance ...................................................................................................................... 19 Automotive Fuel System service ................................................................................................... 24 Now let us discuss about contamination in more detail. .............................................................. 25 Contamination control .................................................................................................................. 25 Automotive Tire &Wheel Service .................................................................................................. 28 Tire Construction ........................................................................................................................... 28 Changing Tire Assembly................................................................................................................. 29 Duties in the body and paint shop ................................................................................................ 30
Ourdepartments staff members like instructor Shewangizaw Workagegnew & who guided as through the process of internship are also have to be appreciated. we thank them all.
Special thanks also go to our graduate friends for sharing ideas and literature. Not forgetting to our best friends who always been there. We would also like to convey thanks to the institute and department for providing as with financial means even if it is not sufficient for survival. Great appreciation goes to the rest of moenco staffs that help us from time to time during our course of time writing the report and project as well. Finally we wish to express our love and gratitude to our beloved families for their understanding and constant love through the duration of our study.
Vision
To be the most customer-centric distributer of vehicles and equipment for the construction, agriculture and industry sectors in Ethiopia with unparalleled after sales services supported by state of the art technology and skilled manpower.
Values
MOENCO being an affiliate company of INCHCAPE PLC, shares same set of values stated hereunder. Respect for each other Passionate about customers Pioneering new ideas Caring for environment Winning together Treating every coin as our own Integrity without compromise.
MOENCO-Adama provides different main services for the customers. The detail of each service is explained as follows.
Periodic maintenance
Every TOYOTA, DAIHATSU & LEXUS vehicles have to be periodically maintained in every 5,000km or by the intervals of 3 months. Periodic maintenance will insure reliability, high resale value, long life and maximum performance. To feelsafe and to have peace of mind bring your car to periodic maintenance and feel all the peace you need.
Express maintenance
The express maintenance service is done for vehicles with mile age up to 50,000km. The service is given by using the best and most advanced automotive equipments and the service provided by their qualified technicians enable them to deliver TOYOTAs quality service to their beloved customers. In servicing of TOYOTA, DAIHATSU & LEXUS the customers can enjoy watching of the check-up process of their vehicles through the window of customer waiting lounge
General Repairs
MOENCOs Service Centers also provide General Repair Service for all sophisticated general mechanical and electrical system on all TOYOTA, DAIHATSU & LEXUS Vehicles. Their General Repair Service comprises of units overhauling (like engines, automatic and manual transmissions/transaxles, fuel injection pumps, differentials, steering gearboxes, vane pumps, starters, alternators, etc.), and diagnosis & repair of any malfunctions on the vehicle using the state-of-art equipment and tools available in the Service Centers.
Towing Service
MOENCO also provide towing service (dragging of a car) to assist our customers in the event of vehicle collapse or malfunction.
DAIHATSU Terios
Constriction
Komatsu Excavator Komatsu Dozer
Agriculture
New Holland Tractor
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MOENCO provides genuine parts for the vehicles and machinery it supplies genuine parts and accessories. Its objective is to deliver the right quality at the right time and the right place.
When they say the right quality, they mean genuine parts for trouble free performance, long life and safe environment.
When they say At the right time, they mean an optimum availability of parts, insuring continuous supply based on customer demand. A fully computerized sales, stock control and electronic parts catalogue system has enabled us to achieve a very high suppliability of parts resulting in remarkable customer satisfaction.
When they say the right place, they are referring to their dealers in different parts of the country and their branches in Awassa, Bahirdar and Adama. They are committed to serve their customers with quality service, wherever they are.
Their parts operation is one of their primary value chain systems. It is based on JIT operation system (Just in time) which in turn is based on sell one buy one philosophy. In effect, their parts operation is backed up by extensive inbound and outbound logistic activities
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To be the winner in this competition, satisfying the customer is no longer enough. To ensure outstanding customer satisfaction, they need to please their customers. Therefore, that is why they are the most customer centric organization.
Their electronic parts catalogue system (EPC) has enabled their salespersons to identify part numbers easily and accurately. This computerized sales and inventory control system has helped increase productivity and efficiency of staff.
They are continuously improving their services to their customers using the concept of kaizen which is a Japanese term for continuous improvement. They apply kaizen at every step in the parts logistics activity (inventory control, parts sales, warehousing, parts marketing, etc.)
In this regard, technology has a big role in simplifying different processes, cost saving, promptness and accuracy, which lead to higher customer satisfaction. They apply improved system (software and hardware) in the inventory control process, sales and warehouse activity.
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By this combination of ordering they are able to achieve very high service rate (availability) and by utilizing the kaizen concept, they are able to reduce the lead-time considerably.
Warehouse
They use storage Kaizen (continuous improvement in warehouse operation) which has created an attractive and convenient layout, an efficient and safe storage technique the 7 Toyota storage techniques and a fast and efficient picking and delivering operation.
Parts Sales
Their customers submit their orders in many ways by mail, fax or telephone and in person at the sales counter. They also have a dedicated dial up line between their branches and Addis Ababa main office for a computerized information exchange such as stock inquiry, order placing and reporting.
Most of the customer orders are addressed through their sales counter where parts stock status information can be easily retrieved from the computerized stock and sales system. They have a local areas network (LAN) with over 20 workstations for front line parts sales, data control supervision and data entry.
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Warehouse Facility
Their warehouse is one of the best among similar African Toyota distributors. Its storage capacity is 10,000 m2. It is well organized and equipped with sufficient storage and handling materials. They also have satellite stores in their Awassa and Bahirdar branches with a capacity of 5,000m2 each.
Parts Counter
Their parts counter is designed in such a way that their customers can be served comfortably and conveniently.
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Vehicles
- Toyota: they deliver genuine parts for Toyota vehicles. They have in our warehouse a stock amounting 22 million Birr currently. Their service rate (availability) has reached 93.2% and it is continuously growing through their effort and commitment. - Daihatsu - Hino Trucks
Construction
Komatsu Dozer, grader, loaders, Excavators, Dump Trucks Wirtgen&Vogelle Asphalt machines, Hamm Rollers Phoenix Asphalt machines, etc
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Work flow
Vehicle Reception
vehicle inispection
Cost estimation
service section - Mechanical Repair - Body and Paint - Engine maintenance - Auto electric service quality control vehicle delivery
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In addition to this, the activities that are performed in this shop can be classified into three main parts. They are:1. Power Transmission 2. Auto Electric 3. Engine Maintenance
Power transmission
This is where all parts of the car, which are used for the power transmission system, are checked and repaired. Some of the main daily activities are Check and replacement of Tires Check and repair of front and rear housing Check and repair of Propeller Shaft Check and repair of gear box Check and repair of Transfer Gear Box Check and repair of joints, like Universal Joint Check and repair of pumps such as Vane Pump, Vacuum Pump, Water Pump Check and repair of timing belt Check and repair of cleaners such as Air Cleaner, Fuel Filter, Oil Filter Refilling of hydraulic oils such as brake oil, clutch oil, power steering fluids. Check and repair of knuckle components such as bearing, spacer, hub and etc Check and repair of hand brake, pad, shoe
In those days we got deep knowledge about the mechanics of the automobile & its system &sub system in simplified manner. In addition, we deal with the essential description of the construction & principle operation of various components as a part of total vehicle system. Until
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Auto Electricity
This is where the electrical part of the car is checked and repaired. Some of the activities are: Check and maintenance of all the lighting system Check and replacement of car battery Check and repair of alternator and starter Check and repair of Air conditioning system Check and maintenance of all the electrical system inside the car.
Engine maintenance
This part is where the engine, gearbox, and differential of the car is checked and maintained. The general main activities that are performed here are as follows. Check and replacement of engine and its accessories including: o Check and installation of the crank shaft o Check and installation of all bearing o Check and installation of camshaft o Check and maintenance of cylinder head o Check and installation of piston with its rings o Check the diameter of cylinder o Check cylinder blocks o Lapping the valve with its valve seat o Check and repair of front and rear differential o Check and repair of gear box o Refilling of fuel, differential and gear box oils
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When we are dealing with automotive fuel system, we must have fundamental understanding of engine design & operation. Fuel is a major combustion control system. The system has many major parts such as intake manifold, fuel pump, fuel return line; fuel tank etc. the fuel tank stores the gasoline or diesel fuel. Steel lines & rubber-hoses connect the tank to the fuel delivery parts on the engine. One or more fuel pumps move fuel from the tank to the carburetor or fuel injection system. One or more fuel filter removes water, dirt, & other impurities from the fuel before it enters the engine. If the impurities mix with the fuel they cause contamination. Contamination will be dealt with further explanation in the next page. Another filter at the engine air inlet removes dirt from the incoming air evaporative emission controls keep fuel vapors from escaping into the atmosphere from the tank, the carburetor & other fuel system parts. The carburetor or fuel injection system atomizes & vaporizes the fuel & mixes it with air in ratios that satisfy engines operating needs from light to full load.
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Contamination control
Why Contamination Control? Customers are demanding
More power Greater breakout forces Faster cycle times
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What is Contamination?
Dirt Weld spatter Paint flakes Rag fibers Metals
Contamination Sources
Factory New oil Machine operation Maintenance/Service
Customers
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Field service
Success Formula Clean Oil+ Clean Components+ Clean Assembly Processes = Clean Machines
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Tire Construction
The carcass prevents the tire from stretching under the force of internal air pressure. The carcass forms the supporting framework of the tire The tire casings, and tubeless tires, are made in about the same way. Layers of cord, called plies, are shaped on a form and impregnated with rubber. The rubber sidewalls and treads are then applied. They are vulcanized into places to form the completed tire. This process molds the rubber into the desired form and gives it the proper wear characteristic and flexibility. The tire quality mainly depends on the cord fabric strength. Increasing the rapture strength of cord-fabric treads enables the number of cord layers (plies) to be decreased, which aids in increasing the radial compliance of tire. By using metallic cord, the number of cord layers (plies) in truck tier can be reduced (from 8-14 in case of non-metallic cord) to 2-4.
Tire size
Tire size is marked on the sidewall of tire. An older tire might be marked 7.75-14. This means that the tire fits on a wheel that is 14 inches in diameter at the rim where the tire bead rests. The 7.75 means the tire itself is about 7.75 inches wide when it is properly inflated.
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Tire pressure
Tire pressure depends on the type of the work carried out, the season of the year, type of tire and so on. The tire pressure specification can be found on the sidewall of many tires. Specifications are for cold tires. Tires that are hot from being driven or from sitting in the sun will have an increased air pressure. As a hot tire cools, it losses pressure. So never, bleed a hot tire to reduce the pressure.
Tire wear
Tire wear depends on several factors: 1) Rapid tire wear can be caused by layout irregularities 2) The speed any style of driving can also cause rapid tire wear 3) The distribution of cars weight on tires
In changing tire assembly there are three main tasks which is to be done by the mechanic i.e. Removing tire assembly installing tire assembly Correcting tire pressure.
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This is the first task during removing the tire then the next task is installing tire assembly. The procedure is as follows. Place the spare wheel on the studs & snug up the lugs. Lower the car, after the tire touched the ground tightening the lugs. Again, follow start pattern, lower the car completely & disassemble the jack Install the cap or wheel cover finally.
After installing the tire, the final task is correcting tire pressure.
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Workshop cleaning
This is the worst scenario that hesitate the cleaners. We perceived the situation at first glance. Imaginative and creative mind will do something in order to solve such a problems. Since the workshop is very wide only two cleaners have the responsibilities of cleaning every time a vehicle parts are disassembled (dismantled) and oils are discharged. The impact of cleaning the floor and oil manually hesitate the cleaners much. The company lacked expertise to deal with the cleaning machine and so dependent too much on the readily available technical ways of manually cleaning the floor. The company where not aware of the cleaners recommendation and comments on how to address the problem Finally through an extensive study and works the machine is designed and developed.
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Engine washing
This is another dangerous issue that may be considered. Engine and its internal parts are washed by the benzene and its internal parts are washed by the use of petrol with pressurized air. Since the carbon droplets will mix with the atmosphere, while inhaled may cause a great and catastrophic damage to health. Even if there are many problems as micro level these are only identified as problem identification. This problem identification may seem exaggerated and someone may think, people working in that area may die. They really die but it does not kill workers over night it is a matter of years.
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Material Requirements
1. 2. 3. 4. 5. 6. 7. 8. 9. Two plates of 3mm each Power wrench Bearing (front hub) Long pipe Ratchet socket 2 slip wheels 50mm diameter Bolt and nut Metal wire (copper wire) 1.5m long 2mm diameter Other used metals and metal residue
Specifications
The top of the power wrench that rotates the plate has Torque = 610 nm Angular speed = 7000 rpm
= 733.03 rad/s
Mass of the disc is 1kg (0.5 each) The lever is made 600inclined with the horizontal. The radius of the disc is 15mm The diameter of the plate is 30 mm
Area
Total area of the disc (circle) is A= , r= radius of the circle The angle from the whole circle is The total parameter is ,
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Principles of operation
The cleaning machine works by rotation. The power of rotation comes from the pneumatic operating impact wrench. When the wrench began to operate the upper plate is welded to the long 600 inclined pipes so that the lower plate only rotates relative to the impact wrench. In the lower plate the cleaner rag (stratchew) is inserted by wire lock (clamper) made from the copper. Using the rotating motion of the plate the oil is cleaned.
= 733.03 rad/s
N 1 D1 = N 2 D2
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This shows that the plate rotates at 122.2 rad/s so that the inertia of rotation decreases rotation of impact operated power wrench by this amount. Tangential speed of the plate can be found from the fundamental equation as follows
Torque
A torque is a net turning effect that is used to rotate the circular plate. A torque of 610 Nm with 7000 rpm rotation of the tip of the power wrench as specified in the specification A torque is also the total moment acting about the axis of rotation It is given by Torque = Force x perpendicular distance
From this equation we can find the force which is used rotate the plate and socket together about its central axis. It is sometimes called as centripetal force.
F= 40.67 KN This tells us that 40.67 KN of force is provided to rotate the given circular plate together with the socket.
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Centripetal force
It is the net force needed to make the plate to follow a circular path As the velocity is changing the object must be accelerating R(Acceleration is defined as the rate of change of velocity) According to Newtons second law, acceleration requires a net force and the direction of the acceleration is the same direction as the net force. Centripetal force always acts towards the center of the circle. The centripetal force required to rotate the plate can be found as.
F= 1.12 KN
This amount of force is required to move the plate. Factors affecting the size of the centripetal force
The mass of the object Velocity and Radius of the carried path followed by the object affected the centripetal force.
The centripetal force Fc is also required to keep the plate from slipping If the friction is not large enough or in another way if the centripetal force is not large enough the plate may skid or slide or produce noise
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T= 0.05142 second per turn This shows that only0.05142 seconds required making one complete revolution The frequency of the plate can be calculated from this relation
This frequency must be less than the resonant frequency that produces noise.
Moment of inertia of the plate
The moment of inertia of a body is a measure of the object resistance to changes to rotation. It depends on the mass of the object and its distance from its center. It can be seen that increasing the mass and the distance from the center increase the moments of inertia. The mass of the plates is 0.5 Kg and radius is 15cm
This briefly illustrates that the moment of inertia of the plate is so small that it can easily rotate at high speed Rotational kinetic energy of the plate Spinning plate posses a kinetic rotational energy KE rotation. Which is due to the rotation of the plate
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The maximum power the rotating plate posses would be found as follows N is rpm of the plate and T is period of plate
This shows that Approximately 6.3 watt power is produced by the moving plate
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Lower Plate
Upper Plate
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Ball Bearing
Socket
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Bolt
Slip wheel
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Recommendation
We recommended MOENCO to improve and soften the challenges that may be faced. Far too little attention is paid by the company on addressing the problems. We have a lot to recommend but few of them are only mentioned here. Since there is only one working Oxy-acetylene welding cylinders; two or more workers may simultaneously need the machine. This may force the workers to wait each other and delay the working hour The delays of hours being counted by computer, as a result the customer have to pay for the delay. The arc welding and MIG welding machines which are not operating should be maintained and used as an alternative. Safety materials for all the welding types, sanding, and grinding such as gloves, goggles and others are not enough. Otherwise the workers that are carelessly doing their job may face a series internal and external injury and may lose his precious life. The painters in the painting shop sometimes knowingly paint outside the recommended painting room. They obliviously protect themselves but other innocent workers may be injured. The main issues about washing engine by benzene and cleaning air filter by using pressurized air is also have to be addressed well. The safety of the supporting stand that is used during car maintenance the company should give attention to the university students by giving them safety clothes and shoes for their safety And also the company should share ideas that support the project such as air filter cleaning
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The rigidity of the company is not limited but extended to not to provide resource and facilities such as library, internet access and other reference materials for the intern students to progress for any type of intended project for further insight should be fulfilled. On the other hand, neither no pocket money is given by the company nor the pocket money given by the university to the internship students is enough. It may be difficult to survive for students from poor background. The serious of sense of punctuality and team working in the company should be admired and promoted for further success.
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William H. Course and Donald L. Anglin (19993) Automotive Manual Transmission and Power Trains, McGraw Hill publishing Company, USA William K. Toboldt (1993) Automotive Encyclopedia Fundamental Principle, Operation, Construction, Service Repair,The Good Heart WillcoxCo.Inc, USA. Frederick C. Nash (1979) Automotive Technology, 2nd ed., McGraw Hill Ryerson Limited, Canada. TesfayeFeleke (2003) Automechanics, Book 1. Mega- Publishing Enterprise, Addis Ababa, Ethiopia.
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