General Health And Safety Precautions In A Workshop

The following rules apply to all workshop personnel, whether they are permanently employed in the workshop or just occasional users:
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Keep the workshop clean and tidy at all times; Always seek instruction before using an unfamiliar piece of equipment; Only use tools and machines for their intended purpose; Report all damaged equipment and do not use it until it has been repaired by a qualified person; Where machine guards are provide they must be kept in place; Never distract the attention of another staff member when that person is operating equipment and never indulge in horseplay; Always use the appropriate personal protective devices and check that they are clean and in good repair before and after use; Long hair needs to be restrained by either a tie or hat; Never use compressed air for cleaning clothing and machinery; Report all hazards and unsafe conditions and work practices.

Over view on 5 S Technic

5S is the name of a workplace organization methodology that uses a list of five Japanese words which are seiri, seiton, seiso, seiketsu and shitsuke. Transliterated or translated into English, they all start with the letter "S". The list describes how items are stored and how the new order is maintained. The decision-making process usually comes from a dialogue about standardization which builds a clear understanding among employees of how work should be done. It also instills ownership of the process in each employee.

Phases of 5S
There are 5 primary phases of 5S: sorting, straightening, systematic cleaning, standardizing, and sustaining. Additionally, there are three other phases sometimes included; safety, security, and satisfaction.

Sorting (Seiri)
Eliminate all unnecessary tools, parts, and instructions. Go through all tools, materials, and so forth in the plant and work area. Keep only essential items and eliminate what is not required, prioritizing things as per requirements and keeping them in easily-accessible places. Everything else is stored or discarded.

Straightening or setting in order / stabilize (Seiton)

There should be a place for everything and everything should be in its place. The place for each item should be clearly labeled or demarcated. Items should be arranged in a manner that promotes efficient work flow, with equipment used most often being the most easily accessible. Workers should not have to bend repetitively to access materials. Each tool, part, supply, or piece of equipment should be kept close to where it will be used in other words, straightening the flow path. Seiton is one of the features that distinguishes 5S from "standardized cleanup". This phase can also be referred to as Simplifying[1].

Sweeping or shining or cleanliness / systematic cleaning (Seiso)

Keep the workplace tidy and organized. At the end of each shift, clean the work area and be sure everything is restored to its place. This makes it easy to know what goes where and ensures that everything is where it belongs. A key point is that maintaining cleanliness should be part of the daily work not an occasional activity initiated when things get too messy.

Standardizing (Seiketsu)
Work practices should be consistent and standardized. All work stations for a particular job should be identical. All employees doing the same job should be able to work in any station with the same tools that are in the same location in every station. Everyone should know exactly what his or her responsibilities are for adhering to the first 3 S's.

Sustaining the discipline or selfdiscipline (Shitsuke)

Maintain and review standards. Once the previous 4 S's have been established, they become the new way to operate. Maintain focus on this new way and do not allow a gradual decline back to the old ways. While thinking about the new way, also be thinking about yet better ways. When an issue arises such as a suggested improvement, a new way of working, a new tool or a new output requirement, review the first 4 S's and make changes as appropriate.

Safety
A sixth phase, "Safety", is sometimes added. There is debate over whether including this sixth "S" promotes safety by stating this value explicitly, or if a comprehensive safety program is undermined when it is relegated to a single item in an efficiency-focused business methodology.

Security
A seventh phase, "Security", can also be added. In order to leverage security as an investment rather than an expense, the seventh "S" identifies and addresses risks to key business categories including fixed assets (PP&E), material, human capital, brand equity, intellectual property, information technology, assets-in-transit and the extended supply chain.

Satisfaction
An eighth phase, Satisfaction, can be included. Employee Satisfaction and engagement in continuous improvement activities ensures the improvements will be sustained and improved upon. The Eighth waste Non Utilized Intellect, Talent, and Resources can be the most damaging waste of all. It is important to have continuous education about maintaining standards. When there are changes that affect the 5S program such as new equipment, new products or new work rules, it is essential to make changes in the standards and provide training. Companies embracing 5S often use posters and signs as a way of educating employees and maintaining standards

Working Principle of 4 Stroke petrol Engine

Four-stroke engine
A four-stroke engine, also known as four-cycle, is an internal combustion engine in which the piston completes four separate strokesintake, compression, power, and exhaustduring two separate revolutions of the engine's crankshaft, and one single thermodynamic cycle.

1. INTAKE stroke: on the intake or induction stroke of the piston , the piston descends from the top of the cylinder to the bottom of the cylinder, reducing the pressure inside the cylinder. A mixture of fuel and air, or just air in a diesel engine, is forced by atmospheric (or greater) pressure into the cylinder through the intake port. The intake valve(s) then close. The volume of air/fuel mixture that is drawn into the cylinder, relative to the volume of the cylinder is called, the volumetric efficiency of the engine.

2. COMPRESSION stroke: with both intake and exhaust valves closed, the piston returns to the top of the cylinder compressing the air, or fuel-air mixture into the combustion chamber of the cylinder head.

3. POWER stroke: this is the start of the second revolution of the engine. While the piston is close to Top Dead Center, the compressed airfuel mixture in a gasoline engine is ignited, usually by a spark plug, or fuel is injected into the diesel engine, which ignites due to the heat generated in the air during the compression stroke. The resulting massive pressure from the combustion of the compressed fuel-air mixture forces the piston back down toward bottom dead centre.

4. EXHAUST stroke: during the exhaust stroke, the piston once again returns to top dead center while the exhaust valve is open. This action evacuates the burnt products of combustion from the cylinder by expelling the spent fuel-air mixture out through the exhaust valve(s).

Working Principle Of Four Stroke Diesel Engine.

There are different types cycles in thermodynamics.Such as Otto cycle,Carnot vapour cycle,Diesel cycle etc.Out of that cycle diesel engineworks on diesel cycle.This cycle is also known as constant pressure cycle.Diesel engine is mostly employed in Stationary Power plants,Ships,Heavy Motor Vehicles. Diesel Engine is mainly worked on below strokes.

01)Suction Stroke:In this stroke,the piston moves down from the top dead centre.As a result,inlet valve opens and air is drawn into the cylinder.After sufficient quantity of air with pressure is drawn,suction valve closes at the end of the stroke.The exhaust valve remains closed during this stroke.

02)Compression Stroke:In this stroke,piston moves up from the bottom dead centre.During this stroke both inlet and exhaust valve are closed.The air drawn into the cylinder during suction stroke,is entrapped inside the cylinder and compressed due to upward movement of the piston.In diesel engine,the compression ratio used is very high as a result,the air is finally compressed to a very high pressure up to 40 kilogram per centimeter square,at this pressure,the temperature of the air is reached to 1000 degree centigrade which is enough to ignite the fuel.

03)Constant Pressure Stroke:In this stroke,the fuel is injected into the hot compressed air where it starts burning,maintaining the pressure constant.When the piston moves to its top dead centre,the supply of fuel is cut-off.It is to be said that the fuel is injected at the end of compression stroke and injection continues till the point of cut-off,but in actual practise,the ignition starts before the end of compression stroke to take care of ignition tag.

04)Working Or Power Stroke:In this stroke,both inlet and exhaust valve remain closed.The hot gases (which are produced due to ignition of fuel during compression stroke) and compressed air,now expand adiabatically,in the cylinder pushing the piston down and hence work is done.At the end of stroke,the piston finally reaches the bottom dead centre.

05)Exhaust Stroke:In this stroke,the piston again moves upward.The exhaust valve opens,while inlet and fuel valve are closed.A greater part of the burnt fuel gases escape due to their own expansion.The upward movement of the piston pushes the remaining gases out through the open exhaust valve.Only a small quantity of exhaust gases stay in the combustion chamber.At the end of exhaust stroke,the exhaust valve closes and the cycle is thus completed.

CHASSIS FRAME AND BODY

Introduction of Chassis Frame: Chassis is a French term and was initially used to denote the frame parts or Basic Structure of the vehicle. It is the back bone of the vehicle. A vehicle with out body is called Chassis. The components of the vehicle like Power plant, Transmission System, Axles, Wheels and Tyres, Suspension, Controlling Systems like Braking, Steering etc., and also electrical system parts are mounted on the Chassis frame. It is the main mounting for all the components including the body. So it is also called as Carrying Unit. Layout of Chassis and its main Components: The following main components of the Chassis are 1. Frame: it is made up of long two members called side members riveted together with the help of number of cross members. 2. Engine or Power plant: It provides the source of power 3. Clutch: It connects and disconnects the power from the engine fly wheel to the transmission system. 4. Gear Box 2 Automobile Chassis And Body Engineering.doc Chapter 1 5. U Joint 6. Propeller Shaft 7. Differential

Lubrication system:
Requirement of lubrication:
When we rub two surfaces the force required has to overcome the opposite friction force loss between the surfaces. Thus some part of the energy applied in rubbing the surfaces is lost in the form of friction. To overcome the friction we apply certain fluids between the two surfaces which are known as lubricants. Which minimizes the force required to rub the surfaces and some part of the energy lost in friction can be saved. In an automobile, chemical energy of fuel is converted into mechanical energy by the engine. In engine there are many rubbing surfaces. The friction loss occurs between these surfaces which leads to loss in mechanical energy. To minimize the friction loss between the rubbing surfaces we use some lubricating systems. Hence the main purpose of the lubricating system is to save the mechanical energy. These lubricating systems are designed to provide the proper lubrication to the rubbing surfaces of the engines.

Functions of lubricating oil:

A good lubricating oil should perform the following function.
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It reduces the friction between the moving parts. It cools the piston so it also acts as a cooling medium. It also prevents the leakage of gas between the piston and cylinder because it makes a film of lubricant between them.

It also reduces the noise between the rubbing surfaces.

Methods of lubrication:
Following methods are used for the lubrication of an engine.
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Mist lubrication or petrol lubrication system Wet sump lubrication system Dry sump lubrication system

COOLING SYSTEM
The cooling system forms an intrinsic part of an automobile engine. It performs multitude of functions such as removing excess heat from the engine, maintaining efficient temperature and allowing engine to perform its task within a short span of time. Ideally, automobile cooling system keeps the engine running at an optimum temperature whatever the operating conditions are. Automobile Cooling System consists of components or equipment installed in vehicles for removing heat from all the moving parts so that they can work suitably without melting, seizing and overheating. More specifically, automotive cooling system makes use of coolant, lubricating oil and fan to maintain and regulate the temperature of other parts of an engine. Basically, there are two types of automobile cooling systems, which are widely used by the automobiles namely: liquid cooling and air-cooling. Liquid cooling is one of the sought after system used by most of the vehicles today while aircooling is mostly used by airplanes, motorcycles and lawn mowers. The liquid-cooling system for automobiles offers the most positive cooling and it maintains an

optimum engine temperature. While air cooling system is feasible for only small vehicles and equipment, as aircooled engines do not operate at consistent temperature and command extensive use of aluminum to disperse heat.

Working of an Automobile Cooling System

Figure illustrated above describes the functioning of cooling system of an automobile. The key components used in a cooling system are pressure cap,heater hoses, thermostat, heater core, reserve tank, lower hose, transmission cooler, water pump, fan, radiator and upper house. The cooling system of a vehicle operates or functions by directing liquid coolant via passages in the engine block and heads. After that the liquid coolant which flows through passages absorb the heat from an engine. Then this fluid passes through a rubber hose to reach to the radiator. At this stage the hot liquid is cooled by air stream entering the engine compartment via grills. Once it gets cooled, then it goes back to engine and same process repeats again.