GOVERNMENT POLYTECHNIC, BEED

MAHARASHTRA STATE BOARD OF TECHNICAL

EDUCATION, MUMBAI

A PROJECT REPORT

ON
“REPORT ON INDUSTRIAL TRAINING”
Submitted by
VARAD RAVINDRA PATIL

Under the Guidance of

MR. V.G. THIGLE SIR
Lecturer
Dept. of Mechanical engineering

in partial fulfillment for the award of

Diploma in mechanical engineering

Department of mechanical engineering

GOVERNMENT POLYTECHNIC BEED
(2023-2024)

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Report on industrial training

Industrial training carried at: Rohan Service center

Training From :
Academic Year: 2023-24.
Submitted by: Patil Varad Ravindra
Submitted to: Prof. V.G.Thigle
Branch: Mechanical Engineering .
Enrollment no: 2100320198

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Maharashtra State Board of Technical Education

Certificate of Completion
Of Industrial Training
(By respective Head of the Institute & Head of the Department)

This is to certify that Mr.- Varad Ravindra patil

With Enrollment No.-2100320198 has successfully completed
Industrial Training (22049) in Rohan Service center. Beed from.
12/06/2023 to 22/07/2023 for partial fulfillment towards completion
of Diploma in Mechanical Engineering from Government
Polytechnic, Beed -431122.
Institute Code -0032.

Signature of Head of
department
Signature of Guide/ Mentor Signature of Principal
Dr. A.K.waghmare Sir Prof. D.G. Wagh Sir Dr.M.R.Lohokare Sir

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ACKNOWLEDGMENT

I would like to express my gratitude to Principal Professor M.R.

Lohokare sir and HOD Mr. A.K. Waghmare sir for their guidance and support
during my industrial training in the Mechanical Division. I am thankful to
Professor V.G. Thigle sir for providing me with this opportunity. & I also like
to extend my thanks to Thigle sir my industrial training mentor, Mr. Ranjit
Shinde, the owner of the workshop, Rohan Service Center, Beed for their
contribution to my training experience.

Attending this workshop has been a truly unique and valuable experience for
me. It has reignited my interest in mechanical engineering and has helped me
formulate new plans for my future career in this field.

Lastly,I want to thank Mr. Mauli, Mr. Shanaz, and Mr. Sammed, the technicians
who patiently taught me about how the service center works. They shared
valuable information and gave me guidance, which helped me learn and
improve my skills while I was at the service center. I appreciate their important
role in enhancing my knowledge and abilities.

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ABSTRACT

I received the wonderful opportunity to participate in a six-week training

program at Rohan Service Center in Beed. During this time, I developed a
strong interest in mechanical engineering, particularly in the area of vehicle
maintenance. At the beginning of the training, I was assessed on my knowledge
of the different technologies used in bikes from various companies, as well as
the knowledge required to set them up correctly. Throughout the training, I
participated in activities that helped me to better understand and answer my
questions. The main goal of the training was to collect information on common
bike problems that people face and to provide quick solutions to fix them

During my time in the workshop I learned valuable guidelines and safety

measures for working on bikes, which made my experience in the workshop
even more valuable. This training program helped me to realize my interest for
the automotive industry. I also met new people, expanded my knowledge, and
developed new skills. Overall, I achieved my learning objectives and gained a
deeper understanding of the service center work.

I learned that it is important to be flexible and strategic when it comes to

financing. I also learned that there are challenges in working on bikes, and that
it is important to collaborate with people from different backgrounds. To be
successful, I need to use my education to address these challenges. I need to
actively exchange knowledge, ideas, and opinions with others, because there is
still a lot for me to learn.

CONTENTS
CONTENT PAGE
NO
Certificate 1

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Acknowledgement 4
Abstract 5
Chapter 1 Organization structure of industry 7
Chapter 2 Introduction of industry 8
Chapter 3 Type of major equipments 11
Chapter 4 Process of service a bike 13
Chapter 5 Major material in service center 20
Chapter 6 Safety precautions Followed 28
Chapter 7 Short note 29
Chapter 8 Special challenge experience 30
Chapter 9 Conclusion 31
Weekly Dairy

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CHAPTER 1. ORGANISATION STRUCTURE OF THE INDUSTRY

 CHAPTER 2 INTRODUCTION OF INDUSTRY

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 Rohan Service Center, founded by Mr. Ranjit Shinde, is a dedicated service center offering
a range of services for bikes. Mr. Shinde, a mechanical engineer and a former student of
Government Polytechnic Beed, established this startup based on his extensive experience
in the mechanical industry.

 Rohan Service Center is a bike repair shop that can do it all. They can help you with
regular maintenance, fix broken parts, and install accessories. They have a team of
experienced mechanics who can get your bike back on the road in no time.
 The service center proudly serves a wide range of bike brands, including Bajaj
Motorcycles, Honda, Hero, TVs, and Yamaha. This demonstrates their expertise and
ability to service bikes from different manufacturers, providing customers with reliable and
efficient solutions.
 Rohan Service Center aims to deliver top-notch service quality, leveraging Mr. Shinde’s
mechanical engineering background and the collective experience of their skilled team. By
focusing on customer satisfaction and delivering exceptional service, they strive to become
a trusted destination for bike owners seeking professional assistance.

 Whether it’s routine maintenance, resolving technical issues, or addressing any bike-
related concerns, Rohan Service Center aims to be the go-to service center for bike owners
in their area. Their dedication to providing high-quality service and their expertise in
handling various bike brands set them apart in the industry.

2.1 Some of their other unique features are:

 Air machine is available

 Parking is available
 Service of all variants available
 Trained technician and Staff.

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 modern tools & equipment.

 accidental repair service is available
 Home delivery of vehicle after service
 Home pickup &delivery of vehicle after service is available for senior
citizens & women’s

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2.2 service center Front View:

Image -2.2.1

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CHAPTER 3 MAJOR EQUIPMENTS

 Air filling machine

 Air Pressure Checking machine
 Screwdriver
 Spanners
 Millimeter
 All tools set which are used in bikes

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3.1 Features of workshop

 All the technicians have great experience in bike field
 They have area for working their
 All genuine parts is available
 All the major & minor faults would be repair in service
 For final inspection they give a ride of bike to customer then customer
check all fault repair or not

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CHAPTER 4 PROCESS OF SERVICE OF BIKE

4.1 INSPECTION OF BIKE

 When a customer brings their bike to the service center for maintenance or repair, the
following steps are typically taken:

 Initial Inspection: The service center inspects the bike thoroughly, examining
components like tires, brakes, chain, gears, suspension, and frame for any
visible or potential issues.
 Problem Identification: After the initial inspection, the service center personnel
note down the specific problems or issues found during the inspection. They
may prepare a customer bike report or a service order, documenting the
identified problems and their recommended solutions.
 Test Ride: To diagnose the bike's issues thoroughly, a technician or mechanic
conducts a test ride, carefully noting any abnormal sounds, vibrations, handling
problems, or other signs of trouble.
 Customer Communication: Once the problems have been identified, the service
center contacts the customer to inform them about the issues found during the
inspection and test ride. They explain the nature of the problems, the potential
impact on the bike’s performance or safety, and the recommended course of
action.
 Parts Replacement : service center personnel identify and replace faulty
components based on identified problems and mechanic expertise. Common
parts include brake pads, tires, tubes, chains, cassettes, derailleurs, cables,
bearings, and more, depending on specific issues..
 Repair and Maintenance: With the customer’s approval, the service center
begins working on the bike. The mechanics or technicians replace the identified
faulty parts, perform necessary repairs, and conduct routine maintenance tasks
such as cleaning, lubrication, and adjustments. The goal is to Repair problems,
make bike performance better.

4.2 WASHING OR CLEANING

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 When the bike comes for maintenance, we clean it first before or after maintenance We
wash the bike with water. We thoroughly clean the bike and clean all parts of the bike
 Washing leaves the bike clean and easy to maintain because after washing dirt particles
are removed from the bike and all dirt on the nuts and bolts of the bike
 This is a milestone in the bicycle service

4.3 CHECKING OLD OIL QUALITY & CONFIRM IT IS ELIGIBLE

FOR ENGINE FLUSH OR NOT

If the engine has been serviced for a long time, it is important to assess the quality of the oil
before deciding whether to flush the engine. If the oil condition is bad, it is recommended to
flush the engine before driving. Engine flushing involves the use of a special fluid to clean
the internal parts of the engine and help maintain vehicle performance.

 Engine flushing is especially necessary in the following cases:

 Servicing bike after a longer period of time and beyond the recommended service
mileage: Over time, deposits, deposits and contaminants can build up in the oil. If the
bike has not been serviced for a long time and has exceeded the recommended service
mileage, a large amount of dirt grime may have accumulated in the oil and inside the
engine. Engine flushing helps remove these deposits, ensuring proper lubrication and
performance. Change Oil Brands Often: If you frequently use a different brand of oil,
there is a risk of incompatible oil or additives. This can cause sludge and deposits to
build up in the engine. Flushing the engine will help remove any residue from the old
oil brand and provide a clean cabin for the new oil.
 In both cases, engine flushing helps remove deposits, deposits and old oil from the
engine. This process helps improve lubrication efficiency, prevent clogging of oil
passages and improve overall engine performance.

4.4 FILLING OIL & CHANGING OIL FILTER

 After draining the used oil from the engine, it is advisable to replace it with the oil
recommended by the manufacturer. The amount of oil required for the engine should
be filled accordingly. It is important to strictly adhere to the type of oil recommended
by the company and to avoid using other types of oil that are not recommended by the
company for your bike.

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 Different grades of oil are available, e.g. 10w40, 10w30, 20w40, etc. These grades
indicate the viscosity and performance characteristics of the oil under different
temperature conditions. In addition, three main types of oil are available:
 Synthetic Oil: This type of oil is chemically made and provides excellent engine
lubrication and protection. It provides better performance in extreme temperatures,
reduces friction and improves fuel efficiency. Synthetic oil is generally recommended
for powerful, modern engines.
 Semi-synthetic oil: Also called mixture, this type of oil combines a synthetic oil and a
mineral oil. It strikes a balance between performance and affordability, offering better
protection over mineral oil while being more cost effective than full synthetic oil.
Semi-synthetic oil is commonly used in a wide variety of engines.
 Mineral Oil: Mineral oil is a simple, cheap, and effective type of engine oil for older or
underperforming engines.
 Get a genuine oil filter for bike & fit it .after fitting of oil filter New oil fill in bike

4.5 OIL BRANDS AVAILABLE IN THE MARKET

1) Gulf oils : Gulf Oil Company, founded in 1901, is a prominent global energy
company known for its orange disc logo. It has played a vital role in the oil and
gas industry, focusing on exploration, production, and refining. Gulf expanded
globally and supplied fuel to the Allied forces during World War II. It introduced
innovative concepts like the first drive-in service station. Under various
ownership changes, Gulf transitioned into a fuel retailer and convenience store
brand. Today, Gulf continues to provide high-quality fuels, lubricants, and
services worldwide, maintaining its legacy of innovation and customer service.

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2)Castrol oil: Castrol is a renowned oil company that specializes in producing and
distributing lubricants. Founded in 1899 by Charles Wakefield, the company has grown
globally and became a subsidiary of BP in 2000. Castrol offers a wide range of high-quality
lubricants for industries such as automotive, motorcycles, and industrial machinery. They have
a strong presence in motorsports, sponsoring events like the World Rally Championship and
Formula One. Castrol is committed to innovation, sustainability, and developing
environmentally friendly lubricants. They also focus on catering to evolving automotive
technologies, including lubricants for electric and hybrid vehicles. Castrol aims to remain a
leader in the lubricants industry through its emphasis on quality, sustainability, and social
responsibility

3)Motul oils :Motul is a renowned French company that specializes in high-performance

lubricants for cars, motorcycles, and industrial machinery. Established in 1853, Motul is a
global leader in the automotive industry, known for its innovative and top-quality products.
They offer a comprehensive range of engine oils, transmission fluids, brake fluids, coolants,
and specialty lubricants. Motul’s involvement in motorsports has further boosted its
reputation, allowing them to gather valuable insights for product development. The company
also emphasizes environmental sustainability by employing eco-friendly practices and
materials. With a presence in over 160 countries, Motul is highly regarded by automotive
enthusiasts, professionals, and major manufacturers worldwide.

4.6 REMOVING TYRES & CLEAN CHAIN & TIGHT OR ADJUST

BRAKES & ADJUST CLUTCH & CHEAKING SUSPENSION AND
BREAK FLUID &FILLING AIR IN TYRES & CLEANING OF
CARBONATOR & REPAIR OR CHECK SETTING

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Once the oil has been filled, the next step is to remove the rear tyre from the bike and
proceed with cleaning the chain. It is important to ensure that the chain remains tight
throughout the cleaning process. After the chain has been cleaned, it is advisable to inspect
the condition of the brakes and make any necessary adjustments based on the customer’s
requirements. If any faults are found in the brake system, they will be promptly repaired.
Following these tasks, attention can be turned to the suspension, ensuring it is appropriately
adjusted. Additionally, it is crucial to refill the brake fluid to complete the maintenance
procedure. After this we can fill air in tyre

After this we can clean carborator of bike firstly we remove it

after removing of carborator we can clean it and fix its setting of fuel
Carborator is important part of bike.

The carburetor in a bike’s engine is important because it:

 Mixes fuel with air to create an efficient combustion process for optimal power
output.
 Regulates the air-fuel mixture to ensure proper engine performance, fuel efficiency,
and emissions control.
 Responds to throttle input, delivering the right amount of fuel and air for smooth
acceleration.
 Works with different fuels, making it versatile and adaptable to various fuel types.

4.7 REPLACING AIR FILTER OR CLEANING AIR FILTER &

IMPORTANCE OF AIRFILTER

 The air filter in a motorcycle is a critical part that helps keep the engine running
smoothly and efficiently. It does this by filtering out dust, dirt, debris, and other
particles that could damage the engine’s components. A clean air filter ensures that the
engine gets the air it needs to run properly, which can lead to better performance, fuel
economy, and engine life.

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 The function of an air filter In a bike involves several important steps. Firstly, when
the bike is in operation, air is drawn into the engine through the air intake system.
Positioned along this path, usually within a box or housing, is the air filter. As the air
flows through the filter material, it captures and retains particles present in the air,
including dust, pollen, insects, and larger debris.

 The air filter serves the primary purpose of filtering incoming air, allowing clean air to
pass through while maintaining a balance with airflow to support efficient combustion
within the engine. However, as time passes, the air filter tends to collect dirt and debris,
leading to a potential clogging of the filter media and a restriction in airflow.
Consequently, regular maintenance becomes crucial to keep the air filter in its best
condition. The specific maintenance requirements can differ based on the bicycle
model and its usage, but typically involve either periodic cleaning of the air filter or its
replacement with a new one.

CHAPTER 5 MAJOR MATERIAL IN SERVICE CENTRE

5.1. Replacement of the oil filter

 A motorcycle’s oil filter is usually located in the same place as a car’s, usually
under the engine. However, the method of maintaining and replacing your bike’s
oil filter may vary depending on the specific make and model. Here is a general
description of the process:

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 Oil Filter Location: Consult your owner’s manual or service manual to

determine exactly where the oil filter is located on your motorcycle. In most
cases it will be near the engine, either on the side or underneath. Prepare your
tools: Gather the necessary tools, including a ratchet or the appropriate size
wrench for the oil filter cover or housing.

 Draining the oil: It is recommended to drain the used oil from the motorcycle
before removing the oil filter. Locate the oil drain plug, usually located at the
bottom of the engine, and place a suitable container under it to catch the oil.
Use a suitable tool to loosen the plug and allow the oil to drain completely.
Remove the old oil filter: After draining the oil, locate the oil filter housing or
cover. Unscrew and carefully remove the cover with a ratchet or wrench. Inside
the housing you will find an oil filter element.

 Oil filter replacement: Remove the old oil filter element from the housing and
discard it. The area around the oil filter housing should be cleaned to ensure
that no dirt or liner remains. Install the new oil filter element into the housing,
making sure it is firmly seated.

 Install new gaskets: It is common practice to replace the gaskets or O-rings that
seal the oil filter housing to prevent oil leaks. Remove the old gasket and
replace with a new gasket that meets the specifications of your motorcycle’s oil
filter system. This ensures a proper fit and a tight seal

 ASSEMBLY AND FILL: Carefully replace the oil filter housing cover and
tighten to the recommended torque in your motorcycle manual. Double check
that all connections are secure. Fill the engine with the correct amount and type
of fresh oil according to the manufacturer’s recommendations

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Oil Filter

5.2.ENGINE FLUSH

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 Engine flushing in bikes is a process used to clean the internal components of

the engine, particularly the oil passages and lubrication system. Over time,
contaminants such as dirt, sludge, and varnish can accumulate inside the
engine, affecting its performance and potentially causing damage.

 The purpose of an engine flush Is to remove these harmful deposits and

improve the overall condition of the engine. It involves adding a special
chemical cleaner to the existing oil in the engine and running the bike for a
short period, usually around 10-15 minutes. The cleaning agent is designed to
dissolve and suspend the accumulated deposits, allowing them to be drained out
with the old oil during an oil change

5.3 Air filter

Air filters play a crucial role in maintaining high air quality by effectively removing solid
particulates and molecular contaminants from the air. Particulate air filters, constructed from
fibrous materials, efficiently trap solid particles such as dust, pollen, mold, and bacteria. On
the other hand, chemical air filters are designed with an absorbent or catalyst material to
specifically target and eliminate airborne molecular contaminants like volatile organic
compounds (VOCs) or ozone. These filters are essential in various applications, including
engine and building ventilation systems, where the preservation of clean and healthy
environments is paramount. By effectively capturing and eliminating hazardous particles and
chemicals, air filters contribute to the creation of safer and healthier space s..

a) Bike air filter. B) scooty Air filters

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5.4 Engine oil

 Engine oils, also known as engine lubricants, are highly developed lubricating oils that
are essential for the proper functioning of internal combustion engines. These oils are
often enhanced with lubrication additives, such as high-pressure additives, to optimize
their performance. Engine oils serve several important functions, including reducing
wear on moving parts, cleaning internal components, inhibiting corrosion, improving
sealing, and cooling the engine by dissipating heat from moving parts.
 In summary, engine oils or engine lubricants are sophisticated lubricating oils that are
crucial for the smooth operation and longevity of internal combustion engines. They
provide lubrication, cleaning, corrosion inhibition, sealing improvement, and heat
removal to ensure optimal engine performance.
 Engine Oil . Grades 1) 100cc bikes: 10W30 or 20w40
2)125cc bikes: 10W40 or 15w40
3)200cc bikes:15W40 or 20W50

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5.5 Clutch plate

A important component of a motorcycle’s transmission system is the clutch plate. It
controls the engagement and disengagement of the engine’s power from the transmission and
is situated between the engine and the gearbox. It features steel plates and friction discs,
which enable effortless gear changes and speed regulation. The clutch plates’ friction
material may deteriorate over time, resulting in decreased performance. To maintain optimal
functionality and power transfer, routine maintenance and the replacement of worn clutch
plates are required.multi-plate clutches are used in motorcycles

Actual image of Clutch Plate

5.6 Brake

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A brake is a mechanical device which inhibits motion, slowing or stopping a moving

object or Preventing its motion. Most brakes commonly use friction between two surfaces
pressed together To convert the kinetic energy of the moving object into heat, though other
methods of energy Conversion may be employed. The brake disc is usually made of Cast
iron, but may in some cases be made of composites such as reinforced carbon–carbon or
Ceramic matrix composites. This is connected to the wheel and/or the axle. To retard the
wheel, Friction material in the form of brake pads, mounted on a device called a brake
calipers, is forced Mechanically, hydraulically, pneumatically, or electromagnetically against

both sides of the disc. Friction causes the disc and attached wheel to slow or stop.

Actual images of brakes

5.7 Final Inspection

The final inspection is a thorough check done on the bike to make sure it is in perfect
condition before giving it to the customer. It is done to find and fix any remaining issues,

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aiming for a flawless service. This inspection is important to make customers happy and
improve the workshop’s reputation and service quality.

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CHAPTER 6. SAFETY PRECAUTIONS FOLLOWED

 Ar Personal Protective Equipment (PPE).This includes safety glasses, gloves, a hard

hat, and steel-toed boots. PPE will protect you from injuries caused by sharp objects,
chemicals, and falling debris.
 Be aware of your surroundings. Watch out for moving machinery and slippery
surfaces. If you see something that could be a hazard, report it to the service
technician immediately.
 Do not operate any machinery unless you are trained to do so.If you are unsure how to
use a piece of equipment, ask the service technician for help.
 Follow all safety procedures. The service technician should provide you with a list of
safety procedures to follow. Make sure you understand and follow these procedures
before starting any work on your bike.
 Be careful when handling chemicals. Chemicals can be harmful if they come into
contact with your skin or eyes. Always wear gloves and safety glasses when handling
chemicals.
 Clean up any spills immediately. Spilled chemicals can be a slip hazard and can also
cause damage to your bike. Clean up any spills immediately with a spill kit.
 Take breaks often. Working on a bike can be physically demanding. Take breaks
often to avoid fatigue and injuries.
 Report any injuries immediately. If you are injured while at a bike service center,
report the injury to the service technician immediately. The service technician should
be able to provide you with first aid and should also report the injury to their
supervisor

CHAPTER 7 SHORT REPORT

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 Rohan Bike Service Center is a leading motorcycle repair and maintenance workshop
in Beed. It offers a comprehensive industrial training program for students who are
interested in a career in the automotive industry. The program covers all aspects of
motorcycle repair and maintenance, including:

 Basic motorcycle mechanics

 Engine diagnostics and repair
 Electrical systems
 Suspension and braking systems
 Safety procedures

CHAPTER 8 SPECIAL CHALLENGING EXPERIENCE ENCOUNTER

DURING TRAINING

 Dealing with a wide range of bike models: At Rohan bike service center, trainees may
come across various bike models, each with its unique design and components. This
can pose a challenge as trainees need to familiarize themselves with the different bike

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specifications and ensure they have the necessary knowledge to service and repair
each model effectively.

 Diagnosing complex bike issues: Some bike issues may be more complex and require
advanced troubleshooting skills. Trainees may encounter challenging problems that
go beyond basic repairs, such as diagnosing electrical or hydraulic system
malfunctions. It would be crucial for trainees to develop problem-solving abilities and
seek guidance from experienced technicians in such situations.

 Time management for multiple repair tasks: The service center may experience a high
influx of bikes needing repairs, especially during peak seasons. Trainees may have to
handle multiple repair tasks simultaneously, which can be overwhelming. Balancing
workload and managing time efficiently becomes crucial to ensure that each bike
receives prompt attention without compromising on quality.

 Working in a fast-paced environment: The service center may have a fast-paced work
environment where quick turnarounds are expected. Trainees may find it challenging
to adapt to this pace initially, as they are learning and gaining hands-on experience.
They must learn to work efficiently under pressure, prioritize tasks, and maintain
customer satisfaction.
 Dealing with dissatisfied customers: Bike owners may bring their bikes for service
with keen expectations. If the service outcome does not meet their expectations,
trainees may have to deal with dissatisfied customers. This can be challenging
emotionally and requires effective communication skills to handle such situations
diplomatically and provide appropriate solutions.
 Continuous learning and staying updated: The bike industry is constantly evolving,
with new technologies and advancements being introduced regularly. Trainees at
Rohan bike service center must stay updated with the latest developments and
continuously enhance their knowledge and skills. The challenge lies in consistently
pursuing self-learning and seeking opportunities for professional growth.

 Overcoming these challenges requires dedication, resilience, and a proactive attitude

towards learning. By leveraging their training period effectively, we can develop the
skills needed to excel in the bike service industry
CHAPTER 9 CONCLUSION

 I am grateful for the opportunity to have participated in the industrial training program at
Rohan Service Center. The training was informative and enjoyable, and I learned a great
deal about bike maintenance and repair. I am now confident in my ability to check every
aspect of a bike’s condition and address common minor defects. I also gained valuable
experience in managing a high volume of bike repairs within a limited timeframe.

 I am particularly interested in how service centers work and I really want to apply what I
have learned in the work environment. I believe that I can make a significant contribution
in the field of mechanical engineering, as I feel that my time at Rohan Service Center has
given me a solid foundation in this field.

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 I am grateful for the support of my mentors at Rohan Service Center, and I am excited to
continue my journey in mechanical engineering. I am confident that I will be able to use
my skills to make a positive impact on industry.

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 THERE ARE SOME IMAGES OF WORKING

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THANKYOU….

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