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Isuzu

Marketing Management (Sri Venkateswara University)

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An Industrial Training Report

On
SERVICING & MAINTENANCE ON AUTOMOBIL
Submitted
To
STATE BOARD OF TECHNICAL EDUCATION AND TRAINING, VIJAYAWADA
In partial fulfillment of the requirements for the award of
DIPLOMA IN MECHANICAL ENGINEERING
By
S.DINESH 20291-M-091

Under the guidance of

Mr.A.SATISH, M.Tech
Lecturer
DEPARTMENT OF MECHANICAL ENGINEERING

DIPLOMA IN MECHANICAL ENGINEERING

SREE VIDYANIKETHAN ENGINEERING COLLEGE

(Autonomous)
nd
(2 Shift polytechnic)
(Affiliated to SBTET, Vijayawada)
A.Rangampeta, Tirupati, A.P-
517102.
2022-2023

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SREE VIDYANIKETHAN ENGINEERING COLLEGE

(Autonomous)
nd
(2 Shift polytechnic)
(Affiliated to SBTET, Vijayawada)
A.Rangampeta, Tirupati, A.P-
517102
DIPLOMA IN MECHANICAL ENGINEERING

CERTIFICATE

This is to certify that Industrial Training report entitled ‘’SERVICING &

MAINTAINCE ON AUTOMOBILE’’ is the bonafide work done by the

following students in the Department of MECHANICAL ENGINEERING, Sree
Vidyanikethan Engineering college, 2nd Shift polytechnic, A. Rangampet and is
submitted to State Board of Technical Education and Training, Vijayawada in partial
fulfillment of the requirement of the award of Diploma in Mechanical Engineering
during the Academic Year 2022-2023.

S.DINESH 20291-M-091

GUIDE: HOD:
Mr.A. SATISH, M.Tech. Dr. P. UMAPATHI REDDY, M.Tech., Ph.D., MISTE, MISCA.,
Lecturer DME, Professor,Vice Principal,
2nd Shift Polytechnic,
2nd Shift Polytechnic,
Sree Vidyanikethan Engineering College,
Sree Vidyanikethan Engineering College,
A.Rangampeta. A.Rangampeta.

Submitted for the Industrial Training viva-voice held on

Internal Examiner External Examiner

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SREE VIDYANIKETHAN ENGINEERING COLLEGE (Autonomous)

(2nd Shift polytechnic)
(Affiliated to SBTET, Vijayawada)
A.Rangampeta, Tirupati, A.P-
517102
DIPLOMA IN MECHANICAL ENGINEERING

DECLARATION

We hereby declare that the work described in this Industrial Training report, entitled “SERVICING

& MAINTAINCE ON AUTOMOBILE ” submitted by us in partial fulfillment for the award of

Diploma in the Department of Mechanical Engineering Sree Vidyanikethan Engineering College, 2 nd

Shift Polytechnic, Tirupati has not been submitted to any other coursesor University for award of any

degree/diploma/associateship/fellowship or for any other considerations.

S.DINESH 20291-M-091

Place:
Date:

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ACKNOWLEDGEMENT

This satisfaction that accompanies the successful completion of the task would be put
incomplete without the mention of the people who made it possible, whose constant guidance and
encouragement, crown the efforts with success.

I am extremely thankful to express our beloved chairman and establisher Dr.M.Mohan Babu
Chancellor MB University who took keen interest and encouraged us in every effort throughout this
course.

I convey our gratitude to our esteemed management and honorable Principal,

Dr. B.M. SATISH for providing all the facilities and support.

I am express our heartfelt gratitude to Dr. P. UMAPATHI REDDY, Professor & Vice
Principal, 2nd Shift Polytechnic for his kind attention and valuable guidance to us throughout this course.

I am thankful to our coordinator Mr.M.RAMESH NAIK ,M.Tech Lecturer, Dept. of

Mechanical Engineering for providing us innovative ideas, motivating and inspiring us throught the
completion of this industrial training

I am thankful to our project guide Mr.A. SATISH, M.Tech Lecturer, Dept. of Mechanical
Engineering for his unstinted support and guidance throughout the process of this project.

I also thank the teaching and non-teaching staff of our college for their valuable guidance and
constant support during the completion of this project work.

We express our deep sense of gratitude to our parents and well-wishers who helped us a lot in
making this project successful.

S.DINESH
PIN:-20291-M-091

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INDEX

S.NO TITLE PAGE NO

1
2 INTRODUCTION 1
3 TYPES OF CARS 2
4 ISUZU MANUFACTURING PLANT 4
5 WORK ORGANISATION IN INDUSTRY 6
6 TYPES OF DEPARTEMENT IN ISUZU PLANT 10
7 FLOW CHART IN BODY SHOP 12
8 TRIM ASSEMBLY 22
9 CHASSIS ASSEMBLY 23
10 FINAL ASSEMBLY 23
11 AUTOMATION TRIM ASSEMBLY 24
12 INSTALLATION OF COCK-PIT 25
13 WINDSHIELD PREPARATION AND FITTIMG 25
14 AUTOMATION IN CHASSIS ASSEMBLY 27
15 VEHICAL TEST 31
16 WHEEL ALIGNMENT TEST 32
17 TURNING RADIUS TESTER 33
18 HEAD LIGHT TESTER 34
19 SIDE SLIP TESTER 35
20 DRUM TESTER 35
21 BRAKE TESTER 36
22 LOGISTIC 37
23 PRODUCTION LINE IN TCF SHOPE 38
24 DOLLY SUPPLY 38
25 FIXING PARTS SUPPLY 38
26 KITTING 39
27 KITTING OPERATION 39
28 SAFETY RULES 40
29 5 SAFETY RULES 40

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SERVICING & MAINTAINCE ON AUTOMOBILE

INDUSTRIAL TRAINING REPORT

I completed my 5 months industrial training in isuzu motors india private limited

in production admin in inventory management department.

INTRUDUCTION;

It is located at sricity in tada,chittoordistrict,andhrapradesh.

It is a japanese company.
In isuzu company car manufacturing is takes place.
Isuzu engines have long been reputed for its excellent fuel economy.
Both our truck and light commercial vehicle engines showcases cutting edge
technology in its fuel system, turbo charger, and vehicle aerodynamics which are
key contributors to fuel efficiency.
Isuzu produces an extensive line-up of industrial-purpose diesel engines with
models ranging from a 4-cylinder 2.2-liter engine to a 6-cylinder 15.7-liter
engine.
Also powering isuzu's n series trucks, the euro 4 emissions-compliant version in
the mu-x produces 130kw at 3600rpm and 380nm at 1800-2800rpm and comes
with a b10 rating of 500,000km, which means 90 per cent of engines are
expected to reach 500,000km before requiring a rebuild.
D-max has 5190 mm length, 1775 mm width, 1690 mm height, 1795 kg kerb
weight, 3095 mm wheelbase, 55 litres fuel tank capacity.
The diesel engine is 2499 cc . It is available with manual transmission.
Depending upon the variant and fuel type the d-max has a mileage of & ground
clearance of d-max is 220mm. The d-max is a 2 seater 4 cylinder car and
has length of 5375mm, width of 1860mm and a wheelbase of 3095mm.

TYPES OF CARS;

In isuzu mainly four types of cars are manufactured .

SREE VIDYANIKETHAN ENGINEERING COLLEGE 2nd SHIFT 1

POLYTECHNIC

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Mux-x
V-cross
S-cabs
Regular cab

Mu-x:

V-cross :

S-cabs :

SREE VIDYANIKETHAN ENGINEERING COLLEGE 2nd SHIFT 2

POLYTECHNIC

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Regular cab:

ABOUT MANUFACTURING PLANT :

SREE VIDYANIKETHAN ENGINEERING COLLEGE 2nd SHIFT 3

POLYTECHNIC

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Isuzu manufacturing plant started on april 2016 in sricity, tada,andhrapradesh.

The facilities spread over 107 acres.

The four main departments in isuzu plant are
Press shop
Body shop
Paint shop

Tcf (trimm chases and final assembly)

Power train (engine shop)

Isuzu motors india private limited is a subsidiary of isuzu motors

limited, japan was established in august 2012 in india having its
Manufacturing plant in sri city, chittor district, andhra pradesh 55km
Away from chennai. Head corporate office present in vadapalani,
SREE VIDYANIKETHAN ENGINEERING COLLEGE 2nd SHIFT 4
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Chennai. Isuzu currently sells a range of isuzu d-max pick-up trucks
That includes variants like regular cab flat deck and s-cab. Isuzu also
Sells the mu- x, a large sized sports utility vehicle (suv) in automatic
transmission in india.

Isuzu motors india unveiled the isuzu d- max v-cross, india's first
Adventure utility vehicle at the auto expo 2016. The v-cross has been
positioned as a lifestyle pick-up and can be registered.

As a personal vehicle. In dec-2020 isuzu motors india launched a contest

for

Existing indian businesses and startups with an aim to reward the best
business

Idea using the isuzu d-max as a trusted business partner, by giving away
the isuzu

D-max super strong variant as the prize to kick-start their venture.

WORK ORGANISATION IN INDUSTRY ;

Automobile final assembly plants are usually divided into three major
departments: (1)

Body shop, (2) paint shop, and (3) trim- chassis-final. This plant will be
Organized accordingly. The three departments must all be contained
within one building, but the paint shop must be

Physically separated from the others because of cleanliness, processing,

and
Ventilation problems associated with spray-painting technology. In
addition,

There will be a fourth department, (4) reprocess, to fix those cars needing
repair
As they exit trim-chassis-final. Storage buffers with substantial capacities
SREE VIDYANIKETHAN ENGINEERING COLLEGE 2nd SHIFT 5
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will
Be installed between the body shop and the paint shop, and between the

paint shop and trim-chassis- final.

Body shop storage buffer reprocess paint shop storage buffer

Trim-chassis-final reprocess
About a thousand spot-welds are made in the body shop. To begin the
assembly.

Individual sheetmetal parts, consisting of the floorpans and side panels, are
loosely fastened together by human workers. The car body then moves
through
A series of spot-welding operations, both robotic and manual, to add more
parts
And permanently assemble the body. After the sheetmetal body is
completed, it then moves into a temporary storage area.

Serves as a buffer in case of significant downtime delays in either the body

shop or the paint shop

That follows. From the temporary storage area, the car bodies move into
the paint shop, where a series of processes are performed to paint the car
body.
The painted car bodies are then transported from the paint shop to another
temporary

Storage area to permit thorough curing and drying of the paint, and to
permit proper sequencing

The components that will be added in trim-chassis-final. Cars are

produced from customer orders with specific combinations of parts, and
the proper parts
Must arrive at the respective workstations at the same time as the
corresponding car bodies

SREE VIDYANIKETHAN ENGINEERING COLLEGE 2nd SHIFT 6

POLYTECHNIC

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The car bodies then move to the trim- chassis-final department, where the
remaining parts

And subassemblies are assembled into the body. These include the engine
and transmission,

Dashboard, seats, tires, and so on. When all of the trim and chassis work
have been completed,

The cars are ready to be driven off the line. However, in some cases, there
are quality problems

That must be repaired on the completed automobile. This repair is

accomplished in the reprocess

Department, which is located after the end of the line in trim-chassis-final.

It consists of a large

Open area with stalls in which repairs are made on cars that have quality
Problems or components. There is no conveyor line in the reprocess
department since even cars needing

Rework can usually be driven after completion trim-chassis-

final press shop

In press shop the gi metal sheet are moulded into required shapes of the
car
Profile

Car front doors

Rear doors
Roof

Hood

Tail gate

SREE VIDYANIKETHAN ENGINEERING COLLEGE 2nd SHIFT 7

POLYTECHNIC

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Body profile e.t.c
The sheet metal is punched by the dies and make it in required design and
dimensions.

TYPES OF DEPARTEMENTS IN ISUZU PLANT;

BODY SHOP :

In body shop the parts which are produced in the press shop can be jointed
here by welding and mak it as the profile of the cab

If any defect is accure on the body it is rectified by the production

department in the body shop .

The sharpened edges and excess welding is grinded by manually in the

body shop

SREE VIDYANIKETHAN ENGINEERING COLLEGE 2nd SHIFT 8

POLYTECHNIC

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Nearly all of the sheetmetal body components in an automobile body are

assembled by spot welding. There are approximately 4000 spot-welds on a
Typical car, about 1000 of which are accomplished in the body shop. The
very
First operations consist of manually fastening the side panels and floorpan
Together to form the initial body assembly. This is called "toy tabbing"
Because the fastening is accomplished by bending metal tabs on the
Sheetmetal parts. Each car body is then fed through a framing system
which
Fixtures the body and performs a limited
number

Of spot welds to hold the subassembly into this alignment. From the
framing system the car bodies are transferred through a series of robotic
stations
Which accomplish additional spot- welds. At subsequent stations in the
body
Shop, the roof, hood, and other sheetmetal parts are added and spot-
welded
In place to complete the car body. To repair any blemishes, scratches, and
Rough

SREE VIDYANIKETHAN ENGINEERING COLLEGE 2nd SHIFT 9

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Spots, the bodies then move through a metal finishing section of the line

where workers grind and wire-brush the imperfections out and smooth the

sheetmetal surfaces.

The body shop is a highly automated department, the automation

consisting of robotic spot welding stations at which approximately 800 of
the 1000 spot Welds in the body shop are performed.

FLOW CHART IN BODY SHOP :

Toyta b-Robogate- Buffer- Manual-Respot-Buffer- manualthe assembly

process begins with body side panels and floorpans being launched onto

the front of

The conveyor line. Toy tabbing is performed at five manual

Workstations to fasten together the body panels before they move into the
framing system.

The framing system, called "robogate", is 100 ft long and 30 ft wide.

Robots and
Other automated devices are used to accomplish the initial spot welds to
Make the car body rigid. A total of 200 spot welds are performed in the
Robogate. A crew of six workers attends to the robogate, providing
supplies,
Reprogramming if necessary, and performing maintenance and

repairs as necessary. The cycle time of the robogate is well within the

required 1.0 min . Production time requirement, even considering

occasional downtime.

SREE VIDYANIKETHAN ENGINEERING COLLEGE 2nd SHIFT 10

POLYTECHNIC

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The robogate is followed by a storage buffer with capacity of 12 car

bodies. This is considered sufficient to maintain an overall production

rate at 60 units/hour.

Next in the sequence are ten manual stations which add the remaining
parts
(roof, trunk, lid, etc.) Except doors. No welding is performed at these
stations.

The respot line is followed by a storage buffer with capacity of 12 car

bodies, which is considered sufficient to maintain overall production rate

at 60 units/hour.

After the storage buffer following respot, a series of manual workstations

are used

Assemble the doors and other fixtures that must be on the car body prior
to painting. This section of the line includes manual spot welding stations
that Complete 160 spot welds which cannot be accomplished by robots.

The section also includes a metal finish section where the sheet metal is
Cleaned and repaired using grinding and wire-brushing. This step
prepares the
surfaces of the car body for painting. The manning level in the body
shop for
All manual stations will average 2.0, the balance delay in this department
is
expected to be 0.08, and line efficiency (proportion uptime) in the
manual
Portions of the line = 100%. Repositioning time = 0.15 minute; however,
This time is included in the total labor hours for this (and other)
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departments,
So it need not be considered in the case problem.

After the storage buffer following respot, a series of manual workstations

are used .

Assemble the doors and other fixtures that must be on the car body prior

to painting. This section of the line includes manual spot welding stations

that

Complete 160 spot welds which cannot be accomplished by robots. The

section
Also includes a metal finish section where the sheet metal is cleaned and
Repaired using grinding and wire-brushing. This step prepares the
surfaces of
the car body for painting. The manning level in the body shop for all
manual
stations will average 2.0, the balance delay in this department is expected
to
Be 0.08, and line efficiency (proportion uptime) in

The manual portions of the line = 100%. Repositioning time = 0.15

minute; however, this time is included in the total labor hours for this

(and other) departments,

So it need not be considered in the case problem.

SREE VIDYANIKETHAN ENGINEERING COLLEGE 2nd SHIFT 12

POLYTECHNIC

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Each station in this department is 25 ft in length and 30 ft wide (12 ft on
either side of the

Line, allowing for the 6 ft width of the car body and carrier. The two
storage buffers in this

Department need be only 12 ft wide which includes an allowance for

safety and maintenance.

These buffers are to be on-the-floor conveyors. Synchronous transport of

car bodies must be

Used at all stations in this department, but not in the storage buffers. In
the buffers, quick access
To units in storage is required.

In paint shop the body is first received from the wbs(white body storage)
Then it seated on the c-hanger automatically
After that it entered into the pro desk in pre deck jig are fixed to the cab
and
The skid there are four types of jigs present in the pre deck

Front antifloating jig

Rear anti floating jig
Pu box front jig and

Pu under body jig

First process is pre wash the cab dipped into the tank which containing
water and it having the temperature 43de

SREE VIDYANIKETHAN ENGINEERING COLLEGE 2nd SHIFT 13

POLYTECHNIC

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Degreasing in this section the cab completely dipped into the degreasing
chemicals this help to remove the oil on the surface of the body which is
applied
During the wielding in the body shop it maintain temperature 45degree

Water rinse 1 in this process the excess chemical on the body is removed
Water rinse 2 in this the water is sprayed by the four sides through the
nozzles this maintain the body in wet condition.

Surface condition this is the first coating on the cab in the paint shop

SREE VIDYANIKETHAN ENGINEERING COLLEGE 2nd SHIFT 14

POLYTECHNIC

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Phosphorus this is the second coating on cab the cab dipped into the
phosphate bath.

Ater rins 3 here di water is sprayed on the body

Water rins 4 here the same di water is sprayed on the body through the
nozzles

Fresh water rins here fresh water is sprayed on the cab

Ed coating this is the third layer of paint here 1000amps dc
Power is supplied to the cab and positive is connected to the tank here the
paint is coated in electro deposition process .

Ultra filtration 1 : here the excess ed paint on the cab is removed

Ultrafiltration 2: here the cab is dippedinto the chemical tank this filter the
remaining excess paint.

Di water rins : the di water is sprayed on the cab in this process

Pre deck: here jig unloading takes place and then air blowing takes place .
Then the cab entering into the oven in the oven 162 degrees maintained
The cab then went into the buffer

Then the cab entering into the ed sanding

Ed sanding roof here the dust particles on the roof are rectfied
Ed sanding floor here the contiminents in doors ,tail gates,fender e.t.c are
rectfied if any contiminents present it will noted in the check sheet.

Then the cab enters into the sealer line. In sealer line we have six stations.
Rear floor
Floor-1

Floor-2

Roof

Under body spray (ubs)

Stone guard coat (sgc)

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We will use two types of sealers in sealer line
High viscosity sealer (hv sealer)
Stone guard coat sealer (sgc sealer).
The viscosity of the hv sealer is more than sgc sealer.
Ithe main purpose of the sealer is to cover the weld gaps formed by
welding and to prevent corrosion between the edges.

In rear floor station the pu box is sealed with sealer . In floor 1 station
inside the cab is selaed with sealer.

In floor-2 station melt sheets are applied in the cab which is used to
absorb the vibrations from the cab.

Then the bonnet is lifted with the help of jig and it is toiched up with the
sealer. And finally the fuel door is toiched up with the help of spatula.

And it enters into the roof station.

Then the cab enters into stone guard coat sealer section where the can is
first gone into the under body spray and then into the stone guard coat.

Then the cab went into the top coat here the paint is coated on the cab
Then the cab entered into the final line here the defects on the paint can
be rectfied. Then the cab go to pbs paint body storage from that it went
into the tcf.

Here the body and chases and the interior and the engine assumbling takes
place.

Wing shield

Sensors

Head lights
Seats

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POLYTECHNIC

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Wiring

Enginee

All parts are assemble here by line by line.

TRIM ASSEMBLY:
Harnesses and controls-otherelectrical
Pedal assembly, insulator
Air duct, heater, head liner
Weather-strip, horn, stop switch
Front/rear shock absorber, shift cable
Wiper link, washer tank

Condenser, rear set belt, radiator insulator.

CHASSIS ASSEMBLY:

Brake tube, filler neck, splash shield

Fuel pipe, fuel tank, canister
Rear axle, stabilizer
Clutch tube, heat protector, engine
Knuckle, tie rod

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POLYTECHNIC

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FINAL ASSEMBLY:

Exhaust, undercover
Tire, front /rear seat
Front/rear bumper
Rear pillar trim, trunklid latch
Console bracket, carpet, trunk roomtrim
License plate lamp, radiator, hose
Seat belt, centre pillar trim
Heat hose, steering shaft
Air-conditioner pipe
Parking brake, garnish
Glove box, battery tray, seatbelt anchor cover
Rear combination lamp, sunvisor
Air cleaner, front/rear seat
Battery cable, silencer
Front grille, drip molding
Front turn signal lamp, console box
Combination meter, a/c gas
Front/rear glass, roof molding.
AUTOMATION IN TRIM ASSEMBLY:
Many operations in the area of trim assembly can be automated , fig. 8.6 .
Installation of door liners: a robot takes a liner for the interior door trim
From a magazine,

Moves it under a stationary applicator for hot adhesive and attaches it to

the
Door. The fast

Measuring system makes it possible tofind the precise position o f the

door quickly.

Hood 2. Front module 3. Guard rail 4. Front seat 5.front/rear carpet 6. Drip
moulding 7. Trunk lid 8.
Headliner 9. Rear lite 10. Windsheild 11. Cockpit module 12. Front/rear
SREE VIDYANIKETHAN ENGINEERING COLLEGE 2nd SHIFT 18
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door 13. Battery

INSTALLATION OF COCK-PIT :
The cockpit are preassembled separately. The cockpit is lowered into the
Body from above. A robot gets the sealant applied beforehand to seal
the joint.

Cockpit is also automatically bolted to the body on the sides.

WINDSHIELD PREPARATION AND FITTING:

The windshields are automatically (or manually)

Loaded into pallets and centered. A robot attaches the required number of
clips to hold the

Trim-frame to the outer edge of the windshield with special attachment.

Primer and adhesive

Are also applied by a robot on down- the-line stations.

Continuous monitoring of the process

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Ensures that the adhesive is metered and dispensed in proportion to the
Robot’s speed.
Travel. The wind shield are fitted into the opening by a robot with an
integrated vision system

Sensor system based on principle of laser-light intersection) in order to

Guarantee that the

Windshields are fitted accurately into the respective openings.

AUTOMATION IN CHASSIS ASSEMBLY:

The docking process has already been automated. In one case, the power

train, suspension, steering and exhaust are mounted on 4 sub-pallets on a

standard pallet in the form of a frame suitable for any model. Some uses

two separate

Pallets - one for the power train etc. And the other for the rear
suspension. Fig.
8.8 shows a chassis assembly system. The assembly

System includes a preassembly line for the undercarriage and drive-train

Components, the main assembly line for automatic assembly of chassis

module

To body. A large pallet holds the individual pre-assembled undercarriage

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and

Drive-train units in the proper position. The units are manually assembled
to

Form the chassis module. After the chassis module enters the
main assembly

Line, the chassis module and the body are automatically decked in a lift

Station. The remaining fastening operations are completed manually.

Components, the main assembly line for automatic assembly of chassis

module

To body. A large pallet holds the individual pre-assembled undercarriage

and

Drive-train units in the proper position. The units are manually assembled
to

Form the chassis module. After the chassis module enters the main
assembly

Line, the chassis module and the body are automatically decked in a lift

Station. The remaining fastening operations are completed manual.

Crossover transport

Unloading front-axle and rear-axle carriers.

Loading front-axle and rearaxle carriers

Loading engine and transmission

Lowering station

Pre-assembly line

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Main pallet

Bypass line

Lift and decking station

Crossover station for bodies

Fastening station

Main assembly line

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Some use the conventional carousel and lift system for the
docking, and the
System may be adapted for automatic working. The lifts which move
around the

Carousel synchronised with the main line, consists of fixtures.

Thus are similar to those used in manual lines. The innovation is the
addition of a

Pair of trolleys that can shuttle between the two docking stations and these

Incorporate automated nutrunners. When the lift arrives at the first

Docking station, the two other trolleys start to move forward, and
synchronise speed with that

Of the carousal. To locate the trolley to the body, they push four pins up
into
Holes in the car body and some horizontal pins locate the trolley to the lift.
Thus the three trolleys and body are located together precisely and
Mechanically. Next, the lift raises the engine to the body, and immediately
Afterwards the nutrunners move upwards and insert and tighten the bolts.
The
Complete operation is performed quickly, and simply , and because the
method of

Locating the trolleys to the body is mechanical, it is easy for the

operators to
See the cause of any problem
VEHICLE TEST;

After the vehicle comes out of the final assembly line, it is driven on its
own
Power to vehicle

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Testing area. Inspection equipment include :
Wheel alignment tester
Turning radius tester
Headlight tester
Side slip tester
Drum tester
Brake tester

WHEEL ALIGNMENT TESTER:

It performs measurement/adjustment of toe of the front and rear wheels as

well as camber of the front and rear wheels of an assembled vehicle. It

also sets the

Steering wheel at a position where it becomes horizontal during the

straight ahead running.

The vehicle is driven onto the tester and is centered roughly by means of

the equalizers and by its own propelling force. The roller for driving the

wheels are

ROTATED. SIMULTANEOUSLY THE SIDE ROLLERS ARE PUSHED

AGAINST THE SIDE OF EACH
WHEEL FOR ACCURATE CENTERING. THE SIDE ROLLERS ARE
USED AS MEASUREMENT ROLLERS.
THE AMOUNTS OF TOE AND CAMBER OF THE WHEELS ARE

MEASURED UNDER THE ROTATING CONDITIONS. THE MEAN

VALUES OF ALIGNMENT
MEASURED DURING ROTATION IS INDICATED.

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TURNING RADIUS TESTER:

It measures the right and left turning angle of the front wheels of an
assembled vehicle in order to ensure that the turning angles are with in the
specified limit. The test vehicle is driven

On to the tester, the front tread setting is automatically made. As for the
rear equaliser, the rear tread is set forcibly by the air cylinder.

HEAD LIGHT TESTER:

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At about 4 meters ahead of the turning centres table of the turning radius
tester, an opening/ closing type screen device is provided. The director of
photometric axis of head lamps of an assembled vehicle is aimed on the
screen. The headlamps are adjusted in such a way that . The light patterns
on the screen get aimed on the specified positions. In test position the turn
table remains locked.

SIDE SLIP TESTER:

It measures the amount of side slip of the front and rear wheels of the
assembled vehicles. The vehicle driven by the driver passes slowly over
thetester tread plates with the steering wheel held at its straight ahead
position.

DRUM TESTER:
It conducts evaluation of the indication of speedometer of an assembled
vehicle by driving the vehicle or rollers. It also checks the driving
condition. The tester consists of the front wheel section and rear wheel
section connected with each other by means of a transmission section
( comprising of v belt and pulleys in one case). During the test, the
rollers driven by the driving wheel are put under the actual running
conditions. Speed indication is compared with the speed applied and
evaluation regarding meeting the specification is made.

BRAKE TESTER:

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It conducts evaluation of the brake system of an assembled vehicle

by measuring braking force of each wheel (drag, service brake,
parking brake). In the tester, each of the rollers for right and left is
rotated by a motor. When the brake is applied, a strain gauge detects
the reaction force applied to the rollers and measures it as the
braking force.
In power train the engine is supplied to isuzu from revotec company.
Isuzu has used both its own engines and general motors-built
engines. It has also produced engine for general motors, renault,
saab, honda, nissan, opel, toyota, and mazda.
In power train it is tested by the superiors.
And it is finally assembled with the body.

LOGISTICS;
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Logistics is the process of planning and exceuting the efficirnt

transportation and storage of goods from the point of origin to the point
of consumption.
The goals of logistics is to meet customer requirements in a timely,cost-
effective manner.
They supply parts to all lines.
They receive pats from ware house through the transporting vehicle and
they scane the qr cord and they unpack all the parts.
Received parts are set in order.
Entire production is been divided inti 4 lines and 6 sub asm.
Each line is taken for supplying materials to line which is taken care by
mainpower(10 min takt time) on an average which includes sub asm.

PRODUCTION LINE IN TCF SHOP;

Trim-1
1. Trim-1sub asm
Trim-2
1. Ip(instrument panel)sub asm
Chassis line
1. Frount axle sub asm
2. Rear axele sub asm
3. Engine sub asm
Final line
1. Bumper sub asm

TYPES OF SUPPLY;
As we discussed before, parts which are in supply list(bom) to be
supplied to tcf/production for manufacturing into vehicle.
Parts are supplied to tcf/production into three concept.

1. Dolly supply
2. Fixing parts supply
3. Kitting

DOLLY SUPPLY;
Dolly – direct to line, usally parts which are bigger in size will come
under the category of dolly.

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Dolly parts are defined by pe logi, pe tcf & logistics & tcf by
considering the space in line side and also feasibllity of picking the part
by production team. example: engine, rr axile, tyre ect…,

FIXING PARTS SUPPLY;

As the name suggest, it is usesd to fix (assemble) two or more
parts examples: bolts, nuts and stickers comes under the category
of fixing parts supply.

KITTING;
In simple partswhich are not comes under the catrgory of dol and
fixing, will comes in kitting supply method.
But, kitting method is most powerfui tool for supplying correct
part, at correct quantity and at correct time.

KITTING OPERATION;

In order to understand kitting operation, first we need to know the details

which are present in supply list/bom.

Supply & kitting training manual:

Introduction to logistics.
Logistics operation range at IMI
Press shop
Body shop
GA shop
Power train
Logistics operation at IMI
Receiving and unpacking KD parts
Sorting of KD parts
Supplying of KD and local parts
Kitting process
DPI process
Scrap management
Logistics operational range @IMI

1. Logistics operational range @IMI

2. Press shop
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3. Body shop

4. Paint shop

5. Power train

6. GA/TCF SHOP

SAFTEY RULES

3 principals of safety control :

Stay organized (clean & order)

Follow work instruction
Inspection & maintenance of tools & equipments
5 safety rules;

When something goes wrong, press red button to stop

When working together as a group ,send and receive signal with meaning .
Strictly work step by step ,as per work instruction.
Incase of abnormality ,wait and check before touching .
Check before start of working ,and tidy up before finish of working .

When something goes wrong, press red button to stop .

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When working together as a group ,send and receive signal with meaning :
.

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Incase of abnormality ,wait and check before touching:

Check before start of working ,and tidy up before finish of working :.

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REFERENCES
^ Jackson, Kathy (4 February 2008). "Isuzu's collapse". Automotive News. Crain Communications, Inc. Archived from the original on 10
October 2019.

^ Jump up to:a b c Ruiz, Marco (1986). 'The Complete History of the Japanese Car: 1907 to the Present. Rome: ERVIN srl. p. 130. ISBN 0-517-

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61777-3.

^ "Isuzu Website". Archived from the original on 5 May 2017. Retrieved 25 May 2017.

^ Jump up to:a b Ishikawa, Kenji (1 May 2012). [Truck Manufacturer Archive: Everything Isuzu]". Camion (in Japanese). Tokyo, Japan:
Geibun Mooks: 98. ISBN 978-4-86396-183-8.

^ "Investor Relations: Company History". Isuzu Motors. Archived from the original on 20 April 2012. Retrieved 28 August 2012.

^ Ishikawa, p. 7

^ Yamaguchi, Jack (February 1968). "14th Tokyo Motor Show: & Still Trying Harder". Road & Track. p. 113.

^ "Isuzu" (brochure) (in Japanese). Isuzu Motors. October 1967: 8–9. 42.10.

^ Jump up to:a b Ruiz, p. 131

^ Bedwell, Steve (2009). Holden vs Ford: the cars, the culture, the competition. Dulwich Hill, Australia: Rockpool. p. 199. ISBN 978-1-921295-
17-1.

^ Jump up to:a b "GM ties with two Japanese car makers". Nihon Keizai Shimbun. Tokyo: 1. 18 August 1981.

^ "Isuzu, Suzuki tie up in sales and production". Machinery. Nihon Keizai Shimbun. Tokyo: 10. 18 January 1986.

^ Truett, Richard Truett (21 October 1993). "Expert Reviews: 1993 Isuzu Rodeo". Orlando Sentinel. Archived from the original on 23 September
2015. Retrieved 4 October 2015.

^ Jump up to:a b c Krebs, Michelle (1 July 2001). "Isuzu's U.S. Presence Leans on G.M." The New York Times. Archived from the original on 24
September 2017. Retrieved 23 September 2017.

^ Jump up to:a b c "Isuzu falls back after GM rescue plan". CNN.com. 15 August 2002. Archived from the original on 24 September 2017.
Retrieved 23 September 2017.

^ "Press Release: Isuzu Motors Limited Unveils the New Three-year Business Plan and Re-capitalization Plan, involving Decrease of Capital and
Debt-for-equity Conversion". www.Isuzu.co.jp. Isuzu Motors. Archived from the original on 24 September 2017. Retrieved 23 September 2017.

^ Belson, Ken (15 August 2002). "G.M. Moves to Increase Control of Some Isuzu Units". The New York Times. Archived from the original on 24
September 2017. Retrieved 23 September 2017.

^ "Mitsubish becomes top shareholder of Isuzu". Autoblog. Archived from the original on 8 May 2016. Retrieved 26 April 2016.

^ Bensinger, Ken (31 January 2008). "Isuzu quitting U.S. car market". Los Angeles Times. Archived from the original on 31 January 2008.
Retrieved 30 January 2008.

^ Jump up to:a b Johnson, Drew (30 January 2008). "Isuzu to leave U.S. market". Leftlanenews.com. Archived from the original on 13 March
2012. Retrieved 5 February 2012.

^ "Consumer complaints about Isuzu - Engine Failure". Consumeraffairs.com. Archived from the original on 16 January 2012. Retrieved 5
February 2012.

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