Internship Report 201 2 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 1
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Internship Report 2012
Table of ContentsAcknowledgement..........................................................................................................................3
Benefits of Doing an Internship....................................................................................................45
Benefits of Doing an Internship............................................................................................................45
Gain Valuable Work Experience..............................................................................................................45
Have an Edge in the Job Market..............................................................................................................45
Transition into a Job................................................................................................................................45
Gain Confidence......................................................................................................................................46
General benefits of an internship.................................................................................................46
AcknowledgementThis report would not have been possible without the support of many people. We wish to express our sincere gratitude to our supervisor instructor Dawit Kebede who was abundantly helpful and offered valuable assistance, support and guidance as well.
Deepest gratitude also due to the members of moenco staffs, without whose knowledge and assistance this report would not have been successful.
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.
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Executive summaryInternship the core of new curriculum is one of the main changes that were introduced to help students to integrate a thought and to provide dynamic linkage between the industry and the universities institutions of technology to meet the demands of the ever growing economy of Ethiopia.
As being one of the beneficiaries of this program we were able to incubate new ideas and meet the demands of the internship we were assigned for.
Internship is also without a shadow of doubt will place the students a dynamic environment and make students test and smell a new working environment. This strange environment shines a new light on our life to cultivate our theoretical backgrounds and made us to know the hidden secretes of this world.
The final internship report is designed for the accomplishments of fourth year second semester ME internship program. This program takes about 120 days in the motors and engineering company of Ethiopia Adama branch. In this final report the background main activities in the organization, responsibilities of intern the qualities developed by the intern, the design and the operation of a pneumatically operated rotating mop used to clean the workshop that substitute manually cleaning the workshop, conclusion, recommendation and references are included.
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CHAPTER ONE
IntroductionInternship forms a steel ground linkage between university student and industry .it also establishes a “win-win” situation for students to dig and cultivate their theoretical background. In addition practical skill may be nurtured and developed for those with an unquenchable thirst for knowledge. Moreover, it places student in a strange and dynamic environment that perhaps forces to test and smell challenges, and absorb and digest problems. A student develops a sense of punctuality, work ethics, honesty and loyalty, social life and entrepreneurial skill from an internship.However, far too little attention is paid to internship students on how they proceed in learning for their duration of time.The reader should bear in mind that, in order to capture the essence of our report in a lucid and succinct way we attempt to use table and figures .due to practical constraints cannot provide comprehensive review of the automobile.Two projects were also conceived during our time working in a repair shop and body and paint shop.The overall structure of the report takes a form of five chapters including this introductory chapter.Chapter two begins by illuminating the background of the company, mission and vision, values and also laying out; service of the company, customer of the product and product range.Chapter three is concerned about Internship experience on Auto- service department maintenance schedule for periodic service, Power transmission, Auto Electricity, Engine maintenance, Automotive Fuel System service, Contamination control, Automotive Tire &Wheel, service, Tire Construction, Changing Tire Assembly, Duties in the body and paint shop.
The fourth section presents the main activities and finding of the project focusing on workshop cleaning mop and spray holder with detail analysis and part drawings.The last chapter includes the benefits of internship during the course of this projectFinally the conclusion gives brief summery and critics of the findings during the internship period also recommendation and references that we use in the writing of this report are included.
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CHAPTER TWO
Background of the companyAround 51 years ago in Addis Ababa Mexico area MOENCO was established for the first time in the form of small garage with the capital of 200,000 Ethiopian birr. It was founded by Mr. Y.D .Lappine in small rented house. His far sighted vision became reality with the help of other resourceful people such as Ato Minase Lemma, the then governor of the national bank of Ethiopia and the boss of imperial Insurance Company.
MOENCO is began to be established nine years later by taking Toyota Franchise business for Ethiopia when inch cape which is London based international organization became a major share holder injected a considerable amount of capital. This was the milestone moment in the firm’s journey to become the MOENCO of today. In addition to TOYOTA business, at different times MOENCO used to represents general motors for various type of vehicles and trucks of American and England like Ingersoll-rand, WABCO, Pettibow, Universal, Dupont, and General tire, Fregidire, Zanussi and Thomas Delarue
All the challenge in work gives MOENCO a great experience and makes to focus on people, service and innovation over the past five decades. The strength they have acquired in these years has also endowed MOENCO with the resilience to survive during the many difficult times.
Now MOENCO has five operational sites are two in Addis Ababa, One in Awasa which is launched in 1998, third in Bahirdar launched in 2004, and another one in ADAMA which is launched in 2010. Their networks include 13 major dealers across the country. Currently the company employed more than 600 employees and has annual turnover of over one billion Ethiopian birr. Besides the famous TOYOTA brand; MOENCO is currently distributing Daihatsu vehicles, komatsu construction equipment, Suzuki bikes, listerpetter diesel engines case, new Holland and etc.
MOENCO Adama is one of the branches of MOENCO that we spent our internship program. It is initial investment of birr 30 million rests in area of 20,000 m2 in good location of Adama. This branch gives a quality service to customers in Adama and surrounding area.
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The motor and engineering company of Ethiopia (MOENCO)
Mission and Vision Statements.
Mission Providing vehicle sales, parts and service in the world-class purpose built centre. Providing Excelling service and many magic moments by customer friendly service, Advisor, sales people, Toyota certified technician and support staff. Minimizing time for the service of Toyota vehicle by using special service Shop, genuine spare parts and sophisticated equipment.
VisionTo 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.
ValuesMOENCO 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.
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Services of the company (organization)MOENCO represents TOYOTA one of the great Automobile Company of this world. The main reason that makes MOENCO the great organization is its providing of different service for the customers. Service that are given by MOENCO are PDI Service, Free Service Check-up, Express Maintenance Service, Periodic Maintenance, General Repair, Body & Paint Repair Service, Annual Vehicle Inspection, Towing Service.
PDI Service (pre delivery Inspection)
Before delivering a new vehicle to the customers the pre delivery inspection is done. The job of PDI staff includes removing the protective materials applied to prevent possible damage on the vehicle during transportation from the supplier to the distributor, inspection of mechanical status, body parts and any paint defects on each and every vehicle, installation of different accessories to confirm the finished condition and guaranteeing the quality standard that TOYOTA, DAIHATSU & LEXUS stand for.
Free service Check up
In MOENCO there is free service check up for vehicles that are purchased from MOENCO in every 1,000 km & 5,000 km this makes the customers feel safe with their properties and satisfy with their new vehicle. Only the customers have to pay replacement of lubricant and filters.
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.
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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 TOYOTA’s 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
Body and Paint Repair
MOENCO by teaching the proper fundamentals of Body and Paint through a continued in-house and overseas training program and using the state-of-the-art equipment manages to develop full-fledged Body and Paint technicians who can correctly trouble shoot and carry out major and minor Body & Paint repairs to mint condition.For the vehicles that has problems with body & paint is serviced in body and paint repair service class. This job is carried out by technicians that are highly trained and skilled.
General Repairs
MOENCO’s 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.
Annual vehicle inspection
The Ethiopian Transports Authority decides for all vehicles have to be annually inspected for safety of the human life and economic disaster this inspection carried out in the designated vehicle inspection center. Provides inspection service to all Toyota, Daihatsu and Lexus vehicles.
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Towing Service
MOENCO also provide towing service (dragging of a car) to assist our customers in the event of vehicle collapse or malfunction.
The sale service provide those machines and VehiclesAutomotives
TOYOTA Yaris TOYOTA Hilux
DAIHATSU Terios
Constriction
Komatsu Excavator Komatsu Dozer
Agriculture
New Holland Tractor
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Customer of the product (service)
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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Recent trends show that the market in the motor industry is characterized by increasingly fierce competition in after sales. The value of the after sales market is increasing due to longer vehicle ownership and diversification of customer needs.
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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Inventory control
Stock items to be replenished and new items to be ordered are automatically generated by the computer on bi-monthly basis. In addition, they also place small frequent emergency orders to address their customers’ urgent needs.
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
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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.
Staffing and facility
Staff
There are total of 60 staff on permanent and contractual basis working in the different sections of parts department – Parts office, main counter, service counter, data control, customer relation and tender section, ordering officials.
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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Product rangeThe following are the product types for which they deliver genuine parts.
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.
- Body and Paint- Engine maintenance- Auto electric service
quality control
vehicle delivery
Internship Report 2012
CHAPTER THREE
Internship experience
How we get into this company?
We gave the application letter to MOENCO in the summer of 2011 and they told us they will accept us with warm face and good sense of humor. Next at the end of February 2012 we join the company and stay there for about four months.
In our four year mechanical engineering experience we began to realize that this world is only can go far in innovation and creating things that uses to provide for humans best need to achieve their needs energy is must. Especially mechanical energy.
In the study of mechanical engineering many problems are solved and if the study widens its horizon students are able to solve many problems related to industries in the future. In our world of competition vehicles provide a best track to let everyone do what he/she want and to win the race. We are one of the competentwe prefer to win our race by studying the track provider (vehicles) this motivation encouraged us to know more about designs of the cars and their systems.
In Ethiopia there are many companies that relate their job in servicing of vehicles and automobiles like Rise engineering, Nyala motors, MOENCO, National Motors. From these companies we get the one which has many services, facilities and well organized company that is MOENCO in its branches exists in Adama.
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Jimma University 4th year mechanical engineering students’ internship program is appropriate for increasing student’s practical knowledge. The letters that asks for internees to do their internship program in the MOENCO is given to us. The latter is accepted by the company managers and they allow as joining the moenco staffs and workers after 6 month of application.
Auto- service department maintenance schedule for periodic service
the service is given for the vehicles of HILUX 2L,3Land 5L engine, Condor 5L Engine, Land Cruiser, Station Wagon, Pick-Up and Hard Top (diesel 1HZ Engine)
Service type A= 5/15/25/35/45/55/65/75,000 km
Service type B= 10,000/30,000/50,000 and 70,000km
Service type C= 20,000 and 60,000 km
Service type D= 40,000 and 80,000 km
In addition to this, the activities that are performed in this shop can be classified into three main parts. They are:-
1. Power Transmission2. Auto Electric3. Engine Maintenance
Power transmissionThis 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
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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 now, we tried to get proper knowledge, skill & attitude that are necessary & sufficient in order to maintain modern automobile. Let see some of the duty and tasks in detail that we discover from the 4-month experience in Repair & maintenances shop.
Repair & maintenances shops one of the biggest shops, which accomplish different big duty & tasks for the customer as well as for the company. In this class, there is different service person, which accomplishes the work. Such as fuel system serviceperson, lubricating system service person, cooling system service person, power train service person, tire & wheel person, hydraulic brake system service person& steering system service person.
Auto ElectricityThis 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 maintenanceThis 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 it’s accessories including:o Check and installation of the crank shafto Check and installation of all bearing
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o Check and installation of camshafto Check and maintenance of cylinder heado Check and installation of piston with its ringso Check the diameter of cylindero Check cylinder blockso Lapping the valve with its valve seato Check and repair of front and rear differentialo Check and repair of gear boxo Refilling of fuel, differential and gear box oils
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Automotive Fuel System serviceIntroduction about fuel
In MOENCO Adama. Everything seems nice we quickly adapt the environment of the organization. We get nice friends in there. They told us everything about the life of industry, they also advice us a lot of things. Since they are experienced, they told us what they know without hesitation. Now we have some knowledge about automobile & vehicle.
For this week, our supervisor Ato Afework told us to work in automobile fuel system service area. In this class, there are different duties & task to be done. Those are:-
servicing air cleaner servicing fuel tank servicing fuel line servicing gasoline engine fuel pump servicing carburetor servicing fuel filter Servicing transfer pump service etc these are some of duties.
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
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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 engine’s operating needs from light to full load.
In this day, we tried to get some idea about fuel & its components and also we visit some of class that is found in automobile fuel system area &differentiate the tasks & duties which is to be done.
Now let us discuss about contamination in more detail.
Contamination controlWhy Contamination Control?
Customers are demanding
More power Greater breakout forces Faster cycle times
Modern Industry systems or trends are
Electro-hydraulics Higher system pressures Tighter clearances
Today’s fluid systems are more sensitive to contamination from these systems Hydraulics Transmissions / Final drives Fuel systems Engines
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Contaminated fluid systems:
Reduce efficiency and cycle times-up to 20% before you detect it Shorten component and fluid life Lead to catastrophic failure and costly downtime and repairs 75-85% of hydraulic system failures are caused by contamination
If We Don’t Address ContaminationWe Can Expect:
Repair costs to increase Redo to increase Repeat failures and associated failures to increase Customer satisfaction to decline
What is Contamination?
Dirt Weld spatter Paint flakes Rag fibers Metals
Sealing Materials Grease Water Air Products from oil oxidation
How much is too much?
1/2 Teaspoon of Dust Will Contaminate 55-Gallon Drum / System! Even Particles Too Small to see is Harmful!
Contamination Sources
Factory New oil Machine operation Maintenance/Service
Roles & Responsibilities
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Machine Maker- Build & ship clean products & components- Design machines to be kept clean- Provide tooling support- Educate employees, dealers and customers
Customers- Educate operators and service personnel- Implement contamination control measures
Contamination Control Procedures
Housekeeping- Sweep floors daily- Clean up spills immediately- Keep work benches uncluttered and free of debris- Limit use of floor storage
Oil storage and transfer- Filter new oil - Use drum covers- “Kidney loop” system oil
Parts handling and storage- Keep components packaged until ready to install- Return parts to storage in packaging- Clean in-process components
Hose assembly and storage- Protect bulk hose with caps and plugs- Clean assembled hoses- Protect assembled hoses with caps and plugs
Component repair and assembly- Establish a “clean repair” process- Use cylinder washer after honing- Separate welding and cleaning operations- Keep fuel injector rooms closed
Field service
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- Keep exchange parts and components packaged until ready to install- Filter new oil- Stock vehicles with High Efficiency Filters
Contamination Control Will Require a cultural change Reduce redo Enhance value of rental fleet Improve machine performance Improve customer satisfaction
Tire is the only element that connects a vehicle with the road. The tire supports the vehicle in all condition of load and on its proper speed.
Tire is air-filled cushions that absorb most of the shocks caused by road irregularities. The tires the road to provide good traction that enables the car to accelerate, brake and turns without skidding.
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.
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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.
Tires carry several markings on the sidewall. The markings include a letter code to designate the type of car the tire is designed for:
D- Light weight car.
F- Intermediate.
G- Standard.
H, J, L – for large luxury cars and high performance vehicles.
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:
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1) Rapid tire wear can be caused by layout irregularities2) The speed any style of driving can also cause rapid tire wear3) The distribution of car’s weight on tires
Changing Tire AssemblyThere are three common duties, which are to be done are:-
When we are removing the tire, assembly there is procedures that are to be done.
Set the parking brake Remove the spare tire, jack &wrench from the car Set jack in its stand & attach the saddle to the bumper Break loose all the lug nuts Raise the car by jack, until the tire lifts off the ground Finish the lugs & pull of the vehicle.
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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Duties in the body and paint shopThe main process of this service is provided in the body section for cars coming to the company with a different form of crushes, and injury. In this case, the body of the car would be shaped in accordance with its specific body design. The main techniques which are used to perform this activity are techniques like forging, bending, tearing, rolling, and welding.
This shop is the second main shop where the body of the car is repaired, and painted by different mechanical activity, main activities that are performed in this shop are:
Body repairing Body painting Repairing of seat inside the car Keeping the equilibrium position of the supporting part like housing, frame and
others. Releasing the bolt’s that are tightened hardly by using heating and cooling
systems Making the car more attractive for the customer
The services done during internship program are listed in the two month internship reports in this report we focus on the problem that the company has and the action we take
CHAPTER FOUR
Main Activity (Technical Content, Industry-based problem solving and originality).
Industry based problem solving
MOENCO is a huge company that provides quality services of repair and fixed time vehicle inspection (periodic maintenance). And also provide genuine spare parts for the customers.
The quality of products and better service they provide made them built reputation and respect in the field.
“Out of sight is not out of mind” this is to say that positive thinker sees the invisible, feels the intangible and achieves the impossible.
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In every company and industry, as well, if you deeply observe you may arrive at something that may have risk or harmful but it may be quite small or uncountable.
The extensive study of problems we made produced a number of key findings.
This can be treated as follows
Workshop cleaningThis 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.
Air Filter CleaningWe also intended to do project on air filter on how to address the primitive ways of cleaning air filter by blowing dust here and there by using a pressurized air. The dust when inhaled has the ability of bringing chronic lung cancer.
We gave a proposal to the company managers, to do some project on air filter that may reduce the chance of being caught by a cancer that claims lives of thousand’s death.
But, the company could not give attention, and facility to provide for us to proceed with the project. As a result we fail to do nothing better.
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Engine washingThis 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.
The design of workshop cleaning mop
An Introduction to the cleaning mopThe only thing better than the smell of freshly blossoming flower is the smell of success. For us, the possibility of cleaning the whole workshop without hesitation and need of rest using a pneumatically operated rotating machine become probable, but for others it is only dreaming up theories.
A discussion at lunch rotated around a table on the creation of new, light weight, strong material that would clean the workshop by rotating; that would mean a transformation in cleaning.
A design sketched on a napkin that day gradually grew into an actual mop.
Many became interested in the project due to our enthusiasm.
Out of regard for us nothing like equipment and service are donated. for our design to be truly valuable it needs to evolve with our daily struggle to survive and stay relevant in face of uncertainty.
We take slightly different approach when it comes to our design; employing 360 degree approach where in we receive feedback.
This allows us to see all the things that need to accomplish and how they fit in relation to each other.
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At first the test was imperfect. We looked for a ways to overcome the problems. Despite repeated failures, we continued to strive for excellence or mastery.
Although we lacked resources and materials;
We did have the capacity for perseverance. The word and touch were enough to urge and inspire us.
We organize our effort in sprit of team work .our shared respect and team work showed our outstanding performance throughout the four month.
By the end of March 2012 the machine was ready for a test.
After the machine has launched to operation and shows good performance test it works, it works like a charm.
It is time to give bolt and nuts of our project design to mangers. The success of the test boosted the hope that the design of the mop is only the beginning of the cleaning .design of the cleaning mop took place in MOENCO Adama branch.
By making a conclusion based on what has been done you may be able to predict what will happen next in a story.
Material Requirements1. Two plates of 3mm each2. Power wrench3. Bearing (front hub)4. Long pipe5. Ratchet socket6. 2 slip wheels – 50mm diameter
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7. Bolt and nut8. Metal wire (copper wire) 1.5m long – 2mm diameter9. Other used metals and metal residue
SpecificationsThe top of the power wrench that rotates the plate has
Torque = 610 nm
Angular speed = 7000 rpm
ω=2πN60 = 2π (7000)
60 = 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 π r2
A=π r2 , r= radius of the circle The angle from the whole circle is 2π or circanfrence of the disc is 2π c=2 πr , r=radius The total parameter is 2πr , P=2 πr
Principles of operationThe 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
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lock (clamper) made from the copper. Using the rotating motion of the plate the oil is cleaned.
Angular speed of the plateThe plate rotates when the tip of the impact power wrench rotates at 7000 rpm the tip of the power wrench meshes with socket number 21 which is welded to the inner race of ball bearing and lower plate the upper plates is made fixed, while the bottom plate is made to rotate.
The rotation of the tip of the impact power wrench do not directly transferred to the bottom plate, so that the rotation of the tip of the power wrench due to the inertia of rotation of the plate and socket and bearing decreases the rotation. The diameter of the socket is 5mm while the diameter of the plate is 30cm.
Therefore the rpm can be calculated from the following relation
N1= 7000 rpm
ω1= 2πN60 = 2π (700)
60=2π (7000)60
ω1= 733.03 rad/s
N 1
N 2
=D1
D1
N1 D1 = N2 D2
N2=N1D 1
D2
N2=1166.67 rpm
ω2=2π N2
60=2 π (1166.67)
60
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ω2=122.2 rad /s
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
V=ωr
V= (122.2) (15 x 10-2)
V= 18.33m/s
TorqueA 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
τ=F x r ………
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= τr=610Nm15mm
= 610Nm
15×10−3m
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 Newton’s 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=m v2
v=0.5(18.33 m
s)2
0.15m
F= 1.12 KN
This amount of force is required to move the plate.
Factors affecting the size of the centripetal force
F=m v2
r
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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The period and frequency of the rotating plateThe period is the time taken to make one complete revolution (circular turn).
For motion in a circle of radius r the circumference of the circle, C= 2∏r
It the period of one rotation is T, the angular rotation also known as angular velocity ωis
ω=2πT
,T=2πω
= 2 π122.2
s
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
f = 1T
=19.45Herz
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
I=12(o .5kg)¿
I=5.625 x10−2kg .m2
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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KErot=12
I ω2
¿ 12(5.625 x 10−2)(122.2 rad
s)
¿3.44 joule
The maximum power the rotating plate posses would be found as follows
Pmax=2πNT60
N is rpm of the plate and T is period of plate
¿(1166.67)(0.05142 s)
60
Pmax=6.282watt
This shows that Approximately 6.3 watt power is produced by the moving plate
The parts drawing
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The Long pipe (Handle)
Lower Plate
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Upper Plate
Ball Bearing
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Socket
Bolt
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Slip wheel
The full Assembly
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Paint Spray HolderThe last project but not the least is spray holder that solves a great problem in the painting room. This project is paint spray holder this holder is done because we see the problem of flowing of the paint when it is kept on inappropriate holder like barrel or floor they take it by their hand till the paint is over.this problem also needs a preliminary solution.
We have donea spray holder that is used by fitting on the wall by bolt.
The holder is made from residue metals simply by welding together.
Spray spray holder
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CHAPTER FIVE
Benefits of Doing an Internship
Benefits of Doing an InternshipFinding work can be a real challenge, especially if you don't have any experience. Yet to get experience you must first find a job. It's a nasty catch that can be difficult to get around but an internship is a good way to do it. Internships provide work experience opportunities to university students, recent graduates and people considering career changes. Employers are willing to hire interns with little or no experience, especially if the intern is willing to accept little or no monetary compensation. However, the benefits of doing an internship go far beyond your pay cheque.
Gain Valuable Work Experience
An internship provides the opportunity to gain hands on work experience that you just can’t get in the classroom. First time job seekers and career changers aren’t usually desirable candidates, but companies are willing to train them as interns and give them the experience they would need to get a job.
Have an Edge in the Job Market
Employers are usually more concerned with your work experience than your qualifications and internships are often the only way to get the work experience you need to secure a job, so they're a vital part of your resume. Many employers prefer or require applicants who have done an internship or relevant work experience and in many of the more competitive job markets it is essential to set you apart from the others.
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Transition into a Job
Employers see interns as prospective employees and many finish their internships and continue working with the company full time. Internships are the number one way for employers to find new staff. Think of it as a really long interview, after which you’ve proved that you are a capable and hardworking employee. Just as you’re giving the industry and the company a trial run, they’re doing the same for you.
Networking Opportunities
Internships are a great way to meet people in your field. Even if you have experience, knowing people never hurts. An internship allows you to meet people who might help you land a job later on and give you the contacts in the industry you’re trying to break into. Plus, references from people in the industry will really add weight to your application.
Apply Classroom Knowledge
An internship can be seen as the pinnacle of your undergraduate education and give you the chance to use the skills you've learned in the classroom in a real-world setting. It’s a chance to prove the worth of your qualifications and to show that you can perform in the role you've been given.
Gain Confidence
Getting experience is a great way to build your confidence. What's more, if you have an impressive resume, you will be more confident in your chances of securing a job. After you’ve done an internship, if an interviewer asks if you know how to do something, you won’t say “um, yes, I think I would be able to do that but can say “absolutely and supplement your assertion with examples.
General benefits of an internship Adaptability Loyalty Professionalism Strong Self – Confidence Strong Work Ethics
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Self – Motivated Honesty and Integrity Motivated to Grow & Learn Possessing a Positive Attitude. Dependability and Responsibility Developing sense of entrepreneurship
ConclusionDuring internship period we tried to work and learn some of the duties and tasks in repair and service shop.
We have acquired adequate knowledge about the mechanics of automobile, its systems and sub-systems in a simplified manner.
We have also dealt with the essential construction and principles of operation of various components as a part of total vehicle system.
Moreover, we tried to grasp basic knowledge and skill that are necessary and sufficient to maintain and provide service for modern automobiles.
The design of workshop cleaning mop is also an important component in this company and plans a key role in reducing and saving the time and energy loses of the workers in cleaning area.
The issue of cleaning machine has received considerable critical attention by all the staff in the company.
The design of this machine is at the heart of our understanding but the availability of resource and materials to develop this machine creates imperfection that we have faced.
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This made us desperate and nothing better to do, but without losing hope and by absorbing and digesting risks, problems and other frustrating conditions.
The machine is finally put into practice and shows now pathetic our efforts were.
Finally, at the last but not the least the spray holder is designed and put into effect during our time of working in body and paint workshop.
RecommendationWe 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.
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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
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.
