15ME390L INDUSTRIAL TRAINING

A REPORT

Submitted by

MK VIGHNESH[RA16110020100216]
in submission for assessment and award
of Grade

BACHELOR OF TECHNOLOGY

IN
MECHANICAL ENGINEERING

Of

FACULTY OF ENGINEERING & TECHNOLOGY

S.R.M. Nagar, Kattankulathur, Kancheepuram District

MARCH 2019

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 SRM INSTITUTE OF SCIENCE AND TECHNOLOGY
(Under Section 3 of UGC Act, 1956)

BONAFIDE CERTIFICATE

Certified that this report titled 15ME390L INDUSTRIAL TRAINING is the

bonafide work of MK VIGHNESH who carried out the training

In FORD SERVICE CENTRE. Certified further, that to the best of my

knowledge the work reported herein does not form any other training report on

an earlier occasion on this or any other candidate.

SIGNATURE SIGNATURE

Dr.R.Santhanakrishnan Mr.I.Aatthisugan

FACULTY ADVISOR FACULTY IN CHARGE

MECHANICAL DEPARTMENT MECHANICAL DEPARTMENT

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 ACKNOWLEGEMENT

First of all, I would like to thank the almighty for the successful completion of
this Training.

I would like to thank HOD/Mechanical, School of Mechanical Engineering

SRM Institute of Science and Technology for allowing me to undergo training
in Industry of our interest pertaining to period of training not less than fifteen
days.

I would like to extend our gratitude to ALY FORD for giving an opportunity
to undergo training, which is one of the reputed organisations.

I place my gratefulness to all those department related people in the

organisation for disseminate their knowledge of experience and on task
functioning.

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 CONTENTS

CHAPTER NO. TITLE PAGE NO.

1. INTRODUCTION

1.1 ABOUT THE ORGANISATION 6

1.2 HISTORY 7
1.3 ENTRY IN THE INDIAN MARKET 8
1.3.1 FACILITIES
1.3.2 TRAINING COMPANY

2 DESCRIPTION OF TRAINING

2.1 OBJECTIVES OF TRAINING 9

2.2 SERVICE SCHEDULE FOR FORD 10

2.3 BASIC SERVICE 11

2.4 AUTOMOBILE PARTS 12

2.5 AUTOMOBILE TOOLS 14

2.6 CAR PAINTING AND WASHING 15

3 CONCLUSION 17

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 ABOUT THE ORAGANIZATION

The Ford Motor Company (commonly referred to simply as "Ford") is

an American multinational automaker headquartered in Dearborn, Michigan, a suburb
of Detroit. It was founded by Henry Ford and incorporated on June 16, 1903. The company
sells automobiles and commercial vehicles under the Ford brand and most luxury cars under
the Lincoln brand. Ford also owns Brazilian SUV manufacturer, Troller, and Australian
performance car manufacturer FPV. In the past, it has also produced tractors and automotive
components. Ford owns an 8% stake in Aston Martin of the United Kingdom, and a 49%
stake in Jiangling of China. It also has a number of joint-ventures, one in China (Changan
Ford), one in Taiwan (Ford Lio Ho), one in Thailand (Auto Alliance), one in Turkey (Ford
Otosan), and one in Russia (Ford Sollers). It is listed on the New York Stock Exchangeand is
controlled by the Ford family, although they have minority ownership (but majority of the
voting power).
Ford introduced methods for large-scale manufacturing of cars and large-scale management
of an industrial workforce using elaborately engineered manufacturing sequences typified by
moving assembly lines; by 1914, these methods were known around the world as Fordism.
Ford's former UK subsidiaries Jaguar and Land Rover, acquired in 1989 and 2000
respectively, were sold to Tata Motors in March 2008. Ford owned the Swedish
automaker Volvo from 1999 to 2010. In 2011, Ford discontinued the Mercury brand, under
which it had marketed entry-level luxury cars in the United States, Canada, Mexico, and the
Middle East since 1938.
During the financial crisis at the beginning of the 21st century, it was close to bankruptcy, but
it has since returned to profitability.
Ford is the second-largest U.S.-based automaker (preceded by General Motors) and the fifth-
largest in the world (behind Toyota, VW, Hyundai-Kia and General Motors) based on 2015
vehicle production. At the end of 2010, Ford was the fifth largest automaker in Europe. Ford
is the eighth-ranked overall American-based company in the 2010 Fortune 500 list, based on
global revenues in 2009 of $118.3 billion. In 2008, Ford produced 5.532 million
automobiles and employed about 213,000 employees at around 90 plants and facilities
worldwide.

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 HISTORY
Henry Ford's first attempt at a car company under his own name was the Henry Ford
Company on November 3, 1901, which became the Cadillac Motor Company on August 22,
1902, after Ford left with the rights to his name. The Ford Motor Company was launched in a
converted factory in 1903 with $28,000 in cash from twelve investors, most
notably John and Horace Dodge (who would later found their own car company). During its
early years, the company produced just a few cars a day at its factory on Mack Avenue and
later its factory on Piquette Avenue in Detroit, Michigan. Groups of two or three men worked
on each car, assembling it from parts made mostly by supplier companies contracting for
Ford. Within a decade, the company would lead the world in the expansion and refinement of
the assembly line concept, and Ford soon brought much of the part production in-house in
a vertical integration that seemed a better path for the era.
Henry Ford was 39 years old when he founded the Ford Motor Company, which would go on
to become one of the world's largest and most profitable companies. It has been in continuous
family control for over 100 years and is one of the largest family-controlled companies in the
world.
The first gasoline powered automobile had been created in 1885 by the German inventor Carl
Benz (Benz Patent-Motorwagen). More efficient production methods were needed to make
automobiles affordable for the middle class, to which Ford contributed by, for instance,
introducing the first moving assembly line in 1913 at the Ford factory in Highland Park.
Ford offered the Lifeguard safety package from 1956, which included such innovations as a
standard deep-dish steering wheel, optional front, and, for the first time in a car, rear
seatbelts, and an optional padded dash. Ford introduced child-proof door locks into its
products in 1957, and, in the same year, offered the first retractable hardtop on a mass-
produced six-seater car.
In late 1955, Ford established the Continental division as a separate luxury car division. This
division was responsible for the manufacture and sale of the famous Continental Mark II. At
the same time, the Edsel division was created to design and market that car starting with the
1958 model year. Due to limited sales of the Continental and the Edsel disaster, Ford merged
Lincoln, Mercury, and Edsel into "M-E-L," which reverted to "Lincoln-Mercury" after
Edsel's November 1959 demise.
The Ford Mustang was introduced in April, 17, 1964 during New York World's Fair. In 1965,
Ford introduced the seat belt reminder light.
With the 1980s, Ford introduced several highly successful vehicles around the world. During
the 1980s, Ford began using the advertising slogan, "Have you driven a Ford, lately?" to
introduce new customers to their brand and make their vehicles appear more modern. In 1990
and 1994 respectively, Ford also acquired Jaguar Cars and Aston Martin.During the mid- to
late 1990s, Ford continued to sell large numbers of vehicles, in a
booming American economy with a soaring stock market and low fuel prices.
With the dawn of the new century, legacy health care costs, higher fuel prices, and a faltering
economy led to falling market shares, declining sales, and diminished profit margins. Most of
the corporate profits came from financing consumer automobile loans through Ford Motor
Credit Company.

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 ENTRY IN THE INDIAN MARKET

Ford India Private Limited began production in 1926 as a subsidiary of the Ford Motor
Company of Canada, but was shut down in 1954 as the company was in loss. Ford re-entered
the market in October 1995 as Mahindra Ford India Limited (MFIL), a 50-50 joint venture
with Mahindra & Mahindra Limited. Ford increased its interest to 72% in March 1998 and
renamed the company Ford India Private Limited. The total investments made by Ford Motor
Company since it set shop in 1995 stands at $2 billion as of April 2012.

Ford India Private Limited is a wholly owned subsidiary of the Ford Motor
Company in India. Ford India Private Limited's headquarters are in Maraimalai
Nagar, Chennai, Tamil Nadu. It currently is the sixth largest car maker in India after Maruti
Suzuki, Hyundai, Tata, Mahindra.
.

FACILITIES
FIPL's main manufacturing plant located in Maraimalai Nagar, 45 km from Chennai has a
capacity to produce 150,000 cars on a two-shift basis and 200,000 with three shifts. In 2010-
11, the company's production crossed the 100,000 mark.
As its new hatchback Figo was launched in March 2010, Ford Motor Company has invested
$500 million to double capacity of the plant to 200,000 vehicles annually and setting up a
facility to make 250,000 engines annually. The engine plant opened for operations in January
2010.
To meet the growing domestic demand and with an eye on engine exports, the company has
invested $72 million to raise engine production capacity to 330,000 units.
The company is rolling out the urban SUV Ford EcoSport in June 2013. It had announced a
$142-million investment on this. With Ford EcoSport, the Chennai plant will ramp up to full
capacity (200,000 units). Last year, production touched 127,000 units.

TRAINING COMPANY

ALY FORD is the authorized dealer for Ford Cars India for Calicut, Chennai, Malappuram
and Palakkad districts .

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 OBJECTIVES OF TRAINING

 Understand the various types of service that a Ford car goes through in a

work shop.

 Understand the job allocation to various technicians in the workshop.

 To analyze the level of efficiency and productivity of technicians.

 Study about basic service.

 Study on car parts (engines, doors etc.).

 Study of repair on cars that has been in an accident.

 Understanding various tools.

 Basic painting and washing.

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 SERVICE SCHEDULE FOR FORD
Ford has 3 free services

1st service comes at 2500 Kms or 3 month

2nd service at 10000 Kms or 12 Month

3rd service at 20,000 Kms or 24 Month

Here is the detail of service plan for Ford Figo.

Ford FigoPetrol Ford Figo Diesel

Engine Oil 10,000 Kms or 12 months 10,000 Kms or 12 months

To be replaced when To be replaced when Engine

Oil Filter
Engine Oil is replaced Oil is replaced
Ford WSS-M2C913-C
Engine Oil Type Ford WSS-M2C913-C

To be replaced every 60000 To be replaced every 30000

Fuel Filter
Kms Kms
Every 20000 Kms. Cleaning Every20,000 Kms. Cleaning
Air Filter
in every service in every Service
Ideally Every 40000 Kms or Ideally Every 40000 Kms or
Cabin AC Pollen Filter
48 month 48 month
To be replaced every 40000 To be replaced every 40000
Spark Plug
Kms Kms
Brake Fluid, Clutch Fluid Every 20000 km Every 20000 km
Every 90000 km or 108 Every 90000 km or 108
Coolant
months months
Wheel Alignment &
Every 10,000 Kms Every 10,000 Kms
Balancing
Tyre Rotation Every 10,000 Kms Every 10,000 Kms

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BASIC SERVICE
The actual schedule of car maintenance varies depending on the year, make, and model of a
car, its driving conditions and driver behaviour. The car service must be booked before
bringing the car for service. The service provider will let you know when to bring the car.
Ford uses software called FordEtis. FordEtis lets the dealer know everything about the
customer’s car. When a car is reaching service period, the dealer calls the customer and
informs him. When the customer brings the car for service, the floor manager takes the car
and gives the car to a suitable mechanic. The floor manager knows the ideal person for a
particular job. After receiving the car, the mechanic marks the seat position and steering
height. The most basic services a car gets when it reaches is as follows

 Change the engine oil

 Replace the oil filter
 Replace the air filter
 Check level and refill brake fluid/clutch fluid
 Check Brake Pads/Liners, Brake Discs/Drums, and replace if worn out.
 Check level and refill power steering fluid
 Check level and refill Automatic/Manual Transmission Fluid
 Grease and lubricate components
 Inspect and replace the timing belt or timing chain if needed
 Check condition of the tires
 Check for proper operation of all lights, wipers etc.
 Wash the vehicle and clean the interiors.

Service depends on the condition of the car and the amount of km that it ran.

Engine oil -After 10k km engine oil must be changed, Ford uses a synthetic engine oil.
The cap on the engine is removed and the used oil is drained. New oil is then added.

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 Oil filter – An oil filter is a filter designed to remove contaminants from engine
oil, transmission oil, lubricating oil, or hydraulic oil. Oil filters are used in many different
types of hydraulic machinery.

Air filter – Air filter removes contaminants that comes from air.

Break fluid/clutch fluid – There is no separate brake or clutch fluid. It is a single

which serves both the purpose.

Water level – Water is refilled in the radiator and wiper fluid compartment.

Tire – Grip of the tire is checked. Air is filled in the tire. Wheel alignment is also
checked.

Brake pads – They are changed if worn out

AUTOMOBILE PARTS

PETROL ENGINE AND DIESEL ENGINE

The diesel engine (also known as a compression-ignition or CI engine), named after Rudolf
Diesel, is an internal combustion engine in which ignition of the fuel which is injected into
the combustion chamber is caused by the elevated temperature of the air in the cylinder due
to mechanical compression (adiabatic compression). Diesel engines work by compressing
only the air. This increases the air temperature inside the cylinder to such a high degree that
atomised diesel fuel that is injected into the combustion chamber ignites spontaneously. This
contrasts with spark-ignition engines such as a petrol engine (gasoline engine) or gas
engine (using a gaseous fuel as opposed to petrol), which use a spark plug to ignite an air-fuel
mixture. In diesel engines, glows plug (combustion chamber pre-warmers) may be used to aid
starting in cold weather, or when the engine uses a lower compression-ratio, or both. The
original diesel engine operates on the "constant petrol engine is an internal combustion
engine with spark-ignition, designed to run on petrol (gasoline) and similar volatile fuels.

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In most petrol engines, the fuel and air are usually mixed after compression (although some
modern petrol engines now use cylinder-direct petrol injection). The pre-mixing was formerly
done in a carburetor, but now it is done by electronically controlled fuel injection, except in
small engines where the cost/complication of electronics does not justify the added engine
efficiency. The process differs from a diesel engine in the method of mixing the fuel and air,
and in using spark plugs to initiate the combustion process. In a diesel engine, only air is
compressed (and therefore heated), and the fuel is injected into very hot air at the end of the
compression stroke, and self-ignites.

ssure" cycle of gradual combustion and produces no audible knock.

ANTI-LOCK BRAKING SYSTEM

An anti-lock braking system or anti-skid braking system (ABS) is an automobile

safety system that allows the wheels on a motor vehicle to maintain tractive contact with the
road surface according to driver inputs while braking, preventing the wheels from locking up
(ceasing rotation) and avoiding uncontrolled skidding. It is an automated system that uses the
principles of threshold braking and cadence braking which were practiced by skillful drivers
with previous generation braking systems. It does this at a much faster rate and with better
control than many drivers could manage.

ABS generally offers improved vehicle control and decreases stopping distances on dry and
slippery surfaces; however, on loose gravel or snow-covered surfaces, ABS can significantly
increase braking distance, although still improving vehicle steering control.

Since initial widespread use in production cars, anti-lock braking systems have been
improved considerably. Recent versions not only prevent wheel lock under braking, but also
electronically control the front-to-rear brake bias. This function, depending on its specific
capabilities and implementation, is known as electronic brake force.
distribution(EBD), traction control system emergency brake assist, or electronic stability
control (ESC).

EXHAUST SYSTEM

Internal combustion engines are often cooled by circulating a liquid called engine coolant
around the engine block, where it is heated, then through a radiator where it loses heat to the
atmosphere, and then returned to the engine. Engine coolant is usually water-based, but may
also be oil. It is common to employ a water pump to force the engine coolant to circulate, and

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also for an axial fan to force air through the radiator. An exhaust pipe must be carefully
designed to carry toxic and/or noxious gases away from the users of the machine.

AUTOMOTIVE EQUIPMENTS

Automotive equipment and tools are a very important part of the automobile industry. They
can range from simple hand held devices to large structures that can even lift a heavy truck.
The uses of these equipments in the world of automobiles cannot be undermined. For
carrying out repairs, for changing a tire, for lubricating, for servicing, for charging up the
battery, and for cleaning the vehicles, these equipments are very important.

Here Is A Brief Note On Some Of The Uses Of These Equipments.

Automobile Equipment Usage

* Automotive Lifts: Hydraulic lifts are very common in the industry and are used in
showrooms, repair shops, and automobile factories. They generally come in the form of a
platform fixed on a zigzag leg that can be raised or lowered as required. Heavy vehicles can
be raised by the use of this equipment. These are how cars reach the first or second floor of a
showroom or how the repairs to the lower part of vehicles are carried out in a mechanic's
shop. These lifts can be of different types like motorcycle lifts, runway lifts, drive on lifts, in-
ground lifts, etc.

* Lubrication Equipments: As the name suggests, these are used to lubricate parts of the
vehicle. There is a long list of lubrication equipments available and each is used for different
lubrication purposes. Oil and grease reels, grease guns, oil drains, and oil and grease pumps
are all examples of such commonly used equipment. Blacrank is a good brand when it comes
to these equipments. Blacrank oil pumps are indisputable masters of the group.

* Compressors: Air compressors are used to do various works on automobiles. Generally, air
compressors give additional pressure to drive in screws and give more power to tools like
wrenches and nail guns. These are also used to remove dirt from the vehicle.

* Service Equipments: A vehicle needs to be serviced from time to time to ensure its proper
running. This is where service equipments come in. These are battery chargers, fuel transfer
device, brake fluid exchangers, coolant service equipment, tire changers, etc.

* Reels: These come in different shapes and sizes and are an important member of any
automotive equipment list. Reels could be air reels, exhaust hose reels, grease reels, etc.
Reels help to keep the pipes and hoses in place and also to extend its life. They can be easily
reeled out to the required size and stored by reeling back.

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 CAR PAINTING AND WASHING

Car painters (refinishers) are responsible for reinstating the pre-accident paint finish to cars
after the structure and/or the panels have been repaired or replaced. They may also be asked
to completely repaint a whole vehicle either to change its colour or reinstate its newness. Car
painters may also become involved in matching colours to an original colour no longer
available or to colours that prove difficult to match. A car painter must match the colour,
shade and texture of the adjoining panels that are not being painted.

Car painters can work in various work environments from an auto body repair shop to an
aircraft hangar, dependent upon what vehicle or transport system they are painting. They
work to apply paints inside an enclosed spray booth/oven in order to protect the environment
from harmful products.

Car painters prepare panels or vehicles to receive paint. They may carry out minor panel
repairs and apply undercoats, colour coats and clear sealant coats which provide the high
gloss levels required. They may be required to identify a colour code using various methods,
mix the correct amount of colour to pre-determined formulae and spray test cards to test the
suitability of this colour match to the original colour and shade.

A Car painter needs to be aware of time schedules and may often be working on several
vehicles at one time while waiting for previously applied materials to dry.

Car painters (refinishers) may be required to refinish a wide range of items such as passenger
cars, racing cars, vintage and classic vehicles, commercial goods vehicles, trains, aeroplanes,
static structures or furniture. They may be required to refinish a wide variety of materials
such as metals, plastics, composite materials or wood.

While there are many types of car washes, most fall into the following categories:

 Hand car wash facilities, where the vehicle is washed by employees.

 Self-service facilities, which are generally coin-operated, where the customer does the
washing, including pressurized "jet washing".

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 In-bay automatics, consist of an automatic washing machine and dryer that rolls back and
forth over a stationary vehicle - often seen at filling stations and stand-alone wash sites.
 Tunnel washes, which use a conveyor to move the vehicle through a series of fixed
cleaning mechanisms.
 Chemical car wash, also known as waterless car wash, uses chemicals to wash and polish
car surface. Claims to be an eco-friendly car wash method. Recommended only for cars
with light dirt accumulation to avoid paint damage.
 Steam car washes use a jet of steam and micro fibre towels, some include detergent
injection. Known to have originated from South Korea, steam car washes have been
especially popular as a low-investment, eco-friendly car wash solution in Asia, Middle
East, and Europe thanks to its sanitizing features and mobility.
 Mobile car washes, often also serving as mobile detailing systems, which carry plastic
water tanks and use pressure washers. Sometimes these systems are mounted on trailers,
on trucks, or in vans. Generally these operators also have a generator to run a shop vac.,
buffers, and other tools as well.

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 CONCLUSION

This 15-day training in ALY FORD service centre has been a wonderful
educative experience for me. I was able to understand the major process in the
servicing and maintenance of various types of automobiles and its components,
and also I could learn the experience of working and atmosphere of such a well-
known industry. I am thankful to all those who helped me in this training and I
believe that this will enrich the engineer in me. During one semester training
period, a lot of experience, knowledge and exposure that I have handled. All
disclosure were awaken myself in a boost of self-confidence to face life more
challenging now. Practical is a compliment to the science or theory learned.
This is really the concept of science and charity was they have learned without
practice will be lost and will not give anything-what effect. So if we do without
the knowledge of course there will be problems in terms of grip and stance ever-
changing.

During my industrial training, there are many changes from the point of
learning environment and discussions among colleagues. It can directly increase
the dedication and rational attitude towards myself.

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