A REPORT

ON

SIX WEEK INDUSTRIAL TRAINING AT

GITA AUTOMOBILES

Submitted by
OM YADAV (19BAM1009)
in partial fulfillment for the award of the degree of

BACHELOR OF ENGINEERING
IN
AUTOMOBILE ENGINEERING

University Institute of Engineering

Chandigarh University

JUNE 2022
TRAINING CERTIFICATE

i
 DECLERATION

It is hereby certified that this

“Report on Industrial Training at Gita Automobiles.”

is an outcome of the 6 months internship I, Om Yadav have gone through at Gita Automobiles.

This is to confirm that this report is my original work. The facts presented in this report are from
various primary and secondary sources. I have given my full effort to complete and present this
report to declare completion of my industrial training for the partial fulfilment of my course
requirement for the degree of Bachelor in Automobile Engineering.

i
 ACKNOWLEDGMENT

The success and final outcome of this internship required a lot of guidance and
assistance
from many people and I am extremely privileged to have got this all along the
completion
of my internship. All that I have done is only due to such supervision and
assistance and I
will not forget to thank them.
The success and final outcome of this internship required a lot of guidance and
assistance
from many people and I am extremely privileged to have got this all along the
completion
of my internship. All that I have done is only due to such supervision and
assistance and I
will not forget to thank them.
The success and final outcome of this internship required a lot of guidance and
assistance
from many people and I am extremely privileged to have got this all along the
completion
of my internship. All that I have done is only due to such supervision and
assistance and I
will not forget to thank them.
The success and final outcome of this internship required a lot of guidance and
assistance
from many people and I am extremely privileged to have got this all along the
completion
of my internship. All that I have done is only due to such supervision and
assistance and I
will not forget to thank them.
The success and final outcome of this internship required a lot of guidance and assistance from
many people and I am extremely privileged to have got this all along the completion of my
internship. All I have done is only due to such supervision and assistance and I will not forget to
thank them.

I would like to thank management of Chandigarh University for providing me with resources to
attend this physical technical training at Gita Automobiles, which is anauthorized distributor of
Hero two-wheelers.

ii
 First, I would like to thank Mr. Dinesh Gaud Kahar, CEO,Gita Automobiles for giving me the
opportunity to do internship in his organization as well as Mr. Rakesh Chaudhary, Executive
Manager, Gita Automobiles.

I would also like to thanks all the people who worked along with me at Gita Automobileswith
their patience and openness, they created an enjoyable working atmosphere.

I would like to thank my friend Mr. Siddhartha Baral for making it happen to me to do internship
through paper work of mine by him at university level.

I would like to give my special thanks to Dr. Navdeep Sharma Dugala (HOD Automobile) and
Mr. Deepak Kapila (Academic coordinator) for guiding me to successfully complete this training
within given time frame, and also making me aware about advantages of such trainings.

ABSTRACT
This internship report serves the propose to record the details of our industrial
attachmentwhichwasconductedinGita Automobiles.ThesubsidiarycompanyofNGM Hero,
Nepal-anauthorizeddistributorofHero two-wheelersproducedbyHero Moto Corp, which
provides sales and after-sales services. This report will cover the details of my internship
of six-month duration which commence from 15 th January, 2023 to 30th July,2022.

The four years course of Bachelor in Automobile Engineering includes choice between
industrial training or physical class attend for four to six months at the end of the degree.
The main purpose of this attachment is to boost up practical knowledge and develop
iii
 professionalism within the students. During my internship period, I was assigned to
service department which helped me to acquire the information related to management
and service engineering. This helped me to gain knowledge on how to deal with
repair/general servicing of an automobile, customer satisfaction, fault diagnosis, and
managerial functions of a service advisor.

In conclusion, this was an opportunity to develop and enhance skills andcompetencies in

career field of an automobile engineer before graduation.

TABLE OF CONTENTS

DECLARATION i
ACKNOWLEDGEMENT ii
ABSTRACT iii
TABLE OF CONTENTSiv-v
LIST OF TABLESvi
LIST OF FIGURES vii
iv
1. INTRODUCTION 1-7
1.1 HISTORY OF COMPANY 1
1.2 COMPANY PROFILE 2-3
1.3 INTRODUCTION TO THE ORGANIZATION 3
1.4 ORGANIZATIONAL STRUCTURE 4
1.5 PRODUCTS AND SERVICES 5-7
2. METHODOLOGY 8
3. MANAGEMENT INFORMATION SYSTEM 9
4. PRODUCTION SYSTEM DESIGN 10-13
4.1 LOCATION ANALYSIS 10
4.2 PLANT BUILDING 10
4.3 PLANT LAYOUT 11
4.4 MATERIAL HANDLING EQUIPMENT 12-13
5. SERVICE PLANNING AND CONTROL 14-15
5.1 SERVICES 14
5.2 ROUTING 14
5.3 SCHEDULING 14-15
6. INVENTORY CONTROL 16-17
6.1 TECHNIQUES 16-17
6.2ANALYSIS 17
7. MATERIAL REQUIREMENTPLANNING 18
8. LOG SHEETS 19-28
9. DETAILS OF GENERAL SERVICING 29-35
9.1 PROCEDURES FOR ENGINE OIL CHANGE29
9.2 PROCEDURES FOR OIL FILTER CLEANING 30
9.3 PROCEDURES FOR AIR FILTER CLEANING 30
9.4 PROCEDURES FOR CLEANING SPARK PLUG 31
9.5 PROCEDURES FOR WASHING OF VEHICLE 31
9.6 BENEFITS OF HERO MOTOCORP GENUINE PARTS 31
9.7 CONSEQUENTIAL DAMAGES OF USING NON-GENUINE PARTS
32
9.8 JOBS APPLICABLE TO PEROIDIC SERVICES 33
9.9 BASIC TROUBLESHOOTING 34-35
10.WARRENTY DETAILS AND POLICY 36-37
10.1 SCOPE OF WARRENTY 37

v
 10.2 TERMS & CONDITIONS37
11.NEWS AND EVENTS 38-39
11.1 NEW YEAR 2079 OFFER 38
11.2 HERO ENGINE OIL DISCOUNT 38
11.3 DASSHAIN MELA OFFER 38
11.4 HERO MOTOCORP 10 YEARS PRESS RELEASE 39
11.5 HERO GLAMOUR PRESS RELEASE39
12.CASE STUDY 40-44
13.TEST DRIVE 45
14.RECOMMENDATION AND SUGGESTION 46
15.CONCLUSION 47
16.REFERENCES 48

LIST OF TABLES

Table No. Title Page No.

Table 5.1 Operations & their required time 15

Table 9.7 Consequential damages on using non-genuine parts 32

vi
 LIST OF FIGURES

Figure No. Title Page No.

Figure 1.1 Hero Moto Corp Logo 1

Figure 1.4 Organizational hierarchical of Gita Automobiles 4

Figure 1.5 Hero Scooter Products at Gita Automobiles 5

Figure 1.5 Hero Motorcycle Products at Gita Automobiles 6

vii
Figure 4.3 Plant layout of Gita Automobiles 11

Figure 4.4 Tool Box 12

Figure 9.1 Engine Oil Changing Process 29

Figure 9.2 Oil filter replacement/cleaning process 30

Figure 9.3 Air filter replacement/cleaning process 30

Figure 9.4 Spark plug cleaning/ replacement process 31

Figure 9.9.1 Basic Troubleshooting (A) 34

Figure 9.9.1 Basic Troubleshooting (B) 35

Figure 10.1 Warranty Policy 36

Figure 11.1 New Year 2079 Offer 38

Figure 11.2 Hero Engine Oil Discount 38

Figure 11.3 Dashain Mela Offer 38

Figure 11.4 Hero MotoCorp 10 Years Press Release 39

Figure 11.5 Hero Glamour Press Release 39

Figure 12.1 Stripped drain plug bolt 40

Figure 12.2 Clutch Plate change of Hero Super Splendor 41

Figure 12.3 Battery Problem of Hero Pleasure 43

Figure 13.1: Final test drive 45

Figure 15.1 Some Stock Photograph at Gita Automobiles 47

viii
 CHAPTER-1: INTRODUCTION

1.1 HISTORY OF COMPANY

Hero MotoCorp is the World's single largest two-wheeler motorcycle company.

Honda Motor Company of Japan and the Hero Group entered a joint venture to setup
Hero Honda Motors Limited in 1984. The joint venture between India's Hero Group
and Honda Motor Company, Japan has not only created the world's single largest two-
wheeler company but also one of the most successful joint ventures worldwide. Hero
MotoCorp Ltd. formerly known as Hero Honda is world’s largest Two-Wheeler
company having its registered office in India. The company started with a joint
venture between
the Japanese Two-Wheeler manufacturing company Honda in 1984, but in 2010
Honda decided to move out and Hero Cycle bought their shares and became a new
independent identity. The new company which was renamed Hero MotoCorp in
August 2011 is now the world’s largest manufacturer of two – wheelers. The
company has been working intelligently and trying to utilise every opportunity to
promote its new brand identity. The Company started with a vision of empowering
India by its bikes and making it a mobile and much more empowered country by
taking it to global market with its world class bikes. In the 1980‟s Hero Honda
introduced low cost- and fuel-efficient bikes in India. The Japanese technology which
came from their Japanese partner “Honda” in the Hero motorcyclesmade it a huge hit
in Indian market. The company continued to use the same technology till theyparted
ways with Honda. The company offers wide range of two wheelers including
motorcyclesand scooters.With its three manufacturing plants located at Haridwar,
Gurgaon and Dharuhera, Herochurns out approx. 3 million bikes in a year. Not only
in manufacturing the company is a real“hero” in customer service also with a huge
network of about 3000 dealerships and service centers across India.

Figure 1.1: Hero Moto Corp Logo

1
1.2 COMPANY PROFILE

Hero MotoCorp Ltd. (Formerly Hero Honda Motors Ltd.) is the world's largest
manufacturer of two – wheelers, based in India. In 2001, the company achieved the
coveted position of being the largest two-wheeler manufacturing Company in India
and also, the „World No.1‟ two-wheeler Company in terms of unit volume sales in a
calendar year. Hero MotoCorp Ltd. continues to maintain this position till date.

Vision
The story began with a simple vision – the vision of a mobile and an empowered
India, powered by its bikes. Hero MotoCorp Ltd., company’s new identity, reflects its
commitment towards providing world class mobility solutions with renewed focus on
expanding company’s footprint in the global arena.

Mission
Hero MotoCorp’s mission is to become a global enterprise fulfilling its customers‟
needs andaspirations for mobility, setting benchmarks in technology, styling and
quality so that it convertsits customers into its brand advocates. The Company will
provide an engaging environment forits people to perform to their true potential. It
will continue its focus on value creation andenduring relationships with its partners.

Strategy
Hero MotoCorp’s key strategies are to build a robust product portfolio across
categories, exploregrowth opportunities globally, continuously improve its
operational efficiency, aggressivelyexpand its reach to customers, continue to invest
in brand building activities and ensure customerand shareholder delight.

Manufacturing
Hero Honda bikes are manufactured across three globally benchmarked
manufacturing facilities.Two of these are based at Gurgaon and Dharuhera which are
located in the state of Haryana innorthern India. The third and the latest
manufacturing plant is based at Haridwar, in the hill stateof Uttarakhand.

Technology
In the 1980‟s the Company pioneered the introduction of fuel-efficient, environment
friendlyfour-stroke motorcycles in the country. It became the first Company to launch
the Fuel Injection(FI) technology in Indian motorcycles, with the launch of the
Glamour FI in June 2006.Its plants use world class equipment and processes and have
become a benchmark in leannessand productivity. Hero MotoCorp, in its endeavor to
remain technology pioneer, will continue toinnovate and develop cutting edge
products and processes.

Products
Hero Honda's product range includes variety of motorcycles that have set the industry
standardsacross all the market segments. The Company also started manufacturing

2
 scooter in 2005. HeroHonda offers large no. of products and caters to wide variety of
requirements across all thesegments.

Distribution
The Company’s growth in the two-wheeler market in India is the result of an intrinsic
ability toincrease reach in new geographies and growth markets. Hero MotoCorp’s
extensive sales andservice network now spans over to 5000 customer touch points.
These comprise a mix ofauthorized dealerships, Service & Spare Parts outlets, and
dealer-appointed outlets across thecountry.

Brand
The new Hero is rising and is poised to shine on the global arena. Company’s new
identity“Hero MotoCorp Ltd.” Is truly reflective of its vision to strengthen focus on
mobility andtechnology and creating global footprint. Building and promoting new
brand identity will be central to all its initiatives, utilizing every opportunity and
leveraging its strong presence across sports, entertainment and ground- level
activation.

1.3 INTRODUCTION TO THE ORGANIZATION

Gita Automobiles, located in Ramgram-5, Parasi (Bypass Road), Nawalparasi, is an

authorized distributor agency owned by the vibrant CEO, Mr. Dinesh Gaud Kahar.
The agency is a private firm registered business owned by Mr. Dinesh Gaud Kahar in
the name of his beloved wife Mrs. Gita Kahar.

Hero Moto Corp is oneof theleadingAutomobilecompanies (Two-wheelers brand)

inNepal.Ithasadealernetworkspannedacrossthe country and has been catering to the
need of various customer segments. Mrs. Gita Kahar holds the Chief Operation
Officer position in thecompany. Gita Automobiles has a wholly-owned subsidiary
company named as Gita Automobiles Pvt. Ltd. offers both sales and after-sales
services of Hero motorcycle & scooter along with distribution all over the
country.Gita AutomobileshasbeenimportingHero two-wheelers of various models &
specifications in Nepal through NGM Pvt. Ltd. (Nepal General Marketing Private
Limited) as well as responsible for after-salesservices.

Gita Automobiles is an automobile firm which has been successful in providing new
experience for customers with its excellence services. It has been observed that it is a
trusted company for two-wheeler.

3
1.4 ORGANIZATIONAL STRUCTURE

Gita Automobiles follows a hierarchical organizational structure, also known as line

structure.Herethechainofcommandflowsdownfromthechairman/CEOtoCOOand
through COO rest of the company from top to bottom. This makes the organizational
structure of Gita Automobiles a centralized organizationalstructure.

CEO

COO

Manager

Sales Service Accounts

Sales Service S
Officer Manager,
Advisor &
Office
Mechanics
Assistant

Figure 1.4: Organizational hierarchical of Gita Automobiles

4
1.5 PRODUCTS AND SERVICES

Gita Automobilesdealswiththeproductsof Hero two-wheelers.Itimportstwo wheelers

fromNGM(Nepal General Marketing Private Limited), Nepal & NGM purchases from
Hero Moto Corp, Indiaandprovidesthese inNepalitwo-wheelers markets.Gita
Automobiles predominantly import motorcycle, scooter and their spare parts etc. as
per demand of market. The available products of Hero at Gita Automobiles are
shown in the tablebelow:

Figure 1.5: Hero Scooter Products at Gita Automobiles

5
 Figure 1.5: Hero Motorcycle Products at Gita Automobiles

Gita Automobiles is an authorized distributor which provides dealerships of Hero to

dealers over all Nepal. Each dealer and the distributor have a service workshop for
repair and general servicing and they do after-salesfunction too.

Services offered by Gita Automobilesare:

a) Sale of Hero motorcycle and scooter of different specification and model.

b) General Servicing which includes replacement of Engine Oil, Air Filter&
drain plug washer.Firstly, generalservicingisdoneevery500-750 km. or in1
month. Then after, interval of 3000-3500 km. or every 3 months.
c) Fault diagnosis using physical checking of parts and test drive for inspection.

d) Spare parts replacement. Spare parts are classified in the workshopas:

 Fast Moving parts: drain plug washer, engine oil, air filter, brake and
clutch wireetc.

6
  Medium moving parts: lights, i3s switch, brake shoeetc.
 Slow-moving parts: Clutch plates, gears, housingetc.
e) Dent, paint, andwash.

7
 CHAPTER-2:METHODOLOGY

For the completion of this report, I carried out all the direct and indirect methods
and have come to a point where I have sufficient ideas regarding organizational
structure, personal management, inventory control, public relation, motivation and
workshop operation process. Some of the highlighted methods are:

a) Observation:
Observation has been a key method for the attainment of technical knowledge
regarding workshop operation. Internship at Gita Automobiles gage me a 6
months hand experience in automotive (two wheelers) field and I can now
map the bridge between our theoretical and practical knowledge.

b) Participation:
After the first day of observation, I was introduced with staff members as well
as allowed to work with vehicles for general servicing and was given
relatively simple tasks. Participation in the repair, general servicing &
diagnostics, master service schedule participation helped me a lot regarding
data acquisition as well as hand on practice skill.

8
 CHAPTER-3: MANAGEMENT INFORMATION SYSTEM
Gita Automobiles uses multiple software for the information flow. The use of
computer software for inventory control, data collection, part number extraction,
and spare parts availability for import are the major management information
system used in Gita Automobiles. It helps the company to run its daily activities
effectively. MS Excel is used for inventory control. The data of the store is stored
in the database and shared network which lists the number of products left in the
store. MS Excel and Google Sheet is used for vehicle entry details which stored the
vehicle model, name of the owner, number plate, and phone number of the client.
These are also used for booking the vehicle for servicing and repair.
For the proper schedule of servicing, NGM Connectis used. It is useful for
checking the status of service schedule for a particular bike or scooter.Spare parts
are required for replacement purpose is imported from NGM Hero, Kathmandu
with its unique part number.
The data available in above mentioned software collectively help to run the
management of Gita Automobiles effectively.

9
 CHAPTER-4: PRODUCTION SYSTEM DESIGN
4.1LOCATION ANALYSIS
Gita Automobiles Pvt. Ltd., located in Ramgram-5, Parasi (Bypass Road),
Nawalparasi. It is situated on eastern side of Bhairahawa-Bhumahi Highway near
Parasi vegetable market at the bank of Jharahi river. The headquarter or workshop
is very centered and is accessible to all the clients. Other required facilities like
hospital, vegetable market, petrol pump, pharmacy, etc. are within proximity to the
workshop thereby giving rise to the establishment of a that operates with the
welding and lathe. Thus, the outsourcing of the operations, which couldn’t be
performed in the workshop due to space, machine, and manpower limitation is
easier and lesstime-consuming.
With easily accessible location, relatively time-consuming and tedious processes
like spare part procurement, employee commute distance are very well managed.
The workshop lies beside the national highway, so can be easily reach by everyone
whether for employee and customer. The desired service such as restaurant, medical, recreation
center, park etc. can be reach within few minutes from office.

4.2PLANT BUILDING
To facilitate expansion, efficient material handling, flexibility, and use of natural light
and ventilation the plant building of Gita Automobiles is a single-storied horizontal
type.Theworkshopofthistypecannotbeconstructedinotherpatternsastheoperations to be
performed are heavy duty. Accounts and administrative sections are also incorporated
in the same pattern as this section occupies very less space compared to other general
servicing and repairoperations.

Some of the factors like the high cost of land have to be tackled while carrying out
workshopoperationasthereisnowayaroundandanotherpatternseemstooineffective.

10
4.3PLANT LAYOUT
Gita Automobiles deals with after-sales service of Hero two-wheelers and their
spares, repair and general
servicingareamajorfunctionoftheplant.Forthis,theplantisdividedintodifferent sections
as repair and general servicing section, washing section, dent/paint section, and
account and administrativesection.

1 15 14 13 12 11
2

16
10

3 4 5 6 7 8 9

Figure 4.3: Plant layout of Gita Automobiles

1. Exhibition area
2. Reception
3. Customer waiting room
4. Account section
5. Sales section
6. Service engineer room
7. Manager room
8. Store keeper room
9. Spare parts store
10. Toilet
11. Service area
12. Kitchen
13. Washing section
14. Dent/paint & Welding area
15. Mechanic room
16. Product display area

11
4.4MATERIAL HANDLINGEQUIPMENT

Different material handling equipment is used through the workshop that greatly
simplifies the work to the level where far less effort is required. Gita Automobiles
make the use of various material handling equipment like pneumatic guns,
hydraulic jacks, etc. Various material handling equipment are listed below:
1. Lift

To lift a vehicle to workable height different types of lifting mechanisms are

incorporated, the different types of lifts usedare:

i. Hydraulic washinglift:
Washing lift is used for washing purpose and is driven completely by
hydraulic system coupled to hydrauliccompressor.

ii. Hydraulicjack:
Hydraulicjackisaportablecompactliftingdevice.Ithasacapacitytoliftup to
2tons.

2. Toolbox

It contains all the tools to fasten and tighten all the nuts and bolts such as
wrenches, ratchet wrench, screwdrivers, sockets, extensions, Allen keys,
andpliers.

Figure 4.4: Tool Box

3. Impactgun

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 Pneumaticallydrivenhigh-speed high torque motor which rotates the socket
that acts upon nuts and bolt to fasten and tighten the nuts andbolts.
4. Aircompressor
It is a reciprocating compressor that is used to run pneumatic devices, for
drying purposes,runspraydevices,andinflatesatire.Itspressurerangesfrom0.5to10bar.

5. WashingPump
Itisusedtopressurizethewaterforthewashingprocessinthewashingbay.Its pressure is
about 12 -7 bar when used with a washingnozzle.

6. Tireinflator
Itisusedtocorrectlymeasureandinflatetirepressure.Whenpressureisset,thedevice
automatically inflates the tire using closed-loopfeedback.

7. Specialized tools andequipment

Toolslikeatorquewrench,feelergauge,grinder,tablevice,andscrewjackareusedfor
specializedoperation.

13
 CHAPTER-5: SERVICE PLANNING AND CONTROL

5.1 SERVICES

Gita Automobiles is a service sector that deals with the sales & after-sales service
of Hero two-wheelers. Vehicle general servicing and repair are the services of the
organization. From general servicingtoanyoftheaccidental repair,every aspect of
the vehicle problem is resolved. Gita Automobiles deals with sale and services
only and the production isn’t done in-house rather the genuine spare parts are
imported through national Hero dealer - NGM based in Kathmandu, Nepal and
the assembly of the parts, lubricants, and other fluids are replaced as per the
service manual as a measure for qualitycontrol.

5.2 ROUTING

Vehicles undergoing general servicing and repair will move on a certain path to
carry out overall effective operations. The routing procedure is as:
a) Vehicle conditionanalysis
b) Job cardpreparation
c) Vehicle partsrequirement
d) Jobassignment
e) Machines and toolsrequirement
f) Time required for eachoperation
g) Test drive and finalinspection

5.3 SCHEDULING

The time required to perform each operation is predetermined at Gita

Automobiles such that the effective time utilization is achieved and the delay
period is greatly reduced. For instance, the time is taken for general servicing and
brake inspection, and brake pad overhaul is set such that the number of vehicles
in queue for a day can be determined.
For general servicing, brake pad overhaul and washing operation the time
requiredare:

14
 Table 5.1: Operations & Their required time

Operations Time
required(minutes)

Job card preparation (A) 5

Air filter clean (B) 5

Engine oil, engine oil filter 10

change (C)
Brake shoe inspection and 15
change (D)
Washing (E) 20

For drying (F) 30

15
 CHAPTER-6: INVENTORYCONTROL
Inventory in the case of Gita Automobiles is basically a list of spare parts, tools and
machines that directly aids in the organizational goal of general servicing and repair
of Hero two-wheelers. Inventory control deals with the amount of stock that needs to
be maintainedtoruntheworkshopatoptimumcapacityatamosteconomicrate.Toattain the
goal of optimum inventory, control the techniques and analysis are carried out, which
are asfollows:

6.1 TECHNIQUES

The spare parts procurement process is very scientific and authentic from the
manufacturer. Only genuine spare parts are procured. When the parts number is
dispatched from the software, the inventory status on the vendor side is obtained and
can be ordered then. Hero Moto Corp Limited, New Delhi, Indiais the vendor itself
which is the manufacturer in
India.Inventoryisclassifiedbasedonthedemandforthepartsandaccordingly,the order is
placed. The inventory typesare:
a) Fast movinginventory:
The parts of utmost demand which are required in every servicing are
classifiedasfast-movinginventory.Engineoil,lubricatingoil filter, and drain
bolt washer are classified as fast-movinginventory.

b) Slow movinginventory:
The parts which are changed periodically are classified as slow-moving
inventory.Engineairfilter,brakepad, clutch plate etc. are classified as slow-
movinginventory.

c) Very slow-movinginventory:
The parts which are rarely used and are ordered only upon the client s
requirement are classified as very slow-moving inventory. Engine
componentsandgearboxcomponentsareclassifiedasveryslow-moving
inventory.

The modes of shipment of the parts are:

a) Air shipment
Airshipmentsofthepartsareonlycarriedoutwhentheclientsarewillingto pay
charges in the expense of the time delay. Parts arrive in 5-10 days if parts
are readilyavailable.

16
 b) Containershipment
Container shipments of the parts are generally carried out in bulk and are
thus more economic. For most of the part, container shipment is
carriedout. Parts and lubricants arrive in between 1 to 2 months.

The modes of payment for the procurement of the inventory are:

a) Telegraphic Transfer (T/T mode ofpayment)
Advance form of payment to the vendor which builds up strong commitment, and
improves vendor vendeerelationship.

b) Letter of credit (LC mode ofpayment)

Letter of credit is a form of bank guarantee that the vendor can rely on for the
shipment ofparts.

c) Demand Draft (DD mode of payment)

Demand draft is a form of payment in which cheque is issued in the name of
seller in which the mentioned amount gets collect by seller after delivery of parts
and products.

6.2 ANALYSIS

For the optimum inventory control ABC (Always Better Control) method is applied
where the inventory is classified into a different category based upon the monetary
value and demand. The inventory status is maintained such that the demand is
fulfilled in most economic conditions. For this the inventory classification is the same
as above:
a) Very slow-moving inventory(A)
b) Slow moving inventory(B)
c) Fast moving inventory(C)

17
 CHAPTER-7: MATERIAL REQUIREMENTPLANNING
MaterialrequirementplanninginthecaseofGita Automobilesdealswiththemaster service
schedule, bill of material, and inventory status file. Forecasting plays an
importantroleinthematerialrequirementplanningprocess.Thenumberofpartsand
lubricants(materialinthiscase)ultimatelydependsuponinventorylevelanddemand.

Approach
a) Master serviceschedule
Master Service schedule isrecorded in sheets according to the client's
booking and the materials inventory is planned accordingly based uponit.

b) Bill ofmaterials
Billofmaterialsdealswiththequantityofamaterialthatcanfulfillaservice
demand. Vehicle description, and materials to be used are all obtained
from the master service schedule and the quantity is plannedaccordingly.

c) Inventory statusfile
Minimum inventory is to be maintained at all-time considering the order
delay and lead time. For this the inventory is observed on a daily basis and
necessary order is placed.

18
 CHAPTER-8: LOGSHEETS
Log sheet of Month of Magh

(15th Jan to 18th Feb)

Week 1

Day of Date in Date in No. of Description of the day Remarks

the AD BS Hours
Week
Sunday 15th Jan, 1st Magh, -  Makar Sankranti Festival
2023 2079 holiday

Monday 16th Jan, 2nd Magh, -  Plane crash in National

2023 2079 Pokhara holiday

Tuesday 17th Jan, 3rd Magh, 8  Introduction to staff -

2023 2079 members

Wednesda 18th Jan, 4th Magh, 8  Store introduction & -

y 2023 2079 job assigned

Thursday 19th Jan, 5th Magh, 8  Store management -

2023 2079

Friday 20th Jan, 6th Magh, 8  Parts counting & -

2023 2079 entry

Saturday 21st Jan, 7th Magh, - - National

2023 2079 holiday

19
Week 2

Day of Date in Date in No. of Description of the day Remarks

the AD BS Hour
Week
Sunday 22nd Jan, 8th Magh, -  Servicing of 6 -
2023 2079 Super splendor

Monday 23rd Jan, 9th Magh, -  Clutch lever change -

2023 2079  Servicing of
splendor plus
Tuesday 24th Jan, 10th Magh, 8  Report writing -
2023 2079 started

Wednesda 25th Jan, 11th Magh, 8  Cleaning of store & -

y 2023 2079 workshop area done

Thursday 26th Jan, 12th Magh, 8  Field visits to -

2023 2079 collect money

Friday 27th Jan, 13th Magh, 8  Field visits for -

2023 2079 chamber broken
bike
Saturday 28th Jan, 14th Magh, - - National
2023 2079 holiday

Week 3
20
 Day of Date in Date in No. of Description of the day Remarks
the AD BS Hour
Week
Sunday 29th Jan, 15th Magh, 8  Servicing of 3 super -
2023 2079 splendor & splendor
+
Monday 30th Jan, 16th Magh, -  Clutch plate change -
2023 2079  Engine loud noise
issue solved
Tuesday 31st Jan, 17th Magh, 8  Report writing -
2023 2079 continue with detail
collection
Wednesda 1st Feb, 18th Magh, 8  Maintenance of -
y 2023 2079 workshop area

Thursday 2nd Feb, 19th Magh, 8  Field visits to -

2023 2079 collect money

Friday 3rd Feb, 20th Magh, 8  Field visits to -

2023 2079 collect money

Saturday 4th Feb, 21st Magh, - - National

2023 2079 holiday

Week 4

21
 Day of Date in Date in No. of Description of the day Remarks
the AD BS Hour
Week
Sunday 5th Feb, 22nd Magh, -  Servicing of 9 -
2023 2079 Super splendor

Monday 6th Feb, 23rd Magh, -  Servicing of 4 -

2023 2079 splendor +

Tuesday 7th Feb, 24th Magh, 8  No work (free) -

2023 2079

Wednesda 8th Feb, 25th Magh, 8  Installation of new -

y 2023 2079 tools in workshop

Thursday 9th Feb, 26th Magh, 8  Field visits to -

2023 2079 collect money

Friday 10th Feb, 27th Magh, 8  Field visits for -

2023 2079 money collection

Saturday 11th Feb, 28th Magh, - - National

2023 2079 holiday

Week 5

22
 Day of Date in Date in No. of Description of the day Remarks
the AD BS Hour
Week
Sunday 12th Feb, 29th Magh, -  Servicing of 6 -
2023 2079 Super splendor

Monday 13th Feb, 1st Falgun, -  Servicing of 2 HF -

2023 2079 deluxe & 3
Glamour
Tuesday 14th Feb, 2nd Falgun, 8  Servicing of 7 -
2023 2079 scooters

Wednesda 15th Feb, 3rd Falgun, 8  Stock management -

y 2023 2079 done at end of
month

Thursday 16th Feb, 4th Falgun, 8  Field visits for -

2023 2079 money collection

Friday 17th Feb, 5th Falgun, 8  Salary received -

2023 2079

Saturday 18th Feb, 6th Falgun, - - National

2023 2079 holiday

Monthly Progress Report or Log sheet of Month of Falgun

23
 (13th Feb to 16th Mar)

Week 1

Day of the Date Date in No. of Description of the day Remarks

Week in AD BS Hour
Monday 13th 1st 8  Servicing of 2 Super & 3 -
Feb, Falgun, Splendor plus
2023
2079

Tuesday 14th 2nd 8  Servicing of Hero Destini & -

Feb, Falgun, 2 Glamour
2023 2079

Wednesday 15th 3rd 8  Servicing of 6 Super & 3 -

Feb, Falgun, Splendor plus
2023
2079

Thursday 16th 4th 8  Servicing of 8 Super splendor -

Feb, Falgun,
2023
2079

Friday 17th 5th 8  Parts management -

Feb, Falgun,
2023
2079

Saturday 18th 6th - - National

Feb, Falgun, holiday
2023
2079

Week 2

24
 Day of the Date Date in No. of Description of the day Remarks
Week in AD BS Hour
Sunday 19th 7th Falgun, -  National Democracy Day National
Feb, holiday
2023 2079

Monday 20thFeb, 8thFalgun, -  Drain plug bolt seized -

2023 repair
2079  Servicing of 2 splendor
plus
Tuesday 21st 9th Falgun, -  Lhosar festival Festival
Feb, holiday
2023 2079

Wednesday 22nd 10th Falgun, 8  Cleaning of tools & -

Feb, machine in workshop area
2023 2079

Thursday 23rd 11th Falgun, 8  Field visit to collect -

Feb, money
2023 2079

Friday 24th 12th Falgun, 8  Field visits for Customer -

Feb, feedback
2023 2079

Saturday 25th 13th Falgun, - - National

Feb, holiday
2023 2079

Week 3

Day of the Date Date in No. of Description of the day Remarks

25
 Week in AD BS Hour
Sunday 26thFeb, 14thFalgun, 8  Servicing of 3 super -
2023 splendor & splendor +
2079

Monday 27thFeb, 15thFalgun, -  Clutch plate change -

2023  Engine loud noise issue s
2079

Tuesday 28th 16th Falgun, 8  Servicing of 7 scooters -

Feb,
2023 2079

Wednesday 1st Mar, 17th Falgun, 8  Maintenance of washing -

2023 area and lift
2079

Thursday 2nd 18th Falgun, 8  Field visits for customer -

Mar, feedback
2023 2079

Friday 3rd Mar, 19th Falgun, 8  Field visits to collect -

2023 money
2079

Saturday 4th Mar, 20th Falgun, - - National

2023 holiday
2079

Week 4

26
 Day of the Date Date in No. of Description of the day Remarks
Week in AD BS Hour
Sunday 5th 21stFalgun, -  Servicing of 9 Super -
Mar, splendor
2023 2079

Monday 6th 22nd Falgun, -  Terai Holi Festival

Mar, holiday
2023 2079

Tuesday 7th 23rd Falgun, 8  Pahad Holi Festival

Mar, holiday
2023 2079

Wednesday 8th 24th Falgun, 8  International women day holiday

Mar,
2023 2079

Thursday 9thMar, 25th Falgun, 8  Data entry of serviced -

2023 vehicle
2079

Friday 10thMa 26th Falgun, 8  Stock management -

r, 2023
2079

Saturday 11th 27th Falgun, - - National

Mar, holiday
2023 2079

Week 5

Day of the Date Date in No. of Description of the day Remarks

27
 Week in AD BS Hour
Sunday 12thMa 28thFalgun, -  Servicing of 15 Super -
r, 2023 splendor
2079

Monday 13th 29thFalgun, -  Servicing of 1 HF deluxe -

Mar, & 3 Glamour & 2 Super
2023 2079

Tuesday 14thMa 30th Falgun, 8  Monthly meeting in office -

r, 2023
2079

Wednesday 15thMa 1st Chaitra, 8  Documentation printing -

r, 2023 (job card, feedback form)
2079

Thursday 16th 2nd Chaitra, 8  Salary received -

Mar,
2023 2079

Friday 17th 3rdChaitra, 8  Accidental glamour -

Mar, inspection
2023 2079

Saturday 18th 4th Chaitra, - - National

Mar, holiday
2023 2079

CHAPTER-9: DETAILS OF GENERAL SERVICING

Description:

28
During the time frame of my internship, I dealt with numerous general
servicingservices.
Anautomobilemustbeservicedincertaintimeintervaloraftersomedistancetravelled to keep
it running. If one fails to execute the servicing, vehicle will certainly break down.
Servicing a vehicle is called preventive general servicing. It is carried out to restrain the
passenger from incurring physical loss and owner fromfinancial.

General Servicing:
Service checkup of Hero two-wheelers is mandatory once in 3 months or every 3000
kms., whichever comes first. General Servicing involves the following steps:
a) Replacement of Engine lubricating oil, Oil filter, and drain pluggasket and
washer.
b) Replace/cleaning of air filter.
c) Replacement/scrubbing of brakeshoe.
d) Replacement/cleaning of spark plug.
e) Replacement/cleaning of brake, clutch & accelerator wire.
f) Check for free play of brake and clutch lever.

9.1PROCEDURES FOR ENGINE OILCHANGE

a) Engine oil filler cap was removed usingpliers or hand.
b) Container is placed below drain plug and drain plug was removed to
drainold oil.
c) Drainplugwastheninstalledtothespecifiedtorquewithnewdrainpluggasket
/washer and then it was left for a minute to confirm it wasn’t leaking.
d) New engine oil (SAE 10W30 – Hero genuine engine oil) was refilled to
a specified amount and engine oil filler cap was installed.

Figure 9.1: Engine Oil Changing Process

9.2 PROCEDURES FOR OIL FILTER

REPLACEMENT/CLEANING
a) Remove the engine case cover.

29
 b) Use plier or hand to pull out oil filter.
c) Clean it with compressed air or replace it if broken.
d) Place it back into original position.
e) Apply engine case cover gasket before closing the opened section.

Figure 9.2: Oil filer replacement/cleaning process

After installing oil filter and changing oil, Engine was started for few minutes to
check forimproper fitting of air filter.

9.3 PROCEDURES FOR AIR CLEANER/FILTER CHANGING

a) Remove twomain screws of air filter case assembly.
b) Unscrew 5 to 6 screw from air filter covering.
c) Remove paper filter and clean net assembly of air filter
d) Place new air filter in case needed (only after 10000 kms or depends on
conditions).
e) Tighten all removed screws back to their place and check for sound.
f) Loose air filter makes more noise.

Figure 9.3: Air filter cleaning/replacement process

9.4 PROCEDURES FOR CLEANING/CHANGING SPARK PLUG

a) Clean dirt around the spark plug base.
b) Disconnect the noise suppressor cap and remove the spark plug
with the help of spark plug box wrench provided in the tool bag.

30
 c) Remove carbon content on the tip of electrodes.
d) If case is worse than replace with new one.

Figure 9.4: Spark plug cleaning/replacement process

9.5 PROCEDURES FOR CLEANING AND WASHING OF VEHICLE

a) Wet the vehicle with light water spray.
b) Avoiddirecting water to muffler outlets andelectrical parts.
c) Clean the headlamp lens and other plasticparts using a cloth or sponge
dampenedwith a solution of mild detergent and water.
d) Rub the soiled area gently rinsing itfrequently with fresh water.
e) After cleaning spray water thoroughly.
f) Dry the vehicle by wiping with dry soft cloth.

Conclusion:
All other procedures like top-up of gear oil, engine oil, oil filter, air filter etc. were
done as per the service manual. Proper caution and safety rules were followed while
performing repair/general servicingservices.

9.6 BENEFITS OF HERO MOTOCORP GENUINE SPARE PARTS

 Assures long life
 Ensures economy for a long time
 Safety of vehicle and rider
 Peace of mind
 Value for money
 Assured quality

9.7 CONSEQUENTIAL DAMAGES ON USING NON-GENUINE PARTS

Table 9.7: Consequential damages on using non-genuine parts

31
Clutch Plate  Material used is inferior
 Damages other parts of clutch like, clutch center and
outer clutch
 Affects fuel efficiency
 Poor acceleration
Cam Chain Kit  Poor performance
 Reduced life
Gasket Cylinder Head  Improper sealing
 Engine knocking
 Leads to leakage and smoky exhaust
 Higher emission level
Element Air Cleaner  Improper air filtration resulting in premature engine
failure
 Affects fuel efficiency
 Poor engine performance
Spark Plug  Frequent stalling of engine
 Higher emission level
 Poor engine performance
 Affects fuel efficiency
Chain Sprocket Kit  Noisy Operation
 Failure of chain can cause fatal accident

9.8 JOBS APPLICABLE TO PERIODIC SERVICES or GENERAL

SERVICING

 Wash the vehicle, blow dry with air.

 Inspect fuel line at every service.

32
  Inspect throttle free play and operation at every service, adjust if necessary.
 Clean carburetor at first service then every 6000 km, adjust if necessary.
 Clean air cleaner element at every service. Replace at every 10000 to 12000 kms.
 Inspect, clean spark plugs at every service, adjust if necessary (replace at every 10000
to 12000 kms).
 Inspect the valve clearance at every service, adjust if necessary.
 Replace engine oil or top up as per the maintenance schedule.
 Inspect electric starter operation at every service (optional).
 Inspect oil circulation at every service.
 Inspect, clean, lubricate and adjust the drive chain at every 2000 km.
 Inspect drive chain slider.
 Inspect battery voltage at every service and charge if required.
 Inspect battery electrolyte specific gravity and top up distilled water if required.
Check routing of overflow tube.
 Inspect brake shoe wear at every service, adjust if necessary.
 Clean brake drum and lubricate brake system (brake cam & brake pedal).
 Inspect all lamps, horn and switches at every service, adjust if necessary.
 Inspect headlamp focus at every service, adjust if necessary.
 Inspect clutch free play at every service, adjust if necessary.
 Lubricate the side stand and main stand at every service.
 Inspect whether i3s system is working properly (optional).
 Inspect all the fasteners and tighten to the specified torque (if required).
 Inspect wheels, wheel bearings and tyre pressure at every service.
 Inspect steering for smooth operation, adjust in every alternate service and lubricate at
every 12000 km.
 Inspect front suspension at every service, replace oil once in every 2 year or 30000
km whichever is earlier.
 Inspect rear suspension mounting bushes play, replace if necessary.
 Inspect the hoses for deterioration, damage or loose connections and canister for
cracks or other damages.
 Polish entire vehicle.

9.9 BASIC TROUBLESHOOTING

33
Figure 9.9.1: Basic Troubleshooting (A)

34
Figure 9.9.1: Basic Troubleshooting (B)

35
CHAPTER-10: WARRENTY DETAILS AND POLICY

Figure 10.1: Warranty Policy

36
10.1 SCOPE OF WARRANTY

Hero MotoCorp Ltd. (hereinafter called 'Hero MotoCorp') warrants its motorcycles and
scooters (hereinafter called 'Vehicles') assembled/manufactured in its Plants and sold through
its authorized dealers, to be free from any defect - both in material and workmanship, under
normal use and conditions, subject to the following terms & conditions.

10.2 TERMS & CONDITIONS

a) Hero MotoCorp warrants all its motorcycles for a period of 5 years or 70000 Km and
scooters for a period of 5 years or 50000 Km, whichever is earlier, from the date of
purchase.

b) It is mandatory to avail all free and paid services from the Hero MotoCorp's authorized
workshop(s) only, as per the recommended schedule, to be eligible for warranty benefits.
Each paid service should be availed within 90 days from the date of previous service or as per
the recommended schedule, whichever is earlier.

c) If any defect is observed in the vehicle, Hero MotoCorp's only obligation/ liability is to
repair or replace that part/ those parts which is/ are considered to be the cause of such defect,
provided however that such defect has not resulted due to misuse/ improper handling etc. of
the vehicle. Any vehicle needing repair should be brought along with Owner's Manual as well
as Owner's manual-supplementary to Hero MotoCorp's authorized workshop(s) for necessary
inspection and rectification job.

37
 CHAPTER-11: NEWS AND EVENTS

11.1 NEW YEAR 2079 OFFER 11.2 HERO ENGINE OIL DISCOUNT

Figure 11.1: New Year 2079 Offer

Figure 11.2: Hero Engine Oil Discount

11.3 DASHAIN MELA OFFER

38
 Figure 11.3: Dashain Mela Offer

11.4 HERO MOTOCORP 10 YEARS PRESS RELEASE

Figure 11.4: Hero MotoCorp 10 Years Press Release

11.5 HERO GLAMOUR PRESS RELEASE

39
 Figure 11.5: Hero Glamour Press Release

CHAPTER-12: CASE STUDY

CASE-1:

Figure 12.1: Stripped drain plug bolt

40
Statement of the problem: Stripped drain plug bolt.
Date: 20/02/2023
Vehicle/Model: Super Splendor
Diagnosis:
During regular general servicing of the vehicle, we found oil that had been
leaking from the bottom of chassis. The engine gets heated soon after start.

Findings:
After removing the drain plug, it was observed that the thread had worn out
quite a lot and had minute perforations through which oil was leaking. Due to presence
of least amount of engine oil in engine, the engine starts to heat right after start.

Solution:
The only solution to the problem was to remove the worn-out drain plug bolt and
refill engine oil.
The steps followed were:
a) The bike was put on double stand. A tray is put just below the drain plug bolt to
collect old engine oil
b) Worn drain plug is removed with help of chisel and hammer.
c) Old drain plug bolt is replaced with new one and new engine oil is also added.
d) After that, inspection for leakage is checked and issue is troubleshooted.

Root Cause:
The only possible cause to the problem was that the drain plug is opened by
mechanic with improper training and may be struck of it with the ground while driving.

Days Required: 1 hour

Conclusion:
The client was advised to check the vehicle on regular intervals so that fluid
leakage may see in initial stage.

CASE-2:

41
 Figure 12.2: Clutch Plate change of Hero Super Splendor
Statement of the problem: Clutch plate change of Hero Super Splendor.
Date: 27/02/2023
Vehicle/Model: Hero Super Splendor
Diagnosis:
There is a lag while changing gear. It feels that the engine takes a bit more
load than usual. It meant there was a major problem which could lead further damage
to the engine if not taken care of.

Findings:
After having a test drive of bike, it was clear that it had worn out clutch plates.
Due to this, the issue has arisen.

Solution:
There wasonly one solution to the problem; which is that we need to replace
clutch plates with genuine Hero clutch plates. We followed the procedure of changing
clutch plate.
The steps followed for the solution were:
a) Side housing was first removed so that it would be easier to remove clutch plates.
b) Clutch plate was then removed, with some difficulty by clutch plate removing

tools like .
c) After receiving the part, old seal and clutch plates were replaced and the clutch
plate was re-assembled.

42
Root cause:
Vehicle was fairly old and was used a lot which could have been the main
cause of the failure.

Days Required: 1 hour

Conclusion:
The customer was suggested to regularly check for leaks in the future and if
there were any leaks, the rear axle would have to be changed.

CASE-3:
Statement of the problem: Extra vibration of steering while driving.
Date: 10/03/2023
Vehicle/Model: Hero Glamour
Diagnosis:
The vehicle was driven around by the technicians and it was found that the
turning feels tight while steering as well as extra vibration is observed. There was a
problem in the steering main bolt due to which turning feels tight during steering and
suspension mounting bolt is slightly loose due to that there was a lot of vibrations.

Findings:
The main steering bolt is tight while suspension mounting bolt is loose. This
problem if not identified on time could have caused further damage to both driver and
vehicle itself.

Solution:
Main steering boltis loosened sightly while suspension mounting bolt is
tightened.

Root Cause:
Excessive rash driving and lack of regular checkup in time might have caused
the problem.

Days Required: 1 hours

Conclusion:
The client was advised to check and inspect steering right after repair.

CASE-4:

43
 Figure 12.3: Battery Problem of Hero Pleasure
Statement of problem: Battery problem of Hero Pleasure
Date: 18/03/2023
Vehicle/Model: Hero Pleasure scooter
Diagnosis:
The vehicle was taken to the office with the request that the self-starting was
not working.

Findings:
The battery was taken out and put at charging station. After some time, it is
again fitted to scooter but not functioning.

Solution:

The only solution to the problem was to change battery from the system and
replace with a new one.
The steps followed were:
a) The covering housing was removed and wirings are disconnected with help of
screwdriver.
b) New battery from store is taken to service area and replaced.
c) The setup was reassembled and everything was put back in place.

Root Cause:
The lifespan of battery is over.

Days Required: 1
Conclusion:
The client was advised to check the state of the battery even if such issue was
seen in early stage.

44
CHAPTER-13: TEST DRIVE

45
 Figure 13.1: Final test drive

Finally, test drive is done after the repairs are completed along with washing. The length
and distance of the drive usually based on the nature of repair that was done. Generally,
a test drive gives a technician a good idea about whether a vehicle is running at its
normal levels and if the repair was successful. The vehicle’s engine, brakes, turning
radius and other systems are checked carefully.
The things that are to be discerned during test drive are:
a) Atypical sounds from the engine.
b) Noise from brakes and clutch.
c) Check for electrical system.
d) Overall performance.

46
 CHAPTER-14: RECOMMENDATION AND SUGGESTION

Gita Automobiles has maintained their supremacy in their work till now. But there are
certain improvements that have to be made in order to enhance the efficiency.
The main aspects that can be focused on would be:
a) Addition of tools of the service center to facilitate more vehicles at once.
b) Improvement of method of repairing
c) Increase in skilled manpower to further enhance the efficiency,
d) Lunching of events such as service camp, seminar etc. time to time.
e) Providing door to door service to desired customer.
f) Giving training to workers and technician at least twice a year.

47
 CHAPTER-15: CONCLUSION

Figure 15.1: Some Stock Photograph at Gita Automobiles

The six-month period of job placement training at Gita Automobiles was very fruitful
for gaining technical knowledge. I had been learning all these things for four years but
never had proper chance to work in two-wheeler dealer. I was provided with a proper
learning platform by the organization and it was the most rewarding experience in my 4
years of study.
The work required me to have a hands-on experience in the workshop on a wide range
of vehicles. This has helped me garner knowledge on many different aspects of an
automobile which I know will further help me in my career.

48
 CHAPTER-16: REFERENCES

Authorized dealer & Service Centre: Gita Automobiles Pvt. Ltd.

Phone: +977-078590865, +977-9857046865
Email: gitaautomobiles2022@gmail.com
Dinesh Gaud Kahar (Owner) - +977 9857046865
Rakesh Chaudhary (Executive Manager) - +977 9804427248

49