INTERNSHIP I REPORT

GOVERNMENT POLYTECHNIC COLLEGE PERIYA

KASARAGOD

INTERNSHIP I REPORT

Internship report submitted in partial fulfillment of the

requirements for the award of
Diploma in Mechanical Engineering
Under State Board of Technical Education, Kerala

Submitted by,

ABDUL RAFI
Reg.No:2201020001

Department of Mechanical Engineering

Government Polytechnic College Periya Kasaragod

2023

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GOVERNMENT POLYTECHNIC COLLEGE

PERIYA KASARAGOD
DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

Certified that the internship report is submitted by ABDUL RAFI bearing

Reg.No:2201020001 in partial fulfillment of the requirements for the award of Diploma in
Mechanical Engineering Under The State Board of Technical Education, Kerala during academic
year 2023-24. It is certified that all corrections/suggestions indicated for Internal Assessment have
been incorporated in the report deposited in the departmental library. The internship report has been
approved as it satisfies the academic requirements in respect of internship training for the said degree.

INTERNSHIP COORDINATOR HOD

Sri. GOPINATH P Sri. PRAJINLAL K P

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CERTIFICATE OF INTERNSHIP

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GOVERNMENT POLYTECHNIC COLLEGE KASARAGOD

Our Vision
To be an institute of global repute, moulding socially committed technicians and entrepreneurs
bringing sustainable development.

Our Mission
1. Provide value based quality technical education and training using state of the art
infrastructure, tools and methodologies.
2. Collaborate with industries and academic institutions, bridging the gap between curriculum
and latest industrial practices.
3. Promote co and extra- curricular activities, fostering leadership qualities, problem solving
skills and team spirit.
4. Create an ambience for career building, encourage life-long learning leading to self-actualization.

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DEPARTMENT OF MECHANICAL ENGINEERING

Vision

To Excel in mechanical engineering education moulding engineers and

entrepreneurs for the socio-economic upliftment of society.

Mission - To:

M1. Educate the students via state of art teaching-learning

process and Industry-Institute symbiosis.
M2. Enhance the leadership, innovation, and entrepreneurship
skills to make the students ready for industry.
M3. Enable the students to contribute for the development of
society, following universal human values.
M4. Encourage lifelong learning, consultancy, and
training for overall development.

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DEPARTMENT OF MECHANICAL ENGINEERING

PROGRAM EDUCATIONAL OBJECTIVES (PEOs)

To create engineers and entrepreneurs who will be able to:

PEO 1. Handle technological problems, provide unique

solutions, and satisfy customer needs.
PEO 2. Contribute to the emerging challenges faced by
industries and society following efficient
management practices.
PEO 3. Ethically stand for the well-being of the society and
the environment following universal human values.
PEO 4. Maintain a passion for updating, enriching, and sharing
knowledge.

PROGRAM SPECIFIC OUTCOMES (PSOs)

Students in the Mechanical Engineering Programme will be able to:

PSO 1. Apply the skills in operating advanced machine tools,

industrial maintenance, service and computerized
testing of IC engines.
PSO 2. Apply the skills for designing and
manufacturing innovative products using
modern CAD/CAM tools.
PSO 3. Apply entrepreneurship and management skills to
develop small - scale industry startups.

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DECLARATION

I, ABDUL RAFI [Reg. No.2201020001], student of III rd Semester Diploma in

Mechanical Engineering, Government Polytechnic College Periya Kasaragod hereby declare
that the internship report has been submitted by me in partial fulfillment of the requirements
for the award of Diploma in Mechanical Engineering Under The State Board of Technical
Education, Kerala during academic year 2023-2024.

DATE : NAME:ABDUL RAFI

PLACE :PERIYA REG. NO:2201020001

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ACKNOWLEDGEMENT

First I would like to thank Sri. ANWAR NASEEF, QUALITY MANAGER, NEXA Indus
Motors Kasaragod, Indiranagar for giving me the opportunity to do an internship within the
organization. I also would like all the people that worked along with me at NEXA Indus
Motors Kasaragod, Indiranagar with their patience and openness they created an enjoyable
working environment.
I would like to express my thanks to the Principal Sri. NARAYANA NAIK P for the
encouragement that motivated me for the successful completion of internship work.

It gives me immense pleasure to thank Sri. PRAJINLAL K P, Lecturer and Head of

Department for his constant support and encouragement.

I would also like to thank the Internship Coordinator Sri. GOPINATH P, Lecturer,
Department of Mechanical Engineering and all other teaching and non-teaching staff of
Mechanical Engineering Department who has directly or indirectly helped me in the
completion of the internship work.

Last, but not the least, I would hereby acknowledge and thank my parents who have been a
source of inspiration and also instrumental in the successful completion of the internship
work.

NAME :ABDUL RAFI

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ABSTRACT

NEXA is Maruti Suzuki’s premium sales channel. It marks the first initiative by an
automobile company to go beyond selling cars and create a differentiated retail experience
for its discerning customers. Launched in 2015, NEXA’s philosophy Create Inspire drives its
endeavor to create inspiring experiences through its premium cars, innovative technologies
and lifestyle experiences.

The importance of vehicles is an issue that cannot be overemphasized as the daily routine of
most individuals entails the interaction with vehicles to go about businesses and move people
and goods from one place to another. This implies that with the breakdown of vehicles, our
live sand businesses tend to experience a noticeable amount of stress compared to what it was
before the breakdown. This brings up the issue and ultimately the business of automotive
maintenance and repair. With the possibility of a breakdown on one’s mind, the menacing
topic of automotive maintenance cannot be taken with levity.

This usually comes in form of questions like when should a car be serviced? How are brake
pads fixed or removed? How often should a service operation be done on a vehicle? How can
problems be easily detected in a vehicle? Is it possible to detect faults in a vehicle by using a
compute?

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TABLE OF CONTENT

1. Acknowledgements…………….
4

2. Abstract……………………….
5

3. Table of contents……………...
6

4. Internship objectives………... 7

5. Weekly overview of internship activities… 8

6. Introduction………………… 11

1.1Origin of the Report…... 11

1.2. History of Nexa……… 11
1.3. Scope of Study..,……. 12

7. Company profile…………. 13

8. Internship Diary………… 14
3.1.Day wise activities………………. 14
3.2.Problem identified and solutions……… 20
3.3.Skills attained… …………….. 20

9. Recommendation & Conclusion……….. 24

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INTERNSHIP OBJECTIVES

Achieve knowledge in the practical field of an organization in order to make theoretical

knowledge to be more fruitful and realistic is called practical training or internship
.
 To make theoretical knowledge clear and exact.

 To increase the value of theoretical knowledge.

 To remove the limitations of theoretical knowledge.

 To get practical knowledge about the institution.

 For reporting practice.

 Identify the problems and put forward recommendations.

 To know about the present situation of the institutions.

 To expand the span of knowledge.

 To implement the knowledge of practical training in the practical life.

 To know how to solve managerial problems.

 To innovate new techniques of management.

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 To suggest some measures for the improvement of the profitability Position of an

organization.

WEEKLY OVERVIEW OF INTERNSHIP ACTIVITIES

DATE DAY NATURE OF WORK

16-05-2023 Tuesday Introduction of showroom

17-05-2023 Wednesday Introduction of tools and machines

Introduction of vehicle name’s and

18-05-2023 Thursday
models
WEEK 1

19-05-2023 Friday Introduction of main part of vehicle

20-05-2023 Saturday Holiday

21-05-2023 Sunday Holiday

22-05-2023 Monday Introduction of main part of engine

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DATE DAY NATURE OF WORK

23-05-2023 Tuesday Basic service details

24-05-2023 Wednesday To change the ac filter and coolant.

To change the brake fluid and battery

25-05-2023 Thursday
WEEK 2

water.

26-05-2023 Friday To change the oil and oil filter

27-05-2023 Saturday Holiday

28-05-2023 Sunday Holiday

Removing and installation of break

29-05-2023 Monday
pad

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DATE DAY NATURE OF WORK

30-05-2023 Tuesday To learn how to change front strut.

Removing and installation of

31-05-2023 Wednesday
bearings

01-06-2023 Thursday Introduction of wheel alignment

WEEK 3

02-06-2023 Friday Car washing after service

03-06-2023 Saturday Holiday

04-06-2023 Sunday Holiday

05-06-2023 Monday Training evaluation

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CHAPTER 1
INTRODUCTION

1.1 Origin of the Report :

This internship report on “Automotive Technology and Maintenance & Servicing of Nexa
Indus Motor” is prepared to fulfill the partial requirement of then internship program for the
Diploma in Mechanical Engineering Under The State Board of Technical Education. As a
student of Mechanical Engineering, I had to complete a three weeks internship with any
organization. I was assigned in nexa car showroom in Indiranagar, Kasaragod.

1.2 History of Nexa:

The Nexa is new automobile industry and a brand of Maruti Suzuki. NEXA is the major
initiative. The Company is reaching to new segments of customer into changing India.
During the years, Maruti Suzuki has relied on consumers feedback to introduce new products
according to the need of new feature. It was also the first to attend “solutions” to customers at
its dealerships. The next step is taking the lead in offering customers an new exclusive
automotive experience by introducing NEΧΑ.

Customer face to face feedback, surveys and questionnaire have shown there is appositive
increase in the segment of car buying Indians who desire and value personal care, attention in
their car buying and ownership experience. They want people, technology, showroom
ambience and processes to come together and offer them a “worm experience”.

Maruti Suzuki Nexa launched by the company in July 2015. It has emerged as third-largest
selling retail in the local vehicle market in less than three years of launch, trailing the parent’s

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regular sales channel (which clocked sales of 10,99,998 units) and rival Hyundai Motor
India’ distribution network (4,57,727 units) in terms of volume tillJan2019 The contribution
of Nexa automobiles to Maruti Suzuki’s overall sales volumes nearly doubled to 19.9% in the
period under review compared with 10.9% recorded in the last financial year. The company,
currently come with many cars like Ignis, premium hatchback Baleno, midsize, sedan Ciaz
cross-over utility vehicle S- Cross through the Nexa.

1.3 Scope of Study:

The study would focus on the following areas of automobile.

 Its body and its structural design.

 Its powertrain and amount of performance it can deliver.

 Its automotive technology and its electrical features.

 Its maintenance and servicing system.

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CHAPTER 2
COMPANY PROFILE

NEXA Car Showroom in Indiranagar, Kasaragod

Indus Motor Company is a certified NEXA car showroom at Indiranagar, Kasaragod. We

support the residents of Kasaragod by being a one-stop destination for the NEXA range of
sales, service, and spares that includes the luxurious NEXA range Ciaz, Ignis, Baleno, Grand
Vitara, and XL6.

We at Indus Motor Company, ensure the process of buying a car should be effortless and
hassle-free. We aspire for excellence; we are a luxury car showroom with modern equipment
and a committed team of professionals. We offer comfort, ease, and transparency in
paperwork in your car buying journey.

Create. Inspire. Come, experience a smooth, unique, and stress-free car-buying with Indus
Motor Company, a NEXA car showroom in Indiranagar, Kasaragod.

NEXA Indira Nagar

Indus Motor Company Pvt. Ltd.
Indira Nagar, Chengala P.O. ,
Kasaragod, Kerala-671541
Zubin.johney@indusnexa.com

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CHAPTER 3
INTERNSHIP DIARY

3.1 Day Wise Activities:

1.Introduction of showroom.

2.Introduction of tools and machines.

 12 Drawer Portable Workstation.
 Socket Accessories.
 Socket Sets.
 Reversible Ratcheting Spanner.
 Double Open End Spanners.
 Deep Offset Combination Spanners.
 Wheel Wrenches Double Ended.
 Double Face Plastic Mallet.
 Wheel Balancing Pliers.
 Slim Line Ratchet Handle.

3.Introduction of vehicle name’s and models.

 INVICTO.
 FRONX.

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 IGNIS.
 XL6.
 MARUTI GRAND VITARA.
 JIMNY.
 CIAZ.
 BALENO.

4.Introduction of main part of vehicle.

 Bonnet/hood.
 Car cover.
 Support stick.
 Hinges and springs.
 Bumper.
 Unexposed bumper.
 Exposed bumper.
 Cowl screen.
 Fender (wing or mudguard).
 Fascia.
 Grille (also called grill).
 Pillar and hard trim.
 Quarter panel.
 Radiator core support.
 Rocker.
 Roof rack.
 Spoiler.
 Front spoiler (air dam).
 Rear spoiler (wing).
 Rims.
 Hubcap.
 Tyre.
 Trunk/boot/hatch.
 Valance..

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 Welded assembly
 Door.
 Anti-intrusion bar.
 Outer door handle.
 Inner door handle.
 Window motor.
 Door latch.
 Door lock and power door locks.
 Central-locking.
 Fuel tank (or fuel filler) door.
 Windows.
 Glass.
 Sunroof.

5.Introduction of main part of engine.

 Cylinder block.
 Cylinders.
 Pistons.
 Crankshaft.
 Camshaft.
 Valves.
 Spark plugs.
 Fuel injectors.
 Gasket.
 Timing belt/chain.
 Oil pump.
 Cooling system.
 Air filter.
 Exhaust system.

6.Basic service details.

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 Refer to the Owner Manual.

 Keep a Check on the Tire Pressure.
 Change Oil and Oil Filter.
 Keep the Engine Clean.
 Look for a Faulty Spark Plug.
 Keep the Interiors Clean.
 Carry Out Battery Maintenance.
 Check the Brake Fluid.
 Maintain Fuel Economy.
 Replace the Cabin Air Filter.

7.To change the AC filter and coolant.

a)AC filter:

 Locate your filter.

 Turn off the AC unit.
 Pop open and remove the cover.
 Take out the old filter.
 Find the airflow direction.
 Insert the new filter.
 Replace the cover and turn the power back on.

b)Coolant:

 Ensure Your Engine is Off and Cooled Down.

 Take Off the Engine’s Radiator Cap.
 Drain the Old Coolant.
 Clean the Cooling system.
 Add New Coolant.
 Bleed the Cooling System.

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8.To change the brake fluid and battery water.

a)Brake fluid:

 Drain the old fluid.

 Change brake fluid.
 Flush the calipers/wheel cylinders.
 Bleed the brakes.
 Top-up.
 Repeat the process.

b)Battery water:

 Locate the Battery.

 Inspect the Battery.
 Add Distilled Water.
 Clean the Battery Terminals.
 Reattach the Battery.

9.To change the oil and oil filter.

 Raise the vehicle.

 Position catch pan and remove plug.
 Inspect vehicle while all oil drains.
 Reinstall drain plug and torque.
 Remove old oil filter.
 Clean mount and remove old O-ring.
 Lube new filter and attach by hand.
 Remove oil fill cap and add new oil.
 Replace oil fill cap and start engine.

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 Stop engine, lower vehicle, and check dipstick level.

10.Removing and installation of break pad.

 Remove the wheels.

 Unbolt and remove the caliper.
 Remove the old brake pads.
 Retract the pistons.
 Watch out for brake fluid leakage.
 Insert the new brake pads.
 Replace the brake caliper assembly.
 Reattach the wheel.

11.To learn how to change front strut.

 Locate the strut assembly.

 Remove the wheel.
 Remove the brake line support if necessary.
 Drop the sway bar if necessary
 Remove the bolts from the steering knuckle.
 Open the hood and locate the strut towers to remove the bolts.
 Pull the old strut free.
 You have access to a spring compressor, consider removing the spring.
 Assemble the new strut.
 Install the completed strut assembly back into the steering knuckle.
 Place the strut assembly back into the strut tower and replace the strut tower bolts.
 Replace the wheel.

12.Removing and installation of bearings.

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 Gather Your Equipment.

 Stabilise Your Vehicle or Machinery
 Loosen the Nuts.
 Raise the Vehicle or Machinery.
 Remove the Nuts.
 Remove the Brake Calliper and Bracket.
 Remove the Outer Wheel Bearing.
 Remove the Rotor and Inner Wheel Bearing.
 Install the New Wheel Bearings and Wheel Hub.
 Reinstall the Brake Rotor and Calliper.
 Install the tyre.

13.Introduction of wheel alignment.

 With caster and camber adjusted, then adjust toe angles.

 Restart the car, remove the steering wheel lock, turn the steering wheel back and forth
a couple times, then re-center and replace the steering wheel lock. Recheck alignment
specifications, and then readjust angles as necessary.
 Remove the alignment heads and lower the vehicle.
 Complete the alignment by taking a test drive to ensure any previously noted
symptoms are gone or can be attributed to other vehicle issues (such as vibrations
caused by worn suspension parts).

14.Car washing after service.

15.Training evaluation.

3.2.Problem identified and solutions.

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a)Engine Misfiring:

 Problem,
Engine misfiring occurs as a distinct pop sound when you start your engine. We all know that
internal combustion in an engine occurs as a cycle of intake of air-and-fuel mixture, burning
it, and outletting fumes via the exhaust. If something interrupts this cycle, a misfire happens.
There are several possible reasons for this, with the most common being a spark plug
problem.

 Solutions,
 Check The Spark Plug: Pop up the hood and have a look at the spark plug. If it is black, clean
it with a brush and test again.
 Change The Spark Plug: If the car doesn’t start after cleaning then you will need to change
the spark plug. It is not a costly component and can be changed without much expenditure.
 Consult A Mechanic: If the misfire happens even after replacing the spark plug, then we
would recommend that you get your car checked by a skilled engine mechanic as the problem
could be related to the cylinder or piston head.

b)Dead Battery:

 Problem,
It is also one of the problems that renders your car undriveable and ruins your day.
The symptoms of a dead battery are evident when you start your car. A dying battery
will take longer to crank the engine and get started while a dead battery will not start
the car.

 Solutions,
 Jump Start: It is the most sought after solution to a dead battery if it is in a good
condition, and works most of the time.
 Check Battery Fluid: If your battery works only by jump starting, it would be a good
idea to get it checked as there could be fluid loss in the battery.
 Replace The Battery: If your battery doesn’t respond to a jump at all, then it is time to
install a new battery.

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 Check The Charging System: If you’ve got a battery in good condition and it doesn’t
get charged, then there is an issue with the charging system, which needs the
intervention of a skilled mechanic.

c)Tight Clutch Pedal :

 Problem,
 A normal clutch pedal is smooth and easy to operate, doing so without any breaks.
When you feel that you are using more than usual muscle power to push the clutch
pedal, there is a problem with it.

 Solutions,
 Blocked Pedal: You can check the clutch pedal to see if there’s something beneath it,
and remove it.
 Inspect the clutch cable: Check for signs of wear on the clutch cable (runs from the
clutch pedal below the transmission). If you can’t bend that way, ask your mechanic
for help. Depending on the findings, the cable may be lubricated or replaced.
 Worn-out clutch disc: Ask your mechanic to do a thorough inspection of the clutch
disc. If you have been driving the vehicle for long periods of time, there is a chance
that your clutch disc might have worn out. This can result in an unresponsive or less
responsive clutch in the form of stiffness. Replacing the clutch disc will solve the
problem immediately.
 Adjust the clutch pedal: If you’ve replaced any part of your clutch recently and find it
stiffer than usual, then the pedal needs some adjustment to run smooth and free. This
too can be done at your nearest car garage.

d)Squeaking Brakes,

 Problem & Solutions,

 Pressing your brakes making them squeak out loud? That’s a clear call for help! At
times wet brakes might emit a squealing sound and this is caused because of the water

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layer on the brake pad or brake shoe. Once the water has dried off that sound should
go away. If it doesn’t then the brake pads or the brakes shoes have worn out and
require replacement. It would be a good idea to get these replaced as brakes are a very
crucial and integral part of driving.

3.3.Skills attained.

 Hands-on experience in a specific industry or field.

 Exposure to real-world projects and problems.
 Networking opportunities with industry professionals.
 Development of practical skills such as project management, teamwork, and
communication.
 Opportunity to apply classroom learning to real-world situations.
 Chance to gain insight into potential career paths and make informed decisions about
future education or employment..

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CHAPTER 4
RECOMMENDATION & CONCLUSION

4.1.Recommendation:

The nexa indus motors is a one of its kind in the automobile industry. It is best for the middle
class earning people. Because of its compact shape and small size, it is perfect for daily use.
But to long last the good performance of this care some measures should be taken.

• Always try to maintain a fixed speed limit.

• Do general servicing after running fixed km or after certain time.

• Change air filter, oil filter and lubricating oil after certain period.

• Use high grade fuel if possible.

4.2.Conclusion:

During my three weeks of internship period, the nexa was my basic vehicle for gaining Knowledge.
Because of its having advance technology in automotive and design, learning from It was a great
achievement for me. As I have seen new and used cars in the workshop, I was Able to understand the
initial condition of the vehicle and the performance it can deliver.

Though many customers came with problems in their car, because of the advance technology And
fault detection system of the car, the problem was sorted out quickly and solved as soon as Possible.
Servicing this vehicle needs a special skill and I am sure that I have achieved it.

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