Internship Report by Hamza Mustafa
Internship Report by Hamza Mustafa
MAY 2024
NAME: SIGNITURE
I
Acknowledgement
I praise to almighty God for his support in every of my live and granting me power, courage,
wisdom to finish my study.
First, of all. I would like to thank for Raya University for giving me the chance to take this
internship program
Secondly, I would like to thank for my ADVISOR [Link] G. Who give messenger advice and
guidance during the internship program in order to complete the report. Then, i would like to
thank for my Company supervisor mechanic HENOK for his continuous support during
internship program and i would like to thank for technical in the Company.
Finally, I would like to express my respect and appreciation for the management and workers of
the Company that helped me directed and indirectly during the internship program to finish my
report.
II
Executive summary
HENOK TESFAY Adwa garage stands out as a top-tier, efficient, and competitive automotive
service provider. The report covers a span of two months, with the initial eight days focusing on
tasks such as body maintenance and repair, vehicle body painting, engine and powertrain
maintenance and repair, brake servicing, and battery charging in the electric workshop.
Additionally, it provides insights into the Company's background, organizational structure, and
overall workflow. Internships play a crucial role in enhancing practical skills, theoretical
knowledge, interpersonal communication abilities, and entrepreneurial acumen.
III
Table of Contents
Acknowledgement................................................................................................................................................II
LIST OF FIGURE................................................................................................................................................V
Chapter one...........................................................................................................................................................1
Introduction.......................................................................................................................................................... 1
1.1 History and Back Ground of the Company.....................................................................................................1
1.2 Main Services in the Company.......................................................................................................................3
1.3 Main customers of the Company....................................................................................................................3
1.4 Work flow and Overall Organization of the Company.......................................................................4
1.4.1 Work flow.................................................................................................................................................4
1.4.2 Overall Organization................................................................................................................................... 5
CHAPTER TWO..................................................................................................................................................6
OVERALL INTERNSHIP EXPERIENCE..........................................................................................................6
2.1. Introduction................................................................................................................................................. 6
2.2 Section where I have been working in.........................................................................................................6
2.2.1 The Work Flow of the Section.....................................................................................................................6
2.2.2 The Work Task I Have Been Executing......................................................................................................6
2.2.3 ENGINE......................................................................................................................................................7
2.2.4 Battery....................................................................................................................................................... 15
2.2.5 Brake..........................................................................................................................................................18
2.2.6 Clutch system............................................................................................................................................ 23
2.2.3 Company Tools..........................................................................................................................................25
2.3 Procedures and methods followed during the internship........................................................................28
2.4 Major challenge..........................................................................................................................................28
2.5 Measures I have taken to overcome those challenges..............................................................................29
CHAPTER THREE............................................................................................................................................30
THE OVERALL BENEFITS I GAINED FROM INTERNSHIP......................................................................30
3.1Introduction................................................................................................................................................... 30
3.2 Practical Skill..............................................................................................................................................30
3.3 Theoretical Knowledge...............................................................................................................................30
3.4 Inter Personal Communication Skill............................................................................................................31
3.5 Team Playing Skill......................................................................................................................................31
3.6 Leadership Skill..........................................................................................................................................32
IV
3.7 Work Ethics................................................................................................................................................ 32
3.8 Entrepreneurship Skill...............................................................................................................................33
CHAPTER FOUR..............................................................................................................................................34
CONCLUSION AND RECOMMONDATION............................................................................................................34
4.1. CONCLUSIONS........................................................................................................................................34
4.2. RECOMMENDATION.............................................................................................................................35
APPENDIX........................................................................................................................................................ 37
LIST OF FIGURE
Figure 1 Back Ground of the garage....................................................................................................................1
V
Figure 2Engine..................................................................................................................................................... 7
Figure 3 Cylinder head.........................................................................................................................................8
Figure 4 Engine block.........................................................................................................................................9
Figure 5 Oil strainer and oil sump....................................................................................................................9
Figure 6 Battery..................................................................................................................................................16
Figure 7 Battery charging...................................................................................................................................16
Figure 8 Green and Black and white..................................................................................................................17
Figure 9 Brake....................................................................................................................................................18
Figure 10 Hydraulic brake..................................................................................................................................19
Figure 11 Brake drum.........................................................................................................................................19
Figure 12 Disc brake...........................................................................................................................................20
Figure 13 Brake shoes........................................................................................................................................21
Figure 14 Master cylinder...................................................................................................................................21
Figure 15 Wheel cylinder...................................................................................................................................22
Figure 16 Clutch.................................................................................................................................................23
Figure 17 Flywheel.............................................................................................................................................24
Figure 18 Clutch disc..........................................................................................................................................24
Figure 19 Pressure plate......................................................................................................................................24
Figure 20 Vernier caliper....................................................................................................................................26
Figure 21 Feeler gauge.......................................................................................................................................26
Figure 22 Micrometer.........................................................................................................................................27
Figure 23 : wrench..............................................................................................................................................27
Figure 24 floor jack............................................................................................................................................28
VI
Chapter one
Introduction
1
Appearance Quantity
Number of employees 15
Main office 1
Fire extinguishers 3
Wheel balance 1
Painting room 1
Electricity tester 2
Mechanical holes 5
Press machine 1
2
Employee's changing room 1
Lathe machine 1
mechanical service
Body repair
Painting
1. Africa insurance
2. Awash insurance
5. Wukro klteablailo
3
1.4Work flow and Overall Organization of the Company
1.4.1 Work flow
Workflow is the process how the Company is performed its work. I can see the workflow of the
Company in two types.
A service: this is for service of oil and oil filter in 5000 km distance.
B service: this is for service of oil, oil filter and fuel filter in 10000 km distance.
C service: this is for service of oil, oil filter, fuel filter, and check for disc and drum
brakes, suspension in 15000 km distance.
D service: this is for service of oil, oil filter, fuel filter and maintenance of disk and drum
brakes, suspension in 20000 km distance.
Owner
4
Technician
Finance
Owner
5
CHAPTER TWO
2.1. Introduction
. Upon completion of my third academic year, I was fortunate enough to be offered an internship
opportunity through the university's industrial linkage program. Both my department head,
Tadesse Teklie, and the university's industrial linkage office provided us with an orientation
session to inform us about our assigned hoisting companies. I selected my preferred hoisting
company during this session, and subsequently received an agreement paper from the university's
industrial linkage office. I then submitted the agreement paper to the company's mechanic,
HENOK. I made sure to choose the hoisting company carefully, as I understand the importance
of this internship in enhancing my knowledge and gaining practical experience.
finance
The workflow is efficient, with a team of skilled professionals collaborating in their respective
fields within the company. Additionally, there are on-site mechanics available.
6
assisting in the removal of an engine from vehicle for the technician
Put my significant role in the arrangement of mechanics valve lifters during the
assembly process.
2.2.3 ENGINE
Engine is the brain of the car which provides power to the car's wheel. In present day
automotive engines are internal combustion that means the energy is created with in the
engine. Engine converts chemical energy into heat energy.
Figure 2Engine
Components of Engine
The engine contains the following components.
Cylinder head
7
Figure 3 Cylinder head
Camshaft
Valve seat
Valve
Washer
Valve spring
Valve guide
Valve keeper
Valve returner
engine block
Piston
Connecting rod
Crankshaft
8
Figure 4 Engine block
Oil sump
Oil pump
Oil strainer
9
Disconnect the negative and positive terminals respectively.
10
Remove intake system
Remove the engine from clutch assembly using engine hoist or crane.
Engine Disassembly
After removing the engine from the vehicle, put the engine to the work place using
crane. Inspect the engine parts carefully one by one. Procedures to disassembly the
engine components;
Valve washer
Valve seal
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Valve spring
Valve returner
Valve keeper
Assembling of Engine
After maintenance or replace is taken the next process is assembling. Assemble the engine
carefully. Install the engine parts using the following common procedures.
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1. Put the engine block in a suitable and clean place.
7. Insert gasket
9. Insert gasket
13
12. Fly wheel
13. gasket
19. Tensioner
20. Alternator
21. Belt
Engine Troubleshooting
problems cause Solution
14
rings or cylinders overhaul engine
worn
lack of fuel
15
or replace
2.2.4 Battery
Battery is the primary source of all electrical system.
Figure 6 Battery
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Battery Charging
Battery can be charging either on the vehicle or removed from the vehicle. When charging is
taken, proper connection must be fulfilled because incorrect connections destroy rectifier
diodes and voltage regulator. Using hydrometer (which has three colour), we can know the
condition of the battery. Therefore, check the indicator once every three months. Different
colors represent different battery status.
White color in some vehicle red color indicates lack of electrolyte or failure, then the
battery should be replaced.
series or
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Parallel
Battery in low state of charge, Broken or loose connection in Tighten loose connections or
shown by lack of power when alternator circuit. broken lead.
starting.
2.2.5 Brake
Brake is the opposite of motion.
In the company l see hydraulic brake system which is type of brake system.
Brake system is used to slow/stop the motion of the car. The friction of the tires against the
road is what slows down or stops a car. The brake system slows or stops the rotation of the car.
The brake system converts the motion of the car in to heat by slowing and stopping the car's
wheel. This is done by causing friction at the wheels. In spite of there are three types of brake
system, l see the hydraulic brake system.
Figure 9 Brake
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Hydraulic Brake system
Hydraulic is the use of a liquid under pressure to transfer force or motion.
"Pressure at a point in a fluid is equally disturbed in all directions in space””. According to this
law when pressure is applied on a fluid, it travels equally in all direction. So that uniform
braking action is applied in all rotating wheels.
Components of Brake
Brake system has different component. Let mention some of them.
Brake drum
19
Figure 11 Brake drum
Disc brake
is bolted to the wheel hub and stationary caliper unit which straddles the disc
Brake fluids are liquids that are used to transfer force into pressure. This works because
liquids are incompressible.
Brake fluids are not petroleum based because oils damage rubber seals and hoses in the
brake system.
Brake shoes
20
Figure 13 Brake shoes
master cylinder
The master cylinder transmits the pressure on the brake pedal to each of the four wheel
brakes to stop the car.
lt converts the force exerted on the brake pedal into hydraulic pressure.
The pressure created in the master cylinder, displaces fluid through the various brake
circuit.
It is usually placed at the top of the brake shoes and located in each wheel .
21
Figure 15 Wheel cylinder
Brake Troubleshooting
Troubleshooting is a problem that disables the brake system. The table below shows
problem that can be create in brake system.
water or oil on
linings clean or replace linings
22
valve
Figure 16 Clutch
23
Figure 17 Flywheel
Clutch disc:-grooves are cut into the friction material to aid cooling and release of the
clutch disc.
Operation of Clutch
24
1. When the driver depresses the clutch pedal, the clutch master cylinder actuates the
servo cylinder, which pushes the fork and the fork put force to release bearing in order
to disengage the engine from transmission that is power is stop to transmit from engine
to transmission.
2. When the driver releases the clutch pedal, the clutch master cylinder is not actuate then
the release bearing returns to its original position which allows to transmit power from
engine to transmission.
Clutch Troubleshooting
Troubleshooting is a problem that disables the clutch system. The table below shows
problem that can be create in clutch system.
Vernier caliper: A vernier caliper is a measuring tool that can make inside, outside or depth
measurements .a vernier scale consists of a stationery scale and movable scale.
25
Figure 20 Vernier caliper
Feeler gauge
valve clearance
26
Figure 22 Micrometer
Hand tools: most service procedures require the use of hand tools; therefore, technician
needs a wide assortment of hand tools. Each has a specific job and should be used in a specific
way. Examples of hand tools;
Wrench-is a tool used for twisting bolt heads and nut. Nearly all bolts heads and nuts
have six sides, the jaw of a wrench fits around these side to turn the bolt and nut .
Figure 23 : wrench
Jack is used to raise a vehicle off the ground to a high position. The most common jack is
hydraulic floor jack. Those jacks are controlled by moving the handle up and down.
Floor Jack
Is a portable unit mounted on wheels. The lifting pad on the jack is placed under the chassis of
the vehicle and the jack handle is operated with a pumping action. This force fluid to a hydraulic
cylinder in the jack and the cylinder extends to force the jack lift pad up ward and to lift the
27
vehicle. To release the hydraulic pressure and lower the vehicle, the handle must be release
slowly. When a vehicle rises by floor jack, it should be supported by safety stands.
Preparing plan for activities should have to perform during the internship
Attending punctually each working days
Prepare a short review of daily activities at the end of each working days
Paying attention and asking about anything that is not clear
Listen carefully and take notes
28
2.5 Measures I have taken to overcome those challenges
In order to overcome the challenges
3. Lack of library access to read manual and some references about the operation machine
also lack of recorded data.
29
CHAPTER THREE
3.1Introduction
This internship program is very essential program to me. Because this internship program
develops my theoretical skill in to practically skill and share different idea with my community.
It also gives me the way to decide my future job and company. The benefits that I gained from
the internship program are listed below.
It improves my knowledge about the working mechanism different parts of light vehicle
engines.
It improve my knowledge of how can assemble and disassemble the engine parts ,
clutch parts, transmission parts, engine systems, suspension part, brake parts(disc brake
and drum brake ) etc. of light vehicles in order to maintenance/service, repaired or
replace parts.
30
learnt in different courses theoretically are basically broader of my theoretical knowledge in the
garage.
My internship period was also the time for me to know new theoretical things. I was
working my internship with well-experienced technicians and other workers. I get many new
theoretical things by talking and asking technicians and also the labors. On garage when I am
with technicians, I asked them question which is not clear for me and they give answer to me
briefly, it was my first theoretical resource. By doing these activities I was trying to improve my
theoretical knowledge.
As we know, to have such place the behavior of good interpersonal communication has great
value because one person may judge you from your speaking whether you are talented or not.
So the two month and twenty days I past in Tesfay Gebremedhin Tigray garage (wedi Massa)
were good enough for improving my interpersonal communication skill with different workers
of the company because nothing is to be hide there. Since most things are done openly. This
phenomenon makes us to communicate freely with the workers.
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previously mentioned, teamwork is more effective than working alone. Working with my friends
during the internship provided various advantages, such as sharing documents, handouts,
softcopies, and other useful resources. The core aspect of this internship was centered around
teamwork, where we exchanged diverse ideas, theoretical knowledge, and practical skills with
fellow students from different universities and my classmates interning at the garage. Through
these collaborative efforts, I gained valuable knowledge on problem identification and resolution
by engaging in discussions and understanding together as a team.
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3.8 Entrepreneurship Skill
Throughout the internship semester, I have honed my entrepreneurial skills by breaking free
from the constraints of standardized pay for standardized work. I have actively avoided anything
that hinders my ability to innovate and create new value. By steering clear of routine and
unchallenging tasks, I have fueled my high need for achievement and set my sights on personal
and professional growth. As an engineer, I uphold a strong work ethic, valuing punctuality and
respecting others in all my professional endeavors. I am dedicated to working tirelessly, day and
night, to not only enrich myself but also contribute to the prosperity of my country. My ultimate
goal is to establish my own business in the field of civil engineering and beyond, implementing
effective and modern methodologies to drive success.
33
CHAPTER FOUR
4.1. CONCLUSIONS
The main goal of this internship initiative is to provide technology students with hands-on
experience in a practical setting to apply and enhance their theoretical knowledge. Moreover, it
aims to expose participants to real-world engineering tasks and environments. During my
internship, I had the opportunity to put into practice the theoretical concepts I had learned on
campus. Additionally, I learned valuable skills such as time management, discipline, effective
communication, entrepreneurship, and teamwork. One of the most captivating aspects of my
internship experience was the conducive working environment. The scale of the projects, the
abundance of machinery and equipment in the company, the presence of experienced engineers,
and other factors contributed to my confidence, experience, and expertise. Some of the
advantages I gained from the internship program include:
Practical skills
Generally, this internship program helps me to understand the real engineering works
and practical world environments that used for my future working world.
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4.2. RECOMMENDATION
Throughout my four-month internship, I have observed both favorable and unfavorable
aspects of the hosting company. In this section of my report, I aim to propose some
recommendations for both the hosting company and my university.
For My University
The university should check upon the intern student at least twice in a month.
The university should give enough money to its internship program students for their
basic needs like food, transporting and others by considering time.
I would like to recommend that all engineering department should get enough
time to study. There is no rest in all days of the week. If there is no enough time
to study and rest, there is no successful at all.
Today’s intern students are the engineer for the future. The company will
goanna employ those students as an engineer after graduation. Therefore, for
intern students all the company employers shall give respect and encourage.
Since the students are working in the company, they will have some contribution
in different aspects for the company. Thinking of this, the company shall earn the
student and give various benefits at least giving few birr per month.
35
It is recommended that to import some machines in order to minimalize employer
effort and
The work place is narrow so, the company should use wide house in order to service
many vehicles
36
REFFERENCE
1) WORKSHOP MANUAL FOR THE RENAULT R16 RANGE COMPILED AND WRITTEN BY
PETER [Link]
TIMGILLES
Santa Barbara, CA
APPENDIX
1) Company manual
37
2) Day to day activities
THE END
38
The hydraulic brake system operates based on Pascal's law, which states that when pressure is applied to a fluid in a confined space, it is transmitted equally in all directions . In the brake system, the pressure is initially applied at the master cylinder when the brake pedal is pressed. This force is converted into hydraulic pressure, which travels through the brake fluid to the wheel cylinders . The wheel cylinders then apply this pressure onto the brake shoes, causing them to press against the drum and slowing the vehicle through friction . The proper operation of these components ensures uniform braking action across all wheels .
The steps involved in assembling an engine block begin with positioning the engine block in a suitable and clean place . Next, the crankshaft is inserted, followed by bolting the main bearings and main caps to ensure the crankshaft is securely in place . The connected rod and piston assembly is then inserted, and the rod bearings and rod caps are bolted to facilitate smooth piston movement . Subsequently, the oil strainer is bolted to filter debris from the oil. A gasket is inserted to prevent oil leakage, and the oil sump is bolted on, also ensuring a gasket is placed . The water pump and water jacket are inserted to facilitate engine cooling, followed by critical components like the flywheel, camshaft assembly, and the cylinder head, which are crucial for engine compression and timing . The process is completed by adding elements such as the camshaft pulley, crankshaft pulley, alternator, and belts, which are necessary for the timing and engine's auxiliary systems . This sequence ensures that each component is installed efficiently, maintaining engine integrity and function.