BY ABDURAZAK AMAN & ABDULAZIZ SALIH

Acknowledgement
This report would not have been possible without the support of many people. We wish to express our sincere gratitude to our supervisor instructor Dawit Kebede who was abundantly help full and offered valuable assistance, support and guidance as well. Deepest gratitude also due to the members of moenco staffs, without whose knowledge and assistance this report would not have been successful.

Our departments staff members like instructor Shewangizaw Workagegnew & who guided as through the process of internship are also have to be appreciated. we thank them all.

Cont Special thanks also go to our graduate friends for sharing ideas and literature. Not forgetting to our best friends who always been there. We would also like to convey thanks to the institute and department for providing as with financial means even if it is not sufficient for survival. Great appreciation goes to the rest of moenco staffs that help us from time to time during our course of time writing the report and project as well. Finally we wish to express our love and gratitude to our beloved families for their understanding and constant love through the duration of our study.

Executive summary
Internship the core of new curriculum is one of the main changes that were introduced to help students to integrate a thought and to provide dynamic linkage between the industry and the universities institutions of technology to meet the demands of the ever growing economy of Ethiopia. As being one of the beneficiaries of this program we were able to incubate new ideas and meet the demands of the internship we were assigned for. Internship is also without a shadow of doubt will place the students a dynamic environment and make students test and smell a new working environment. This strange environment shines a new light on our life to cultivate our theoretical backgrounds and made us to know the hidden secretes of this world.

Chapter One Introduction

Internship forms a steel ground linkage between university student and industry .it also establishes a win-win situation for students to dig and cultivate their theoretical background. In addition practical skill may be nurtured and developed for those with an unquenchable thirst for knowledge. Moreover, it places student in a strange and dynamic environment that perhaps forces to test and smell challenges, and absorb and digest problems.

The overall structure of the report takes a form of five chapters including this introductory chapter.

Cont
Chapter two begins by shining a light on the background of the company, mission and vision, values and also laying out; service of the company, customer of the product and product range. Chapter three is concerned about Internship experience on Auto- service department maintenance schedule for periodic service, Power transmission, Auto Electricity, Engine maintenance, Automotive Fuel System service, Contamination control, Automotive Tire &Wheel, service, Tire Construction, Changing Tire Assembly, Duties in the body and paint shop. The fourth section presents the main activities and finding of the project focusing on workshop cleaning mop and spray holder with detail analysis and part drawings. The last chapter includes the benefits of internship during the course of this project Finally the conclusion gives brief summery and critics of the findings during the internship period also recommendation and references that we use in the writing of this report are included.

CHAPTER TWO Background of the company Around 51 years ago in Addis Ababa Mexico area MOENCO was established for the first time in the form of small garage with the capital of 200,000 Ethiopian birr. It was founded by Mr. Y.D .Lappine in small rented house. His far sighted vision became reality with the help of other resourceful people such as Ato Minase Lemma, the then governor of the national bank of Ethiopia and the boss of imperial Insurance Company.

Cont MOENCO is began to be established nine years later by taking Toyota Franchise business for Ethiopia when inch cape which is London based international organization became a major share holder injected a considerable amount of capital. This was the milestone moment in the firms journey to become the MOENCO of today. In addition to TOYOTA business, at different times MOENCO used to represents general motors for various type of vehicles and trucks of American and England like Ingersoll-rand, WABCO, Pettibow, Universal, Dupont, and General tire, Fregidire, Zanussi and Thomas Delarue All the challenge in work gives MOENCO a great experience and makes to focus on people, service and innovation over the past five decades. The strength they have acquired in these years has also endowed MOENCO with the resilience to survive during the many difficult times.

Cont Now MOENCO has five operational sites are two in Addis Ababa, One in Awasa which is launched in 1998, third in Bahirdar launched in 2004, and another one in ADAMA which is launched in 2010. Their networks include 13 major dealers across the country. Currently the company employed more than 600 employees and has annual turnover of over one billion Ethiopian birr. Besides the famous TOYOTA brand; MOENCO is currently distributing Daihatsu vehicles, komatsu construction equipment, Suzuki bikes, listerpetter diesel engines case, new Holland and etc. MOENCO Adama is one of the branches of MOENCO that we spent our internship program. It is initial investment of birr 30 million rests in area of 20,000 m2 in good location of Adama. This branch gives a quality service to customers in Adama and surrounding area.

Mission Providing vehicle sales, parts and service in the world-class purpose built centre. Providing Excelling service and many magic moments by customer friendly service, Advisor, sales people, Toyota certified technician and support staff. Minimizing time for the service of Toyota vehicle by using special service Shop, genuine spare parts and sophisticated equipment.

Vision
To be the most customer-centric distributer of vehicles and equipment for the construction, agriculture and industry sectors in Ethiopia with unparalleled after sales services supported by state of the art technology and skilled manpower.

Values
MOENCO being an affiliate company of INCHCAPE PLC, shares same set of values stated hereunder. Respect for each other Passionate about customers Pioneering new ideas Caring for environment Winning together Treating every coin as our own Integrity without compromise. MOENCO-Adama provides different main services for the customers. The detail of each service is explained as follows.

Services of the company (organization)

PDI Service (pre delivery Inspection) The job of PDI staff includes removing the protective materials inspection of mechanical status body parts and any paint defects installation of different accessories to confirm the finished condition

Free service Check up

In MOENCO there is free service check up for vehicles that are purchased from MOENCO in every 1,000 km & 5,000 km the customers have to pay replacement of lubricant and filters. Periodic maintenance Every TOYOTA, DAIHATSU & LEXUS vehicles have to be periodically maintained in every 5,000km or by the intervals of 3 months. Periodic maintenance will insure: Reliability high resale value long life and maximum performance.

Express maintenance
The express maintenance service is done for vehicles with mile age up to 50,000km.

Body and Paint Repair In this section the technicians carry out major and minor Body & Paint repairs General Repairs General Repair Service comprises of units overhauling (like engines, automatic and manual transmissions/transaxles, fuel injection pumps, differentials, steering gearboxes, vane pumps, starters, alternators, etc.), and diagnosis & repair of any malfunctions on the vehicle using the state-of-art equipment and tools available in the Service Centers.

Annual vehicle inspection

The Ethiopian Transports Authority decides for all vehicles have to be annually inspected for safety of the human life and economic disaster this inspection carried out in the designated vehicle inspection center.

Towing Service
MOENCO also provide towing service (dragging of a car) to assist our customers in the event of vehicle collapse or malfunction.

Customer of the product (service)

MOENCO provides genuine parts for the vehicles and machinery it supplies genuine parts and accessories. Its objective is to deliver the right quality at the right time and the right place. When they say the right quality, they mean genuine parts for trouble free performance, long life and safe environment. When they say At the right time, they mean an optimum availability of parts, insuring continuous supply based on customer demand. A fully computerized sales, stock control and electronic parts catalogue system has enabled us to achieve a very high supplyability of parts resulting in remarkable customer satisfaction. When they say the right place, they are referring to their dealers in different parts of the country and their branches in Awassa, Bahirdar and Adama. They are committed to serve their customers with quality service, wherever they are.

Cont Their parts operation is one of their primary value chain systems. It is based on JIT operation system (Just in time) which in turn is based on sell one buy one philosophy. In effect, their parts operation is backed up by extensive inbound and outbound logistic activities Their electronic parts catalogue system (EPC) has enabled their salespersons to identify part numbers easily and accurately. This computerized sales and inventory control system has helped increase productivity and efficiency of staff.

They are continuously improving their services to their customers using the concept of kaizen which is a Japanese term for continuous improvement. They apply kaizen at every step in the parts logistics activity (inventory control, parts sales, warehousing, parts marketing, etc.)

Cont

In this regard, technology has a big role in simplifying different processes, cost saving, promptness and accuracy, which lead to higher customer satisfaction. They apply improved system (software and hardware) in the inventory control process, sales and warehouse activity.

Inventory control Stock items to be replenished and new items to be ordered are automatically generated by the computer on bi-monthly basis. In addition, they also place small frequent emergency orders to address their customers urgent needs. By this combination of ordering they are able to achieve very high service rate (availability) and by utilizing the kaizen concept, they are able to reduce the lead-time considerably. Warehouse They use storage Kaizen (continuous improvement in warehouse operation) which has created an attractive and convenient layout, an efficient and safe storage technique the 7 Toyota storage techniques and a fast and efficient picking and delivering operation.

Warehouse They use storage Kaizen (continuous improvement in warehouse operation) which has created an attractive and convenient layout, an efficient and safe storage technique the 7 Toyota storage techniques and a fast and efficient picking and delivering operation. Parts Sales Their customers submit their orders in many ways by mail, fax or telephone and in person at the sales counter. They also have a dedicated dial up line between their branches and Addis Ababa main office for a computerized information exchange such as stock inquiry, order placing and reporting. Most of the customer orders are addressed through their sales counter where parts stock status information can be easily retrieved from the computerized stock and sales system. They have a local areas network (LAN) with over 20 workstations for front line parts sales, data control supervision and data entry.

Staffing and facility

Staff There are total of 60 staff on permanent and contractual basis working in the different sections of parts department Parts office, main counter, service counter, data control, customer relation and tender section, ordering officials.

Warehouse Facility Their warehouse is one of the best among similar African Toyota distributors. Its storage capacity is 10,000 m2. It is well organized and equipped with sufficient storage and handling materials. They also have satellite stores in their Awassa and Bahirdar branches with a capacity of 5,000m2 each.

Parts Counter
Their parts counter is designed in such a way that their customers can be served comfortably and conveniently.

Product range
The following are the product types for which they deliver genuine parts.

Vehicles Toyota: they deliver genuine parts for Toyota vehicles. They have in our warehouse a stock amounting 22 million Birr currently. Their service rate (availability) has reached 93.2% and it is continuously growing through their effort and commitment.

Daihatsu
Hino Trucks

Cont

Agricultural and construction machinery

Agricultural New Holland Tractors and combine harvesters Faza Plough Bellucci & Rossini Trailers
Construction Komatsu Dozer, grader, loaders, Excavators, Dump Trucks Wirtgen & Vogelle Asphalt machines, Hamm Rollers Phoenix Asphalt machines, etc

Cont

Suzuki and Zip star motorcycles

Others Lister Petter Engines and generators Accessories grill guard, side steps, roof rack, mud Guard, side visor, etc Tires Toyo tires Batteries maintenance free Silver - Calcium batteries.

Vehicle

vehicle

Reception

inispection

service section Cost estimation - Mechanical Repair - Body and Paint - Engine maintenance - Auto electric service

quality control

vehicle delivery

CHAPTER THREE Internship experience

Auto- service department maintenance schedule for periodic service
the service is given for the vehicles of HILUX 2L,3Land 5L engine, Condor 5L Engine

Service for HILUX 2L,3Land 5L engine, Condor 5L Engine

Service for Land Cruiser, Station Wagon, Pick-Up and Hard Top (diesel 1HZ Engine)

Service for Land Cruiser, Station Wagon, Pick-Up and Hard Top (diesel 1HZ Engine)

In addition to this, the activities that are performed in this shop can be classified into three main parts. They are: Power Transmission Auto Electric Engine Maintenance

Power transmission

Cont

This is where all parts of the car, which are used for the power transmission system, are checked and repaired. Some of the main daily activities are-

Check and repair of front and rear housing Check and repair of Propeller Shaft Check and repair of Transfer Gear Box Check and repair of joints, like Universal Joint

Cont

Refilling of hydraulic oils such as brake oil, clutch oil, power steering fluids. Check and repair of knuckle components such as bearing, spacer, hub and etc

Auto Electricity
This is where the electrical part of the car is checked and repaired. Some of the activities are: Check and maintenance of all the lighting system Check and replacement of car battery Check and repair of starters Check and repair of Air conditioning system Check and maintenance of all the electrical system inside the car.

Engine maintenance
This part is where the engine, gearbox, and differential of the car is checked and maintained. The general main activities that are performed here are as follows. Check and replacement of engine and its accessories including: Check the diameter of cylinder Lapping the valve with its valve seat Check and repair of front and rear differential Check and repair of gear box Refilling of fuel, differential and gear box oils

Many times engine problem is caused by contamination What is Contamination?

Dirt Weld spatter Paint flakes Rag fibers Metals Sealing Materials Grease Water Air Products from oil oxidation
Success Formula Clean Oil+ Clean Components+ Clean Assembly Processes = Clean Machines

Duties in the body and paint shop Body repairing Body painting Repairing of seat inside the car Keeping the equilibrium position of the supporting part like housing, frame and others. Releasing the bolts that are tightened hardly by using heating and cooling systems Making the car more attractive for the customer

changed

CHAPTER FOUR Main Activity (Technical Content, Industry-based problem solving and originality). Workshop cleaning

This is the worst scenario that hesitate the cleaners. We perceived the situation at first glance. Since the workshop is very wide only two cleaners have the responsibilities of cleaning every time a vehicle parts are disassembled (dismantled) and oils are discharged. The impact of cleaning the floor and oil manually hesitate the cleaners much. Finally through an extensive study and works the machine is designed and developed.

Air Filter Cleaning

We also intended to do project on air filter on how to address the primitive ways of cleaning air filter by blowing dust here and there by using a pressurized air. The dust when inhaled has the ability of bringing chronic lung cancer.

We gave a proposal to the company managers, to do some project on air filter that may reduce the chance of being caught by a cancer that claims lives of thousands death. But, the company could not give attention, and facility to provide for us to proceed with the project. As a result we fail to do nothing better.

Engine washing
This is another dangerous issue that may be considered. Engine and its internal parts are washed by the benzene and its internal parts are washed by the use of petrol with pressurized air. Since the carbon droplets will mix with the atmosphere, while inhaled may cause a great and catastrophic damage to health.
Even if there are many problems as micro level these are only identified as problem identification. This problem identification may seem exaggerated and someone may think, people working in that area may die. They really die but it does not kill workers over night it is a matter of years.

The design of workshop cleaning mop

Material Requirements
Two plates of 3mm each Power wrench Bearing (front hub) Long pipe Ratchet socket 2 slip wheels 50mm diameter Bolt and nut Metal wire (copper wire) 1.5m long 2mm diameter Other used metals and metal residue

Specifications
The top of the power wrench that rotates the plate has Torque = 610 nm Angular speed = 7000 rpm

The lever is made 600inclined with the horizontal. The radius of the disc is 15mm The diameter of the plate is 30 mm

Principles of operation
The cleaning machine works by rotation. The power of rotation comes from the pneumatic operating impact wrench. When the wrench began to operate the upper plate is welded to the long 600 inclined pipes so that the lower plate only rotates relative to the impact wrench. In the lower plate the cleaner rag (stratchew) is inserted by wire lock (clamper) made from the copper. Using the rotating motion of the plate the oil is cleaned.

Angular speed of the plate

The plate rotates when the tip of the impact power wrench rotates at 7000 rpm the tip of the power wrench meshes with socket number 21 which is welded to the inner race of ball bearing and lower plate the upper plates is made fixed, while the bottom plate is made to rotate.

The rotation of the tip of the impact power wrench do not directly transferred to the bottom plate, so that the rotation of the tip of the power wrench due to the inertia of rotation of the plate and socket and bearing decreases the rotation. The diameter of the socket is 5mm while the diameter of the plate is 30cm.

Cont Therefore the rpm can be calculated from the following relation N1= 7000 rpm

This shows that the plate rotates at 122.2 rad/s so that the inertia of rotation decreases rotation of impact operated power wrench by this amount.

Cont Tangential speed of the plate can be found from the fundamental equation as follows

Torque
A torque is a net turning effect that is used to rotate the circular plate. A torque of 610 Nm with 7000 rpm rotation of the tip of the power wrench as specified in the specification A torque is also the total moment acting about the axis of rotation It is given by Torque = Force x perpendicular distance

F= 40.67 KN

Cont

This tells us that 40.67 KN of force is provided to rotate the given circular plate together with the socket.

Centripetal force
It is the net force needed to make the plate to follow a circular path As the velocity is changing the object must be accelerating R(Acceleration is defined as the rate of change of velocity) According to Newtons second law, acceleration requires a net force and the direction of the acceleration is the same direction as the net force. Centripetal force always acts towards the center of the circle. The centripetal force required to rotate the plate can be found as.

This amount of force is required to move the plate. Factors affecting the size of the centripetal force

Cont
The mass of the object Velocity and Radius of the carried path followed by the object affected the centripetal force. The centripetal force Fc is also required to keep the plate from slipping If the friction is not large enough or in another way if the centripetal force is not large enough the plate may skid or slide or produce noise

The period and frequency of the rotating plate

The period is the time taken to make one complete revolution (circular turn). For motion in a circle of radius r the circumference of the circle, C= 2r It the period of one rotation is T, the angular rotation also known as angular velocity
T= 0.05142 second per turn

Cont This shows that only0.05142 seconds required making one complete revolution The frequency of the plate can be calculated from this relation This frequency must be less than the resonant frequency that produces noise.
Moment of inertia of the plate

The moment of inertia of a body is a measure of the object resistance to changes to rotation. It depends on the mass of the object and its distance from its center. It can be seen that increasing the mass and the distance from the center increase the moments of inertia. The mass of the plates is 0.5 Kg and radius is 15cm

Cont

This briefly illustrates that the moment of inertia of the plate is so small that it can easily rotate at high speed Rotational kinetic energy of the plate Spinning plate posses a kinetic rotational energy KE rotation. Which is due to the rotation of the plate

The maximum power the rotating plate posses would be found as follows

Cont

The parts drawing

The Long pipe (Handle)

Lower Plate

Cont

Upper Plate

Ball Bearing

Cont

Socket

Bolt

Cont

Slip wheel

Over all assembly

Paint Spray Holder

The last project but not the least is spray holder that solves a great problem in the painting room. This project is paint spray holder this holder is done because we see the problem of flowing of the paint when it is kept on inappropriate holder like barrel or floor they take it by their hand till the paint is over. this problem also needs a preliminary solution. We have done a spray holder that is used by fitting on the wall by bolt. The holder is made from residue metals simply by welding together.

General benefits of an internship

Adaptability Loyalty Professionalism Strong Self Confidence Strong Work Ethics Self Motivated Honesty and Integrity Motivated to Grow & Learn Possessing a Positive Attitude. Dependability and Responsibility Developing sense of entrepreneurship

Conclusion
During internship period we tried to work and learn some of the duties and tasks in repair and service shop. We have acquired adequate knowledge about the mechanics of automobile, its systems and sub-systems in a simplified manner. We have also dealt with the essential construction and principles of operation of various components as a part of total vehicle system. Moreover, we tried to grasp basic knowledge and skill that are necessary and sufficient to maintain and provide service for modern automobiles. The design of workshop cleaning mop is also an important component in this company Finally, at the last but not the least the spray holder is designed and put into effect during our time of working in body and paint workshop.

Recommendation
Since there is only one working Oxy-acetylene welding cylinders; two or more workers may simultaneously need the machine. This may force the workers to wait each other and delay the working hour The delays of hours being counted by computer, as a result the customer have to pay for the delay. The arc welding and MIG welding machines which are not operating should be maintained and used as an alternative. Safety materials for all the welding types, sanding, and grinding such as gloves, goggles and others are not enough. Otherwise the workers that are carelessly doing their job may face a series internal and external injury and may lose his precious life. The painters in the painting shop sometimes knowingly paint outside the recommended painting room. They obliviously protect themselves but other innocent workers may be injured.

Cont
The main issues about washing engine by benzene and cleaning air filter by using pressurized air is also have to be addressed well. The safety of the supporting stand that is used during car maintenance the company should give attention to the university students by giving them safety clothes and shoes for their safety And also the company should share ideas that support the project such as air filter cleaning The rigidity of the company is not limited but extended to not to provide resource and facilities such as library, internet access and other reference materials for the intern students to progress for any type of intended project for further insight should be fulfilled.

On the other hand, neither no pocket money is given by the company nor the pocket money given by the university to the internship students is enough. It may be difficult to survive for students from poor background. The serious of sense of punctuality and team working in the company should be admired and promoted for further success.

Reference
Romesh Chandra Khanna (2006) automobile mechanics, 8th ed.,Khanna Publishers 2-B, NaiSarakDelhi( India). Ellinger, H Robert E. (1977) Automechanics, 2nd ed., Prentice Hall Inc., USA. William H. Course and Donald L. Anglin (19993) Automotive Manual Transmission and Power Trains, McGraw Hill publishing Company, USA William K. Toboldt (1993) Automotive Encyclopedia Fundamental Principle, Operation, Construction, Service Repair,The Good Heart WillcoxCo.Inc, USA. Frederick C. Nash (1979) Automotive Technology, 2nd ed., McGraw Hill Ryerson Limited, Canada. TesfayeFeleke (2003) Automechanics, Book 1. Mega- Publishing Enterprise, Addis Ababa, Ethiopia. http://www. www.automotivecrossing.com/.../Automotive-Internship-Jobshttp://www. www.internships.com/employer/resources/setup/benefits http://www. www.i-to-i.com/benefits-of-internship.html