Bishof Tu

Bishoftu Automotive Industry
2013
Chapter One
Background
1.1 BRIEF HISTORY OF THE COMPANY
1.1.1 ESTABILISHMENT
Metals and engineering corporation Bishoftu automotive industry is one of the military
institutions which is found under the Ministry of National Defense Industry sector, which had
started as project 40720 is an engineering and overhaul complex established in the early 1984
with the main objective of providing overhaul and maintenances cervices to the military
hardwares and equipments of the ground forces of the ministry of national defense.
The project is located in Bishoftu, 45 km to south east of Addis Ababa, the capital city of the
federal democratic republic of Ethiopia. It occupies at total area of 32.5 hectares, out of which
area is covered by various building.
1.1.2 VISION AND MISSION OF THE INDUSTRY
The vision of industry of the project 40720 phase was to be self-reliant on the providing
maintenance and over all service for the military hardware and equipments of the ground force
and ensure combat readiness of the army.
The mission of the industry of the project phase was to ensure the combat readiness of the army
by maintaining and over hauling military hard work and equipment of the ground force with
better efficiency, quality and at lower cost.
To increase manufacturing capacity and capacity for tool, spare part and auxiliary required for
the maintenance and overhaul activities.
The main activities under the company
Bishoftu Automotive industry at the project phase 40720 was equipped with appropriate
technology ,machinery and equipment that enable it to provide efficient services in the following
specialized areas :
overhaul and maintenance services of military iron-made tanks and Armed Person
Carriers( APC)
overhaul and maintenance service of Military Automotive and engineering vehicles
manufacturing of spare parts used for repair and overhauling
JiT Mechanical Engineering department
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Repair and maintenances of light and heavy weapons, generators , Communications

and electrical equipment
Assembly of city bus and cross county bus
Assembly of double and single cabin pick up car
Assembly of super urban vehicle (SUV) car
Heavy duty truck assembly and engine maintenance.
1.2 The Main Products and Services

The main products are:1.2.1 Hongyan-Iveco Truck
Model: CQ4254HTVG324
Drive form: 6x4
Engine type: Fiat F2CE0681*B052
HP: 380 horsepower
Emission standards: China III
Displacement: 8.71L
Torque: 1500Nm
Wheel base: 3225+1350mm
Traction quality: 39.2 tons
The vehicle weight: 9.67 ton
Highest speed: 95 km/h
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Figure 1:- Hongyan Iveco truck

1.2.1 Sino truck (Dump truck)
Overall dimension: 2240x2490x3450 mm

Dump box dimension: 5100x2300x1500 mm
Box inside volume: 17 cubic m
Loading capacity: 30000kg
Drive type: 6x4 left hand drives
Maximum speed: 90km/h
Horse power: 266-366Hp
Fuel type: diesel
Displacement volume: 9726mL
Emission: Euro 02/03
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Figure 2:- Sino truck

1.2.3 SUV(Super Urban Vehicle)
Car model --------------DD6470C

Color --------------------silver/black
Engine model--------------R425DHDC
Four cylinders in line, four stroke, and watercooled, inter cooler electric control,
common rail diesel engine per cycle with four valves.
Displacement(L)-----------------2499CC
Max. power(kw/r/min)-------------------105/4000
Max. torque(Nm/r/min)-------------------340/2000
Vehicle weight---------------------------1860kg
Vehicle + load + passenger + driver -------------------2510kg
Max. speed--------------------------130km/hr
Fuel tank capacity---------------------90L
Emission----------------------------------Euro III
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Figure 3:- supper urban vehicle (SUV)

1.2.4 Single Cabin Pick up
Max. Speed--------------------------------120km/hr
Overall vehicle weight----------------------1240kg
Car model---------------------------------DD1022T
Color--------------------------------------silver/white
Engine model---------------------------------4JB1TI
Four cylinder in line, four stroke, turbo charged and water cooled
fuel tank capacity------------------------70L
Displacement(L)-------------------------2771CC
Max output power(KW/r/ min)---------------75/3600
Max torque(Nm/r/min)------------------------235/2000
Maximum load carrying capacity-------------------230-240kg
Overall dimension-------------------------4995 X 1725 X 1690
Frame(LXW)mm------------------------------4900X130
Cargo(LXWXH)mm-------------------------------2150X425X1455
Wheel base front/ rear(mm)----------------------3025
Wheel track front/rear(mm)----------------------1450/1440
Min ground clearance-----------------------------210mm
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Figure 4:- single cabin pick up

1.2.5 Double Cabin Pick up
Car model---------------------------DD1022T
Color--------------------------------silver/white
Engine model-----------------------4,B1TI
Four cylinders in line, four stroke ,turbo charged and water cooled
Fuel tank capacity---------------------70L
Displacement(L)------------------------------2771CC
Emission----------------------------------Euro III
Max speed--------------------120k/h
Max output power(KW/r/min)------------------------75/3600
Max torque(Nm/r/min)--------------------235/2000
Maximum loading capacity----------------230-240kg
Vehicle weight -----------------------------1650kg
Dimension-overall (LxWxH in mm)--------------------5350X1725X1696
-Frame---------------------4900x130
-Cargo----------------------1715X475X1455
-Wheel base front/rear----------------------3380
-Wheel truck front/rear----------------------1479/1487
-Min ground clearance----------------------210
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Figure 5:- double cabin pick up

1.2.6 City Bus
City buses are specified for passengers inside city only and they carry people or passengers only
across city from village to village. Their design and internal system is specified for short inside
country travels. As a result safety and the number of passengers is not restricted as they do not
carry cargo.
Figure 6:- city bus
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1.2.7 FAW Dump Truck
Gross vehicle weight 32000kg

Top speed 76 kph
Maximum load capacity 16m3
Maximum output power kW/(r/min) 250/2200
Overall dimension (LxWxH, mm) 7393x2500x2890
Figure 7:- Faw model Dump Truck
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1.2.8 Cross-country bus
Cross country buses are buses designed for passengers traveling cross-country. The design and
specification, and safety requirements are different for this case. As the bus travels hundreds of
kilometers carrying passengers plus cargo, it is designed to be safe and strong for passengers
Overall dimension (LxWxH, mm) 9300x2450x3480
Gross vehicle weight 11990Kg
Top speed 110kph
Six cylinder, turbocharged, water cooled diesel engine
Maximum output power (kW/rpm) 155/2300
Figure 8:- cross-country bus

1.2.9 Bush Car
As one can recognize from its name bush car is a military car especially designed and
manufactured armed soldiers into the bush for attack/combat. It is made from ford pick up car by
removing the body and shortening the chassis. The engine and other parts are the same with the
body replaced by thick sheet metal and bullet proof glass. The tire is very hard and resists
damage and it is automatically filled when pierced.
The armed soldiers fire from inside the car through small holes on the cars body.
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Figure 9:- bush car (Zilla)

1.2.10 Tank
Figure 10:- chain and wheel tank
1.3 Main Services

The main services of the company are assembly and maintenance.
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The assembly section includes assembly factories of single and double cabin Isuzu engine
pickups, SUVs, city buses, cross country buses, heavy duty trucks, and military vehicles like,
tank, bush car, APCs (Armed Person Carriers), and bush ambulances.
The maintenance section provides maintenance to military vehicles and after sale maintenance
for customers. After sale services are given for customers depending on the distance the vehicle
traveled before failure. If the mileage reading is up to 5000km, maintenance is given for free.
And for failures after 5000km the customer has to pay.
Free after sale maintenance services include cleaning air filter, changing oil filter, and cleaning
fuel filter. Furthermore if the vehicle has collided, body maintenance, tire maintenance, head
lights and radio and music players, and door locks are maintained.
1.4 Main Customers or End Users

Basic and sale customer of the industry was the federal democratic republic of Ethiopia ministry
of defense. as result if begins to manufacture ,maintain and overhaul different types of military
equipments such as weapons ,military vehicles , and different mission cars. Is organized as a
multipurpose industry under the branch of metals and engineering corporation
As mentioned in the preceding section the industry first started by assembling, overhauling and
maintaining military vehicles like tanks and orals, locomotives, and earth moving machines like
dozers, rollers, graders, and excavators. As a result the products were limited and go to the
military defense ministry and the construction companies. But currently it is assembling and
maintaining almost all types of vehicles in use in our country like construction vehicles, city and
cross country buses, and pickups. So as product diversity increased, the number of customers
also increased. Some of them are the Cross-country Passenger Bus Private sectors , construction
companies, federal and regional government institutions and civil sectors. The company plans to
increase its production and produce many other machineries and spare parts, so in the future it
will reach more customers from institutions to individuals.
1.5 Overall Organization and Work flow

Bishoftu Automotive Industry is growing radically and becoming broader from time to time. It is
opening new assembly and maintenance factories and as a result it is becoming more complex
and the number of workers is also increasing from time to time.
Currently the company has 1627 workers including military, contract, and permanent. The
specific number of the sub-groups with their education status is listed below.
Permanent: - 37 civil workers with degree, 16 military workers with degree, and 391 workers
with diploma.
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Contract: - 26 workers with degree and 1149 workers with 10+2, and the rest 8 workers are
master degree holders.
This profit making industry different types of operational job flow cycles with the main ones as
purchase repulsion, market research for repulsion, and service repulsion.
The work flow and linkage between the various sections and authorities under the company is
shown in diagrammatic format below.
1.5.1Purchase repulsion
Operational
head
Factories
Logistics
administration
Purchasing
department
1.5.2 Market research repulsion for purchase
Factories
Head of
marketing and
sales
Market
research and
advertisement
Logistics
administration
Purchase
department
1.5.3 Service repulsion
Operation
head
Customer
Factories
General
Manager
Market and
sales head
Customer
relation
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Chapter Two
Overall Internship Experience
2.1 How we got into the company
After we got the letter requesting for internship place from the department, we assigned one of us
to take the papers to the company to request for permission and our friend (Mollalign) took the
papers to the company design department and told us that our request was confirmed. Then after
brake we met Mr. Sami, mechanical engineering department industrial linkage, and he made
contact with the company.
The first day we got into the company we joined the companys human resource department.
Then we were sent to the design department. There we met Engineer Saud, who later became our
company supervisor. Engineer Saud showed us all blocks or factories where we were going to
work. Then he introduced us with the company factory heads. And within few days we became
familiar with the environment and gained a general overview of the factories. Then we were sent
to the specific factories to work there. The jobs we had been performing under each factory are
discussed in the following sections.
2.2 The Sections of the Company We Had Been Working In

2.2.1 Light vehicle production factory
In this factory fully assembling of single and double cabin pickups and super urban vehicle (SUV) is
carried out.
Specification of those vehicles:Engine model 4JB1TI 4 cylinder inline, 4 strokes, turbo charged, and water cooled, maximum
speed 120 Km/h, cargo load capacity 5000kg, single disc dry type friction clutch, circulating ball
power steering hydraulic assisted, Euro III emission standard and high position brake light.
2.2.2 City and cross-country bus and mid-bus
Public transport vehicle production factory is one of the factories that found under Bishoftu
automotive industry. This factory produces city bus, mid-bus and cross-country bus. This factory
solves the problem of some Ethiopian town by the direction of public transport. All activities of
this factory are 100% assembly of vehicle part.
The job of public transport vehicle production factory is done under four shops.
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ii.
iii.
iv.
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Chassis and engine assembly shop

Body welding
Color painting shop
Finishing workshop
2.2.3 Heavy duty truck Assembly Factory
This factory fully assembling FAW,BEIBEN Truck, Sino Truck and Kingkan iveco
technology Truck.
2.2.4 Engine room
This room is capable of maintainase and service of different types of engines including tank and oral
engine overhaul, double and single cabin pickup, SUV, bus and heavy duty engines.It is arranged
in different stations. It has disassembly station, inspection station, reconditioning station and
assembly station.
2.2.4 Tank and iron-made vehicles Overhaul section
In this section tanks, bush-cup type, armed person carrier (APC), Bush Ambulance, Bush Car
(special purpose military car), and other military trucks. The section has a large number of
machineries and facilities and has skilled man power who can efficiently utilize this machineries
and facilities. The section uses its full potential to overhaul several types of tanks and iron-made
vehicles, and deliveries the tanks with the efficiency of new tanks after making road tests.
2.2.5 Vehicles system production factory
In this shop hydraulic and pneumatic systems of the vehicles are serviced, maintained and
tested their performance by the use of different test stand bench machines before
assembled to the vehicles system part.
This shop is the last shop for pick up, bus, SUV, and trucks before they are ready for sell. After all the
assembly and painting job is finished, the vehicles are brought into this room for different kinds of
testing. A computer unit called central data account or control panel unit (CPU) takes the signals from
sensors on the test stations and displays the output reading for the technician. The different kinds of
tests in this shop are:
Braking efficiency
Axle weight
Total vehicle power
Wheel alignment
Speed
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Smoke or exhaust
Fuel consumption per rpm
Camber and caster positive and negative
Gross weight
Trumpet and lighting system
2.3 The Work Flow in the Sections

Double cabin, single cabin pick up and SUV room
In this shop two main tasks are performed: - Assembly and maintenance (after sale service).
After sale maintenance activities given for free if the vehicle millage reading is up to 5000km,
and they have to pay for more than 5000km. The activities under after sale service are:
Changing oil filter

Cleaning fuel filter
Cleaning air filter
And other body maintenance for collided cars.
The assembly process goes through different stations.

Station-1
Spare parts are inspected. Then chassis is put on line and rear buffer block is installed. Next rear
and front axle gear oil is filled. Sub assembly of leaf spring and rear axle and installing rear
shock absorber and fuel tank. Followed by sub assembly of lower arm and front shock absorber
torsion bar accessories and installing horizontal stabilizer bar.
Station-2
Spare parts are inspected; markings are made for chassis and whole vehicle nameplate. Spare tire
lifter, front axle, and diverter are installed. Then front brake fuel pipe and breaking hose, and
steering drawing rod are installed. Lastly, tire and spare tire parts are assembled.
Station-3
Spare parts inspection, marking for chassis and whole vehicle nameplate, Install spare tire lifter,
install front axle and diverter; install front brake fuel pipe and breaking hoseand steering drawing
rod.
Station-4
Spare parts inspection, sub assembly rear box, Install gear box and clutch branch cylinder, fill the
engine oil, hoisting engine, painting VIN code, adjusting the height chassis.
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Station-5
Spare parts inspection, front/rear shaft axle, block for bearing of cargo, high and lower pressure
pipe for steering, and inlet and return oil pipe installation.
Station-6
Spare parts are inspected, muffler section is installed, and muffler middle and rear section is
installed.
Station-7
Spare parts inspection, install chassis wire harness, install inlet and return fuel hose, fuel filter,
inlet hose and positive and negative pole line, and riving axle and muffler wiring assembly.
Station-8
In this station chassis is inspected and repaired.
Station-9
Spare part is inspected and cargo compartment is hoisted.
Station-10
Seats are installed and cargo compartment is adjusted and tightened.
Station-11
Install decorative cover, heater hose, Install engine conduit tube install ac compressor high and
low pressure pipe, Steering column connecting, Install brake tube connecting, Install steering
wheel, Install engine room wiring, Install oil filter, and Check all the parts installation.
Station-12
Front and rear wheel fender is installed.
Station-13
Install escutcheon, Install middle net, and Install steering lamps.
Station-14
Install cargo compartment, Install rear bumper (finished), and check all the parts installed.
Station-15
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Fill diesel, Fill glass water, fill anti-freeze fluid, filling power assistant oil installation fuel filling,
and install bellow. Next, filling brake tube and adjusting braking, fix hand brake bracing wire,
and install all the parts installation fluid filling.
Station-16
Wheel alignment is tested, Car height is checked, and mud protecting board is installed.
Station-17
This is the last station which is light testing.
Figure 11:- pick-ups and SUV shop

Cross-countryand city Bus room
In his room both assembly and maintenance are performed. As we mentioned this room have
four shops:
1. Chassis and engine assembly shop
2. Body building shop
3. Color painting shop and
4. Finishing shop
Chassis and engine assembly shop: - this shop is one of the shops that found under the public
transportation vehicle production factory. The activity of this shop is consuming generally 20%
of the total work of the public transport vehicle production factory.
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The step perform through stations

Station one: - axle and wheel assembly
Station two: - welding
Station three: - shock absorber and stabilizer assembly
Station four: - engine assembly
Station five: - steering and valve assembly
Station six: - radiator and selector assembly
Station seven: - electrical and pipe assembly
Body welding shop: - this shop is one of the shops that found under the public transportation
vehicle production factory. The activity of his shop is consuming generally 24% of the total work
of the public transport vehicle production.
The production of the shop is perform under stations
Station-1: -roof welding
Station-2: - body frame alignment welding
Station-3:-body frame welding
Station-4: - floor welding
Station-5: - seal board welding
Station-6: - steep dawn welding
Station-7: - body covers welding
Color painting shop: - also this shop is one of the public transport vehicle production factory.
The activity of the shop is generally 15% of the total work of the public transport vehicle
production factory.
Also the activity of the shop goes through the stations
Station-1: - primary and glue paint the drying
Station-2: - first putty, second putty and polishing
Station-3: - middle coat paint, second putty, drying and polishing
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Station-4: - final painting then drying

Finishing workshop: - this shop is the end work of the public transport vehicle factory.
Generally this shop covers 41% of the total work of the factory.
The procedure of the activity in this shop is perform under eight stations
Station-1: - Ac work, Plug work assembly
Station-2: - Pipe and harness of ac, gauge harness, front and rear lamp
Station-3: - inner roof, floor mat, side wall and door valve
Station-4: - aluminum frame work, speakers and light connection
Station-5: - side mirror, general component, driver seat assembly, hand drill assembly
Station-6: - instrumental gauge connection, passenger door assembly, passenger seat assembly,
front and rear mirror assembly, water drainage assembly
Station-7: - drop fuel into fuel tank, check line of this shop activity by quality controller man,
Station-8: - engine oil filling, engine coolant filling, differential oil filling, gear box oil filling,
steering oil filling, engine fuel filling, and road testing.
Figure 12:- bus assembly shop

Cross country bus assembly shop
The activities in this shop also go through stations
Station-1
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The parts assembled at this station are front leaf spring left and right side, rear leaf spring right
and left, dead axle, rear differential, rear and front U bolt, leaf spring cover plate, front of front
leaf spring bracket, front of rear leaf spring bracket, rear of rear leaf spring bracket, buffer block
or damper, stabilizer bar bracket, brake chamber right and left, rear and front lug, leaf spring
stepper, shock absorber big, front shock absorber bracket, different diameter bolt and nut, and
different diameter pin.
Station-2 A
The parts assembled at this station are; liner, air cleaner bracket, pipe line bracket, out rigger, and
steering pump.
Station-2B
The parts assembled at this station are; flat washer plastic, cotter pin, steering swimming arm,
long plastic hose, high and low pressure hose, short and long tie rod, steering hose, steering
pitman arm, Steering gear bracket, middle arm, cup nut and grader, metal tube for compressor,
front brake chamber, galvanized different types of copper tube for compressor, pipe cover, servo
pipe, front and rear bracket pipe, hand brake pipe, and front and rear door pipe.
Station-2C
The parts assembled at this station are; temperature adapter and sensor, antilock brake system
(ABS), relay valve, protection valve, ABS support, air regulator with its support, quick relay
valve bracket, temperature adapter normal T-joint , brake chamber adapter, and air reservoir
tanker.
Station-3
The parts assembled at this station are steering oil filter, steering oil bracket, and air reservoirs.
Station-4A
The parts assembled at this station are engine, gear box, shifting cable supporter, servo bracket
support, servo bracket; Intake rubber hose, shifting cable, exhaust bend pipe, fan, and air cleaner.
Station-4B
The parts assembled at this station are; exhaust bellows pipe, straight rubber hose, shaped steel
pipe, straight steel pipe, intake steel intercooler, exhaust tail pipe, radiator suspension bracket,
right angle rubber hose, Z-shaped rubber hose, and engine bracket.
Station-4C
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The parts assembled at this station are; exhaust muffler, pipe clip, exhaust pipe bracket, right and
left radiator bracket, rear suspension bracket, muffler, Rear suspension engine Cashion, and
straight rubber hose.
Station-5A
The parts assembled at this station are; pipe cover, AC spring, and copper servo pipe.
Station-5B
The parts assembled at this station are; gear type pump, AC bolt and nut, and crank pulley.
Station-6A
The parts assembled under this station are; servo hose, fiber glass, plate bracket, retarder bracket,
drive line protection bracket, brake hose, and propeller shaft.
Station-6B
The parts assembled at this station are; L-shaped bracket, Spare time extension, Clutch servo
bracket, shifting arm, and tie holder.
Station-7A
The parts assembled under this station are; starter positive wire, generator positive wire, ECU
(electrical control unit) harness, retarder harness, ABS harness, retarder power wire, main chassis
harness, and oil pressure sensor connection wire.
Station-7B
The parts assembled at this shop are; Water and temperature sensor, Retarder sensor, Oil
pressure sensor, Air pressure sensor, Hanny supporter, Metal clamp, and Plastic clamp.
Station-7C
The parts assembled at this station are; Harness anti-heat cover, Pipe heat cover, Generator
supporter with tensioner support, and AC generator belt.
Welding Shop
Station-1
This station is the Top Cover Welding station and the parts welded at this station are;- top body
frame, top sheet cover. And painting is also done at this station.
Station-2
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At this station body-frame alignment is checked by top frame, right side frame, and left side
frame.
Station-3
The welding in this station is body frame sheet metal welding cover.
Station-4
Floor parts welding
Station-5
Sheet metal covering and welding (sealed body welding)
Station-6
The welding activity at this station is fender and step down welding.
Station-7
Skin or body covers welding
Station-8
Final inspection
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Figure 13:- bus body welding shop
Heavy duty truck assembly factory

The two main tasks in this factory are the assembly and the checking of the parts for proper
assembly. There are eight stations in this factory and the jobs in each station are as described
below under their respective stations.
Station-1
Walking beam is assembled and it is checked that the beam is properly assembled and the
torque.
Bend beam or cross member assembly and shim assembly, and check that the beam is
properly assembled and tightened.
Rubber block or vibration damper is assembled and checked that the rubber blocks are
assembled and tightened.
Front leaf spring assembly and checking that the leaf sprigs are firmly assembled and
tightened with U-bolts
Rear leaf spring with guide plate assembly and check that the leaf sprigs are firmly
assembled and tightened with U-bolts
Upper and lower torque rod assembly and checking that the torque rods are firmly
tightened.
Engine support, front and rear suspension assembly and checking that all the front and
rear supports are properly assembled and tightened.
Fastening U-bolts (rear) and checking that the U-bolts of each leaf springs are fastened
tightly.
Install brake line/tie-ins/(left and right) and checking the bracket is firmly installed at the
required torque.
Install shock absorber bucket and check that both left and right brackets are properly
installed and firmly tightened
Station-2
Fastening upper and lower torque rods and checking that the torque rod is fastened firmly
and securely and connected in the right position
Fastening U-bolts/front and check that the U-bolts of each leaf spring are fastened tightly.
Transmission line/propeller shaft assembly both rear and middle and checking that the
propeller shaft is fastened firmly and securely and connected in its right position.
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Front, middle, and rear axles are assembled and the axles are inspected for no damage
and they are assembled correctly and tightened.
Rear and middle brake chambers are installed and made sure that the parts are installed
properly and well tightened.
Transfer case and front shock absorbers/left and right assembly and make sure that the
parts are installed properly and well tightened.
Station-3
Left and right compound tail light with bracket installation and that the part is installed
properly and well tightened.
Air cleaner support assembly and that the bolts of supports for firmly installed.
Fuel tanker and its bracket assembly and check that all the bolts of the fuel taker and its
support for firmly installed.
Cabin support assembly and check that all the bolts of the cabin are fastened firmly and
securely and connected in their right position.
Steering assistance gear box assembly and torque and check that all the bolts of the
steering assistance gear box are fastened firmly and securely at the required torque.
Tie rod assembly torque and inspect that all the bolts of the tie rod for fastened and
securely at the required torque.
Air tanker/reservoir, Battery bracket and case, 4-way protection valve sub assembly and
check that all the bolts of the air tanker and its supports for firmly installed.
Battery bracket and case assembly with chassis frame and check that all the bolts of the
battery bracket and its support for firmly installed.
Air cleaning bracket assembly and check that the bracket is installed and tightened
properly.
Primary fuel filters bracket assembly and check that the bracket is firmly assembled.
Front brake chamber line and compressor bracket pipe line and check that these lines are
assembled firmly.
Terminal box and reversing buzzer and make sure that the parts are properly installed and
well tightened.
Exhaust pipe bracket and check that this bracket is assembled firmly.
Station-4
Engine, clutch, gear box assembly, and toque and check that the bolts of the engine are
fastened firmly and securely and there should be no shake.
Both sides mud guard brackets and cabin lifting cylinder on the right side bracket and
make sure that the parts are properly installed and well tightened.
Gear shifting linkage to transmission assembly and check that gear shifting linkage
should be loosely connected at both ends.
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All air pipe lines assembly and inspect that all the air canals are tightly fastened lest there
should be no leakage.
Assemble gear box upper support and firmly assemble the gear box at the required
torque.
Station-5
Servo clutch seemly and checking for correct ligament of the servo clutch and it should
be fastened tightly
Air cleaner assembly and checking that the air cleaner surface for no damage and
fastened tightly.
Cabin hydraulic system assembly and checking the hydraulic system had pump assembly
and its pipe line with no leakage.
Steering hydraulic system assembly and making sure that the steering system pipe lines
are firmly tightened with no leakage.
Flexile exhaust pipe assembly and inspect the exhaust pipe for no damage and no loose at
joints.
Engine brake throttle valve assembly and check that the engine break throttle valve for
firmly installed.
Cabin support assembly and checking that all the bolts of the cabin are fastened and at
their right position.
Radiator assembly and the radiator should be tightly and firmly fasten to its support with
no shake.
Compressor pipe line assembly and check that both the pipe and the bracket are firmly
tightened.
Air cleaner hose bracket assembly and check that the air cleaner bracket is properly
tightened and clamped.
Primary fuel filter and fuel pump assembly and check that the primary fuel filter is
properly installed and tightened.
Power steering oil reservoir and check radiator assembly and mounting for securement
and condition.
Radiator guard and condenser assembly and check radiator assembly and mounting for
securement and condition.
Ststion-6
Cabin assembly and check the cabin for proper mounting on its support and tighten
firmly.
Side mirror assembly and make sure that all side mirrors are assembled and there should
be no crack.
Air brake assembly and check for proper assembly of park brake
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Cabin hydraulic lifter assembly and inspect that the lifter for proper operation and it must
be firmly tightened.
Water pipe assembly and check the water pipe joints for firmly tightened causing no
leakage.
Accelerator, Brake, and Clutch pedal assembly and check for smooth operation of pedal
assembly and leakage in the accelerating and coast position.
Steering wheel assembly and check for free play, check steering column inside track for
up and down, side to side play, and for proper mounting.
Service brake assembly and inspect drive shaft parking brake assembly for condition,
mounting, securement, and adjustment of linings, drum leakage, and all other related hard
ware.
Mud guard assembly and check that it is properly installed and fastened.
Step pedal assembly and check that the pedal is firmly installed.
Station-7
Gear box and axle oil (SAE 90) and check that all the parts requiring lubricants are
lubricated.
Cab hydraulic oil and check that the specified oil is being filled
Power steering oil (SAE 10) and check that the specified oil is being filled
Coolant oil and check that the specified coolant is being filled
Grease and check that all parts requiring lubricant are lubricated
Clutch oil and check that all parts requiring lubricant are lubricated.
Refrigerant and check that the specified gas is being filled
Vehicle tire assembly (SAE 90) and check that the tire is properly installed and torqued.
Engine oil (SAE 40) and check that the specified oil is being filled correctly.
Station-8
Ignition switch, charging indicating light, pre heating indicating light, engine failure
indicating light, and check the ignition switch at each position and inspect each indicators
response whenever the corresponding switch is turned.
Combination switches of head light, front head lamp, front width lamp, height indicator
light, license plate lamp, night lamp, and fog lamp. The combination switch of head lamp
is at correct position and normally functions; and the function of vehicle lamp controlled
by combination switch of head lamp should be normal.
Foot braking lamp is the lamp controlled by foot braking pedal and it should work
normally.
Steering combination switch, steering lamp, head light on full beam, trumpet and rain
brush or nozzle. The vehicle lamp, the trumpet and rain brush (nozzle), which are
controlled by the steering combination switch, should have normal function
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Hand brake indicating lamp (parking lamp) and braking handle of hand braking should
have normal working functions and the vehicle lamp controlled by the braking handle of
the hand braking should normally work.
High-low-gear indicating lamp. When the air pressure of the combination instrument is
indicated above 7bar, the gear shaft levers are located in the high-gear area and the low
gear area, and the corresponding indicating lamp on the instrument plate should be light.
Differential lock between wheels, the differential lock between bridges, the power take
off and relevant indicating lamps. The differential lock between wheels, the differential
lock between bridges and the power take off switch should normally work, and the arrow
of switch points to the opened direction instrument board, and corresponding indicating
lamp should light.
Alarm device. The alarm switch should normally work, after it is opened, the functions of
the controlled lamp should be normal, and the corresponding indicating lamp on the
instrument board should light.
Lighting lamp in the driving cab, and reading lamp. Lamp controlled by the lighting
switch should have normal functions.
Back light lamp of the instrument. The lamp controlled by the switch of the back light
lamp of the instrument should have normal functions.
Warm-air drier, the warm-air drier has normal functions.
Air conditioner. The air conditioner should have normal functions (surrounding
temperature should be larger than 5 0c)
Radio and check that the radio normally functions.
Radiator/ front cab cover and check that the cover is properly assembled and tightened.
Trailer control valve upper cover and check that the valve is correctly assembled.
Middle and rear mud guard assembly and check that the mud guard for correct assembly.
The different types of oils, glues, and gaskets used are: - Oil for engine grade 40, foe differential
grade 140, steering grade10, gear box grade 90.
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Figure 14:- heavy duty assembly shop

Engine performance testing room
The engine room is arranged in different stations. It has disassembly station, inspection station,
reconditioning station and, assembly station.
The engine group itself in divided two sides dedicated to tank engine overhaul and oral
engine overhaul, double and single cabin pick up, SUV, bus and heavy duty engines.
Disassembly station
In this work group the engine is disassembled into its parts. The tools they use for
disassembly are simple tools like ring wrench and so on. There is no sophisticated tool and there
is no automation.
The engine is disassembled in its reverse order of assembly and the small parts are put in
a dish. The general housing is hoisted by a crane and attached to the hook which is attached to
the ceiling for the handling of the engine and other work pieces. The engine housing is washed
by using hot water, steam and soda ash. For small parts that are on a dish the handling is done by
a method of chain conveyors.
Inspection station
After the Engine is disassembled and its parts are washed, the next step is inspection. The first
part of the inspection process is the visual inspection. Through this process problems like, crack
and breakage on the engine housing and the other parts are detected.
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The parts that are inspected usually in the inspection room are the engine housing, the
crankshaft, the camshaft, journal/shell bearing and the valves. For the inspection of these parts
instruments like the micrometer, Varner caliper, magnetic stand with a dial, dial gage and bore
gage are used.
During the inspection of the crank shaft housing first the bolts of the case are tightened to
the right torque from the manual and then turned again to the right degree. Then the diameter of
the hole is measured either with bearing or without using the bore gage.
Reconditioning station
After the parts of engine (mainly the crankshaft, camshaft and the engine cylinder) have
been inspected, if there is a damaged part it will be reconditioned to a suitable value.
There are different reconditioning methods that will be used for the different parts. For
the camshaft the shaft part will be either ground to a suitable value, if it has been greater than the
set value or it will be filled by welding and ground to a suitable value, if it has been lower than
the set value.
For the crank shaft also, the same procedure that has been used for the cam shaft will be
used. The grounding procedure will be done on a special type of lathe machine that has a suitable
mechanism for this purpose.
The crank shaft holder is also reconditioned by using a boring machine specially set for
this purpose. As for the cylinder lining, a new lining will be inserted in to the old one and it will
be bored in to a suitable value with a special boring machine.
Assembly station
The assembly section has three specific sections, they are:-
Oral engine assembly

Tank Engine assembly
Construction vehicle Engine assembly.
Unlike the disassembly work group, the assembly section follows a set of procedures as
set by the manufacturer on the manual. Special tools will be used in assembly specific to the part
that will be assembled, most of these tools are custom made to lessen the difficulty and reduce
the time that the assembly process causes.
But even with the special tools the assembly process is tiresome and time consuming.
The main cause to this problem is the engine time setting process. On the tank engine the engine
time setting process may take up to one or more days.
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Figure 15:- engine performance testing room
Tank room
Dispatching
Disassembling the machine into parts
Washing
Washing of the parts is carried out by chemical and sand washing to remove the painting and
rust. Sand washing is carried out by spraying pressurized water with fine sand. This pressurized
strike removes the painting and rust from the material surface. Sand washing is the most
economized.
Inspection
Under this step the parts are checked for wear, crack and dimensional inaccuracy by using
different gauges and by visual inspection.
Modification
After the parts are washed and inspected, they are modified and repainted.
Assembling
After all the above processes the machine is assembled as a modified product.
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Checking (testing)
After assembly the machine checked for its performance.
Figure 16:- around tank room
2.4The Tasks We Had Been Executing

The whole internship time we spent in various sections of the company observing the assembly,
overhauling, and making note of the parts assembled and their procedures. In each factory we
spent two weeks and more seeing the work flow and participating in the assembly, welding and
maintenance activities.
The tasks we took part in are: -pick-ups,SUV, bus body and frame welding, Tank engine
overhauling and, Cross country bus assembly, and Heavy duty truck assembly, and Engine
performance testing room.
The machine tools are we used in chassis workshop are:- adjuster ratchet, hammer (metal and
rubber), Alan key, open wrench, ring wrench, pneumatic torque, smart auto torque, screw driver,
measuring tape, manual grease gun, manual oil pump, car crane,1.25ton, compressor (rotary and
piston type), grinder, MIG welder, thicker blade, and drill.
The materials we used in welding workshop are- sheet metal heater, different laps, mallet
hammer, ball pin hammer, Kristin, center punch, chap rule, drill, scabbier, bending machine,
plasma cutter, MIG welder, and cart.
The safety materials we used are: - helmet, shield, glove, eye goggle, ear protector, mask, safety
shoes, slave, and apron.
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The materials we used in finishing room are: - postiche, drill screw driver, knife, disco, beat,
spray gun, and heater.
2.5 The Procedures We Have Followed

In bus body and frame welding factory the welding is made by using MIG (Metal Inert gas
Welding). In MIG welding wire is continuously fed from a spool. MIG welding is therefore
referred to as a semiautomatic welding process.
The procedures in MIG welding are:
Cleaning the base metals from rust, oil, paint, and other contaminants
Mount the wire onto the spool, and feed it through the MIG welder.
Remove the tip of the MIG gun to facilitate the feed
Turn the machine on, and pull the guns trigger on, and feed the wire through the nozzle.
Replace the nozzle and trim the wire between 1/8 to inch / .32 to .64cm.
Set the welding machine polarity to DCEP
Set and clamp the pieces of metal that are to be welded
Wear gloves, welding helmet, and welding coat.
Weld the joint
Turn off the machine and inspect the weld for imperfections.
Grind down the weld if it is defective and re-weld.
2.6 Our Performance

At first we were very much excited and amazed at what we saw during our introductory visit. It
was the first time for us to see the assembly of a vehicle from thr start and such long and
complex production lines. As a result we started by having a detailed look at the activities and
making note of the procedures. Step by step we then started taking part in the different activities
under the workers supervision.
As a result of our curiosity and interest in the activities we soon learned some of the procedures
and worked with them. Our performance was good as a beginner but we would have been more
perfect if we had stayed longer practicing. As it was said that practice makes perfect one grows
to perfection through practice.
2.7 Challenges We Faced

In the first place the company is a military company and it has put limitations and restrictions on
every step in the company. We are not allowed to take in cell phones, cameras, laptops, andother
related electronics. As a result we could not get access to the information that we wanted. The
other related problem is that we could not get books and access to internet in the company.
Besides they dont tell us in detain about the company and its work and performance because
they think a third party would get the information and the companys secret.
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The challenges we faced at the workshop and assembly factories are: - the workers and shop
supervisors not telling in detail due to the companys security and there are no enough safety
materials.
Some sections and heads of the company did not know us through all that time (we think this is
because the external linkage department didnt inform all the sections about us). Due to this we
had problem entering and leaving the company. Related to this, ask we go to other sub shops we
faced many rejections and we are asked for confirmation paper from the design department every
shop we go.
2.8Measures we taken
It is evident that we face challenges everywhere we go but, we may not solve all of them but we
make the best we can at least improve the situations. There were challenges we tried to solve
ourselves those that we recommended a solution and those we just handled the way they were.
And still for others we gave the company ideas to solve them.
There was shortage of safety materials but we used what we had turn by turn. And we allocated a
pair of trousers and shirts for shop work only and some of us bought work cloths.
For problems concerning engineering design we tried our best to come up with design analysis of
the solution.
For pick-up maintenance a hydraulic scissor lift was designed that can lift up to 1.8 meter for
maintenance. We also suggested way to localize some of the spare parts that can be made here.
For example to such is using the method of Jig and Fixtures mass production for bus body frame.
The process and design for these is attached in the project section.
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Chapter Three
Benefits of the Internship
3.1 Practical Skills
Metals and engineering corporation Bishoftu automotive industry is generally an
overhauling company, assembly, welding, engine performance testing and military vehicles.
However some new researches are also being done on new methods of improving the existing
military warfare technology of Ethiopia.
Due to this fact we have been able to acquire practical skills in both overhauling existing
vehicles and research to manufacture new body parts.
After spending four months at the factory we have gained the practical skills on how to
overhaul vehicles and find problems. In the engine room we have learned the steps that should be
taken to overhaul an engine which are disassembly, inspection, reconditioning and assembly. In
each step there are tools that are used specially made for the case and we have familiarized
ourselves with them.
In the systems factory we have learned how the different systems of the vehicle control
the execution of different outcomes like steering and movement of the turret. We have also learnt
how to recondition different damaged parts like the radiator. The most important knowledge we
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acquired in this factory is how to recondition electrical systems and how to integrate them in the
mechanical systems.
In the tank factory we have familiarized ourselves with the steps that should be taken for
disassembling and reassembling a whole vehicle. Fault finding is also one of the skills that we
were able to gain from these factories.
Also we have seen the detail assembly of pick up, heavy duty, bus and SUV as well as
after sell maintenance of pick up and bus. In the bus body welding we have acquired practical
skills on MIG (metal inert gas welding) with automated electrode feeding and welding
inspection.
The most important skill that we acquired from our four months of stay in this factory is
the skill of reading manuals and interpreting them. This is most important because a slight
misinterpretation may cause us many hours trying to find the real fault.
3.2 Theoretical Knowledge

Bishoftu automotive industry is a company that applies most of the theoretical teaching
that we acquired at university, like machine elements and machine design, hydraulics and
pneumatics, thermodynamics, maintenance, mechanisms of machinery, mechatronics, and
internal combustion engines. Due to this fact our stay at the company has helped us upgrade our
theoretical skills on these fields.
The engine room is like a house of knowledge for things ranging from how an engine
works to the mechanisms that are used to the transfer of power from the engine to the hind legs.
In the engine room we have seen different types of engines like inline four and six, v-six, vtwelve, and from medium power engines like Toyota to the high power engine like a tank engine.
By observing these engines we have seen the physical changes that are present according to the
number of cylinder and type of power needed.
We have also observed sensors that can be used for the smooth functioning of engine. For
example smoke control valve can be used to detect the amount of smoke that is expelled and
either increase of fuel that reaches the cylinder or decrease it. The thermostat is also used to
control the temperature of water that flows throughout the engine.
In the power train room we have been able to identify systems like transfer case and
differential. A transfer case is unique to four wheel drive vehicles and is what directs power to
both end axles of the vehicle through two separate drive shafts. It is attached to the rear end of
the transmission and gets input directly from the transmission. Power is directed from the engine
through the transfer case to either the rear wheels or both the front and rear wheels.
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In the next room, which is the systems factory, we have been able to get some knowledge
about the mechanical and electrical systems that control the different functions of a vehicle. For
example we have been able to identify the two types of injection pumps which are the inline and
rotary injection pumps. The other main things from the systems factory are the electrical systems
that control the longitudinal and transverse movement of the turret. These systems incorporate
sensors, amplifiers, hydraulic boosters, and so on.
In the next room, which is the construction vehicles overhauling room, we have been able
to develop the things that we learned about fluid power in the class room. In these vehicles there
will be so many valves that will be controlled by levers in the old cars and solenoids in the
modern ones. These vehicles turn by applying a break clutch to either one of the hind axles.
3.3 Interpersonal Communication Skills

One of the major reasons for a through and reliable work is the work force. Bishoftu
automotive industry employs nearly thousands of workers and those workers are appointed a task
according to their personal skills. A task might be appointed to two or more persons. In this case
interpersonal communication skills are essential. Dividing the task and assigning it to different
pupil is more suitable than everyone trying to do one thing. This will also ensure faster
completion of the task.
One of the main problems that are present in Bishoftu automotive industry is the presence
of too many taskforce. Too many pupils will be assigned for a simple task and they will spend a
precious time talking rather than working. So assigning only the needed amount of task force is
also essential.
The other main thing in interpersonal skills is the ability to accept criticism. One may not
see a problem that the other sees. Just because one did not see the problem does not mean that
one is less good than the other, it just means that two different pupil see one problem from two
different angles. So before some major problem occurs, we should be able to accept criticism and
be open minded.
3.4 Team Playing Skills

In this internship program we have acquired valuable team work skills. In terms of tem
playing we have learned the ability to work cooperatively and task sharing. Working in team we
learned sharing responsibility, understanding others ideas and working together. By working
together on one wider task we learned how to handle responsibility, working diligently, and
finishing the task on time. Above all we learned the significance of the contribution an individual
makes to the success of the team.
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3.5 Leadership Skills

One of the main skills that we acquired during the four months of stay of internship is the
skill of leadership. The task of facilitating a smooth operation of any work is appointed to the
leaders. One of the skills to a leadership knows the task to be done. If the leader does not have at
least some knowledge of the task, he will be unable to lead the taskforce to any point.
We learned one of the key qualities of a good leader that is to have a great idea, and assembling a
team to bring that concept to life. When one of us sees a problem or comes up with an idea, they
would tell the team members and discuss on ways to improve the situation. We used to share
tasks and take responsibility on what we had to do and take responsibility on what we had to do.
3.6 Work Ethics Related Issues

Work Ethics and discipline is one of the major factors for the step to professionalism.
Issues that are related to work ethics like punctuality, honesty, loyalty, and performance are what
make a company a success or a failure. The workers in a company should be motivated to work.
They should be punctual and deliver products on time. Workers should understand the value of
time and use it effectively.
The other factor that is related to work ethics is maintaining a peaceful environment at
work place. There are some workers that quarrel with everybody in reach. This kind of behavior
interrupts the work progress and affects the whole company. Workers should also treat the
companys property as their own and try to handle it respectfully.
Most of the issues that are related to work ethics are also related to the motivation of a
worker. Unless a worker loves what he does and has a goal, his performance will deteriorate.
Therefore the company should do some things in order to elevate the workers motivation. In our
opinion the best way of doing this is paying the workers per time. This will initiate the worker to
work overtime and too deliver the product in time. One of the other methods of motivating the
worker in setting up workshops in order to inform, entertain and motivate the workers.
3.7 Entrepreneurship Skills

The military companies in our country are way too backward and most of the tools and
machines were installed when the Soviet Union was intact in the previous regime. It is not an
overstatement to say that the military companies have stopped growing technologically at an
early stage. Most of the technologies there are not digitally automated, they are manual.
But even with all this problems, this company is the best company technologically among
the other companies in our country. This shows how our country is only at the start of
technological development.
One might see this as a major problem, but an entrepreneur will see this as an
opportunity. In Bishoftu automotive industry only there are many machines that are used for only
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simple routine work but that can be used to produce major products. Most of the machines are
manually operated but with some manipulation they can be made to operate automatically. By
doing these one can change the precession and the output quantity of these products.
Most of the military companies are being transformed in to companies that service the
civil world also. This can be seen by the construction vehicles that are being overhauled and the
new Bishoftu Busses that are being assembled. The company is expanding its efforts to solve
many other problems of the country.
The other new development in the company is the transformation from an overhauling
company in to a manufacturing company. New departments are being constructed to tackle the
manufacturing problems of the country. For example a negotiation is on the way with a china
company to construct a factory that manufactures and assembles construction vehicles.
Through all this, new opportunities are being opened both for the civil entrepreneurs and
military pupil. Civil entrepreneurs can participate by importing machines and selling to the
companies and/or making some simple custom made machines that can be useful in the new
transformation. This can be a major opportunity for the micro enterprises that manufacture tools
and construction materials.
In our job-training at Bishoftu Automotive industry we have been able to perceive the
new opportunities that are being made and how the technical community can participate in the
new transformation, hence developing our entrepreneurial skills. Entrepreneurial skill is not only
about seeing opportunities, we have also developed the skills on how to manage a company,
motivate the workers, and break into the market and so on.
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Chapter Four
Conclusions and Recommendations
Conclusion
In our on job training program in this industry we were able to see the overall structure,
background, the workflow, and the overall activity of the company. During this time we took
part in some of the assembly, maintenance, and welding activities of the industry and improved
our practical skills. We were able to put our theoretical skills into practice and improved our
team playing, leadership, entrepreneurship, and work ethics related skills. We tried to identify
the good qualities of the company like: Production efficiency,
Good security condition,
Good management, and workers diligence and punctuality.
The limitations and problems are: Continual interruption of work due to electrical power failure which results in delay in
delivery.
The spare parts and the vehicles get corroded and damaged due to storage in open
outdoors
There are no enough safety materials in welding and maintenance shops.
Communication problem between workers (Chinese and local) because most the
Chinese workers do not know English.
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Recommendations
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Reference
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Bishoftu Automotive Industry

overhaul and maintenance service of Military Automotive and engineering vehicles

manufacturing of spare parts used for repair and overhauling

JiT Mechanical Engineering department

Bishoftu Automotive Industry

Repair and maintenances of light and heavy weapons, generators , Communications

1.2 The Main Products and Services

JiT Mechanical Engineering department

Bishoftu Automotive Industry

Figure 1:- Hongyan Iveco truck

Overall dimension: 2240x2490x3450 mm

JiT Mechanical Engineering department

Bishoftu Automotive Industry

Figure 2:- Sino truck

Car model --------------DD6470C

JiT Mechanical Engineering department

Bishoftu Automotive Industry

Figure 3:- supper urban vehicle (SUV)

JiT Mechanical Engineering department

Bishoftu Automotive Industry

Figure 4:- single cabin pick up

JiT Mechanical Engineering department

Bishoftu Automotive Industry

Figure 5:- double cabin pick up

Figure 6:- city bus

JiT Mechanical Engineering department

Bishoftu Automotive Industry

1.2.7 FAW Dump Truck

Gross vehicle weight 32000kg

Figure 7:- Faw model Dump Truck

JiT Mechanical Engineering department

Bishoftu Automotive Industry

1.2.8 Cross-country bus

Figure 8:- cross-country bus

JiT Mechanical Engineering department

Bishoftu Automotive Industry

Figure 9:- bush car (Zilla)

Figure 10:- chain and wheel tank

1.3 Main Services

Bishoftu Automotive Industry

1.4 Main Customers or End Users

1.5 Overall Organization and Work flow

JiT Mechanical Engineering department

Bishoftu Automotive Industry

1.5.2 Market research repulsion for purchase

1.5.3 Service repulsion

JiT Mechanical Engineering department

Bishoftu Automotive Industry

JiT Mechanical Engineering department

Bishoftu Automotive Industry

2.2 The Sections of the Company We Had Been Working In

Bishoftu Automotive Industry

Chassis and engine assembly shop

2.2.3 Heavy duty truck Assembly Factory

JiT Mechanical Engineering department

Bishoftu Automotive Industry

2.3 The Work Flow in the Sections

Changing oil filter

The assembly process goes through different stations.

Bishoftu Automotive Industry

Bishoftu Automotive Industry

Figure 11:- pick-ups and SUV shop

Bishoftu Automotive Industry

The step perform through stations