KERALA GOVERNMENT POLYTECHNIC

COLLEGE
WETHILL, KOZHIKODE - 673005

SUMMER INTERNSHIP - I REPORT

Submitted by

AMAN ROSHAN AK (Reg: 2301020431)

ANUGRAH PK (Reg:2301020437)
ANIRUDH SURESH (Reg:2301020436)
YADHU KUMAR AS (Reg:2301020472)

in partial fulfilment for the award of the diploma

in
MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

APRIL 2024
 DEPARTMENT OF MECHANICAL ENGINEERING
KERALA GOVERNMENT POLYTECHNIC COLLEGE
WESTHILL KOZHIKODE- 673005

CERTIFICATE

This is to certify that the report submitted the Industrial Training Report for
partial fulfilment of the curriculum of the diploma in Mechanical Engineering
from the State Board of Technical Education Kerala to the Kerala Government
Polytechnic College,Westhill Kozhikode by

AMAN ROSHAN AK (Reg: 2301020431)

ANUGRAH PK (Reg:2301020437)
ANIRUDH SURESH (Reg:2301020436)
YADHU KUMAR AS (Reg:2301020472)

SALEEM N (Class Tutor) JAISON JOHN

Lecturer Head of department
Department of Mechanical Engineering Department of Mechanical Engineering
KGPC Kozhikode KGPTC Kozhikode

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 ACKNOWLEDGMENT

We would like to express our sincere gratitude to AMG Rotana Hyundai

company for providing us with the invaluable opportunity to intern at

their esteemed Service Centre.. This experience has allowed us to gain

practical insights into the automotive industry and develop a deeper

understanding of various operational and technical aspects.

We are particularly thankful to Mr.Anoop(General Manager), for his

constant guidance, support, and constructive feedback throughout the

internship. Their mentorship has been instrumental in enhancing our skills

and knowledge.We are rather grateful for such whole hearted cooperation

of not only him but also all other members of AMG Rotana Hyundai

service centre who helped us with their patient and friendly behaviour

through the internship programme.

Lastly,We would like to express special thanks to our HOD, Mr. Abdul

salam PK (Mechanical Dept , KGPTC , KOZHIKODE ) and Mr .

Saleem N (Tutor in Mechanical Dept, KGPTC) for their guidance and

support throughout the training.

Thank you all for your continuous support and encouragement.

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 ABSTRACT

This report details our internship experience at AMG Rotana Hyundai

Service Center, where we served as assistants in the vehicle maintenance

and repair department. The primary goal of the internship was to acquire

hands-on experience in automotive servicing and to enhance our technical

skills in a professional environment.

Throughout our internship, We were involved in various tasks, including

conducting routine vehicle inspections, performing diagnostic tests, and

assisting with oil changes and tire rotations. Working alongside skilled

technicians provided us with insights into Hyundai’s service protocols and the

latest automotive technologies. We also learned to use diagnostic tools, which

improved our problem-solving abilities and our understanding of vehicle

systems.In addition to technical skills, We developed experience emphasized

on the importance of communication and customer satisfaction in the

automotive industry.

Overall, our internship at AMG Rotana Hyundai Service Center significantly

deepened our understanding of automotive servicing and prepared us for the

future roles in this field. The knowledge and skills gained during this internship

will serve as a valuable foundation for our career in the automotive industry.

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 TABLE OF CONTENTS

CHAPTER PAGE
TITLE
NO. NO.
ACKNOWLEDGEMENT 6

ABSTRACT 7

TABLE OF CONTENTS 8

LIST OF TABLES 9

1 INTRODUCTION 10

2 COMPANY OVERVIEW

2.1.BACKGROUND OF HYUNDAI MOTORCOMPANY 11

2.2. OVERVIEW OF HYUNDAI SERVICE CENTRE 12

2.3. MAIN OBJECTIVES OF SERVICE CENTRE 13

2.4. FEATURES OF HYUNDAI SERVICE CENTRE 15

3 INDUSTRIAL TRAINING SUMMARY

3.1. WORKING IN A SERVICE CENTRE 16

3.2. DEPARTMENTS IN SERVICE CENTRE 17

3.3. TYPES OF SERVICES IN SERVICE CENTRE 22

3.4. TYPES OF WORK DONE 21

3.5. OVERVIEW OF A CAR 23

3.6. INDUSTRIAL TRAINING OVERVIEW 27

3.7. INDUSTRIAL TRAINING SUMMARY 28

4 CONCLUSION 33

5 FUTURE SCOPE 34

6 REFERENCES 35

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 LIST OF FIGURES

FIGURE No. TITLE PAGE NO.

2.2. OVERVIEW OF HYUNDAI SERVICE 12

2.3. MAIN OBJECTIVES OF SERVICE CENTRE. 13

2.4. FEATURES OF HYUNDAI SERVICE CENTRE. 15

3.2.1. BODY SHOP 17

3.2.2. PAINT SHOP. 18

3.2.3. SERVICE SHOP. 19

3.2.4. WASHING SHOP. 20

3.5.1. MAJOUR PARTSOF CAR AND ITS FUNCTIONS. 25

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 CHAPTER 1

INTRODUCTION
Industrial training is an essential component of professional education,

designed to provide students with practical experience in their respective

fields of study. It bridges the gap between theoretical knowledge

acquired in the classroom and its practical application in real-world work

environments. The primary goal of industrial training is to expose

students to the day-to-day operations of a professional workplace,

allowing them to develop skills, gain industry insights, and understand

the expectations of the workforce.Industrial training provides students

with essential hands-on experience, allowing them to apply classroom

knowledge in real-world scenarios. It enhances technical skills, builds

confidence in using industry-specific tools and equipment, and fosters

critical soft skills like teamwork, communication, and problem-solving.

Industrial training also offers valuable insight into workplace dynamics,

helping students understand professional culture and operational

procedures. Additionally, it increases employability by making students

more competitive in the job market and provides opportunities for

networking with industry professionals, potentially opening doors for

future career prospects.

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 CHAPTER 2

COMPANY OVERVIEW

2.1. BACKGROUND OF HYUNDAI MOTOR COMPANY

Hyundai Motor Company was founded in 1967 by Chung Ju-yung in South

Korea as part of the Hyundai Group. The company began its automotive
journey by launching the Hyundai Cortina in 1968, developed in partnership
with Ford. However, the Hyundai Pony, introduced in 1975 as Korea's first
domestically produced car, established the brand's identity in the automotive
market.
Throughout the 1980s and 1990s, Hyundai expanded its product range and
entered international markets, gaining recognition for producing affordable and
reliable vehicles. The launch of the Hyundai Excel in the U.S. in 1986 marked
a significant milestone, greatly increasing the brand's visibility. Following the
1998 Asian financial crisis, Hyundai underwent restructuring, forming Hyundai
Motor Group as its parent company.
This transition allowed Hyundai to focus on research and development,
leading to improvements in vehicle quality, safety, and technology. Today,
Hyundai is one of the largest automobile manufacturers globally, known for its
innovation, stylish design, and commitment to sustainability. The company
actively invests in electric and hybrid vehicles, positioning itself at the forefront
of the automotive industry's shift toward eco-friendly transportation and smart
mobility solutions.

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2.2. OVERVIEW OF HYUNDAI SERVICE CENTRE

AMG ROTANA MOTOR

14/476D Puthuppanam(NW 31/150)
Vadakara-673105
Calicut Dt
KERALA
Mobile:9072669911
Email:gmsales@amgrotanahyundai.com
Website:www.amgrotanahyundai.com

Fig.2.2

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AMG Rotana Motor LLP is one of the most popular Hyundai
passenger cars Showrooms and dealers with completely in built
sales, service and spares facility. The totally Air conditioned
showroom has a world class exhibition of variety of Hyundai
passenger cars.

We provide the customer with proper guidance to find that perfect

vehicle most suitable in terms of color, model, best finance options
and so on. We are in regular contact with the customer keeping
them in the loop till the delivery of the vehicle. Skilled and proficient
technicians also provide best solution for the cars that need to
undergo maintenance and repairs. The group was able to expand
operations in a short time even as it establishes its unique presence
all over the region.

2.3. MAIN OBJECTIVES OF SERVICE CENTRE

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2.3.1. Our Mission

Build the safety and treasure the quality

2.3.2. Our Vision

We provide Service and World Class Products to cater to the client
needs Quality

2.3.3. Our Values

Our core values focus on innovation and quality with emphasis on
high standards of technology dedicated to delivering highest level of
excellence in automotive. We are committed to the customers as
well as to the society that we serve via continuous innovation

Fig 2.3

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2.4.FEATURES OF HYUNDAI SERVICE CENTRE

Fig .2.4

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 CHAPTER 3
INDUSTRIAL TRAINING SUMMARY

3.1. Working in survice centre

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3.2. DEPARTMENTS IN SERVICE CENTRE
There are 4 types of department;

Fig 3.2.1

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Fig 3.2.2

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Fig 3.2.3

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 Fig 3.2.4

3.3. TYPES OF SERVICES IN SERVICE CENTRE

3.3.1 FREE SERVICE

In Free services labour charge is not taken. Only the charge of parts
replaced is taken. The free service are available when we purchase a
new vehicle

Duration: 1st service : 2months or 1500 to 1800 kms

2nd service:1 year or 8000 to 10,000km
3rd service :2years or 18,000to 20,000km

3.3.2 PAID SERVICE

In paid service every single charge is taken for the repair including
the labour charges.pid services are done for every 10,000
kilometres

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3.4.TYPES OF WORK DONE

1. Routine Maintenance:
Oil Changes: Replacing engine oil and oil filters.
Tire Rotation and Alignment: Ensuring even tire wear and
proper alignment.
Fluid Checks and Replacements: Checking and topping off
fluids such as coolant, brake fluid, and transmission fluid.
Brake Inspection and Replacement: Checking brake pads,
rotors, and fluid, replacing parts as needed.
Battery Check and Replacement: Testing the battery’s
charge and replacing it if necessary.
Air Filter Replacement: Changing the engine and cabin air
filters.

2. Diagnostics and Repairs:

Engine Diagnostics: Identifying and repairing issues with
engine performance.
Transmission Repairs: Repairing or replacing transmission
components.
Electrical System Repairs: Fixing issues with the car's
electrical systems (e.g., lights, sensors, battery, wiring).
Suspension and Steering Repairs: Servicing or replacing
suspension parts like shocks, struts, and ball joints.
Exhaust System Repairs: Fixing issues related to the
exhaust, muffler, and emissions control systems.
Air Conditioning and Heating Repair: Diagnosing and fixing
problems with the HVAC system.

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3. Warranty and Recall Services:
Warranty Repairs: Addressing any defects or issues
covered under Hyundai's warranty.
Recall Services: Correcting manufacturer-identified safety
issues or defects at no cost.

4. Inspections:
Vehicle Inspection: Comprehensive checks for safety and
performance, sometimes required by local regulations.
Pre-purchase Inspection: Assessing the condition of a
vehicle before purchase.
Emissions Testing: Checking for compliance with emission
standards.

5. Body and Cosmetic Repairs:

Collision Repair: Fixing damage from accidents, including
bodywork and paint jobs.
Paint Touch-ups: Addressing minor scratches or chips.
Glass Repair/Replacement: Replacing or repairing cracked
or damaged windows and windshields.

6. Software and Technology Services:

Software Updates: Updating the car's infotainment,
navigation, or ECU (Engine Control Unit) software.
Key Programming: Reprogramming or replacing key fobs.

7. Tire Services:
Tire Replacement: Replacing old or damaged tires.
Tire Balancing: Ensuring even weight distribution around
the tire and wheel assembly.

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3.5.OVERVIEW OF A CAR
3.5.1.MAJOR PARTS OF A CAR AND ITS FUNCTIONS.

1. Engine: The power source that converts fuel into mechanical

energy to move the car.

2. Transmission: Transfers power from the engine to the wheels,

allowing the car to change speeds.

3. Battery: Provides electrical energy to start the car and power

electrical components when the engine isn't running.

4. Alternator: Generates electricity to recharge the battery and

power the electrical systems while the engine is running.

5. Radiator: Cools the engine by circulating coolant to prevent

overheating.

6. Fuel Tank: Stores fuel for the engine.

7. Starter Motor: Helps start the engine by cranking it when the key
is turned.

8. Exhaust System: Directs exhaust gases away from the engine

and reduces noise and emissions.

9. Brakes: Slow down or stop the car by applying pressure to the

wheels.

10. Steering System: Allows the driver to control the direction of

the car.

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11. Suspension: Absorbs shocks from the road, providing a
smoother ride and keeping the car stable.

12. Wheels: Support the car’s weight and provide traction for
movement.

13. Tires: Provide grip and traction on the road surface for steering,
acceleration, and braking.

14. Drive Shaft: Transmits torque from the transmission to the

wheels.

15. Clutch (in manual cars): Engages and disengages the engine
from the transmission to change gears.

16. Differential: Distributes engine power to the wheels while

allowing them to rotate at different speeds (important when turning).

17. Windshield Wipers: Clear rain or debris from the windshield for
visibility.

18. Air Filter: Cleans the air before it enters the engine for
combustion.

19. Dashboard: Displays important information like speed, fuel

levels, and warnings.

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 Fig 3.5.1

3.5.2. MAJOR TYPES OF SENSORS IN CARS AND THEIR

FUNCTIONS
1. Oxygen Sensor (O2 Sensor): Monitors oxygen levels in
exhaust gases to adjust the air-fuel ratio for efficient
combustion and emission control.

2. Mass Air Flow (MAF) Sensor: Measures the amount of air

entering the engine for precise fuel injection.

3. Throttle Position Sensor (TPS): Detects the position of the

throttle valve to regulate fuel and air flow.
4. Coolant Temperature Sensor (CTS): Monitors engine
coolant temperature to prevent overheating and optimize
engine performance.

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5. Crankshaft Position Sensor: Tracks the position and speed
of the crankshaft for proper ignition timing and fuel delivery.

6. Camshaft Position Sensor: Measures the position of the

camshaft to synchronize fuel injection and valve timing.

7. Knock Sensor: Detects engine knocking caused by

incorrect combustion and prevents engine damage by adjusting
timing

8. Vehicle Speed Sensor (VSS): Measures vehicle speed for

speedometer reading and helps the ABS and transmission
systems.

9. Manifold Absolute Pressure (MAP) Sensor: Measures air

pressure in the intake manifold to calculate engine load for
proper fuel delivery.

11. Tire Pressure Monitoring Sensor (TPMS): Monitors tire

pressure and alerts the driver if it drops below a safe level.

12. Parking Sensors: Detect obstacles near the car while

parking, providing warnings to prevent collisions.

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3.6. INDUSTRIAL TRAINING OVERVIEW

DAY 1 20 /05/24 OIL CAPACITY OF CARA

DAY 2 21/05/24 AIR FILTER CLEANING
DAY 3 22/05/24 CHANGING OF OIL
DAY 4 23/05/24 CHECKING OF FUEL TANK
DAY 5 24/05/24 AIR BAG AND ITS FUNCTION
DAY 6 25/05/24 TYPES OF ENGINES
DAY 7 26/05/24 TYPES OF MODULES
DAY 8 27/05/24 OBD SCANNER
DAY 9 28/05/24 TYPES OF SENSORS
DAY 10 29/05/24 VEHICLE SERVICE
DAY 11 30/05/24 REPALCEMENT OF BREAK PAD
DAY 12 31/05/24 ALIGNMENT OF WHEEL

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 3.7. INDUSTRIAL TRAINING SUMMARY

TRAINING LOG

DAY 1
20/05/24

We arrived at AMG Rotana Motor in Puthuppanam at

9:30am.At first they introduced various kinds of work and briefly
explained the processes involved.After introduction ,we started
to watch the work we that we have to do.We familiarised with
various types of cars and their oil capacities which varies from
one car to another.

DAY 2
21/05/24

We arrived at 9.00 am,changed into workshop clothes and

started the very first work,that is air filter cleaning.We would
each get a chance to clear the air filter using car pressure gun
after removing it from the car.It was a rather entertaining
work.The work stopped at 6.00pm.

DAY 3
22/05/2024

Arrived at 9.00am and as usual changed into another set

of clothes and started to do the work.The work was oil
changing.After explaining the process,they allowed us to

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change oil from car individually.At first there was some
mistakes,but we overcame that finished the work at 6.00pm.

DAY 4
23/05/24

Arrived at 9:00am.It was a rainy day.So there was some

difficulty in arriving ath the centre.As usual we started our work
which was checking the fuel pump.It was a rather unique
work.At this point we established friendship between the
workers.It was an enjoyable day.The work ended at 6:pm

DAY 5
24/05/24

Arrived at 9:am.It was an another rainy day.We arrived at

the company and went straight to the area where different car
parts were being fixed.The eye catching part was air
bag.Because of its astronomical price and safety methods,it
was the topic for today's session.They explained about the
working,usage and effects of it.The session ended at 6:pm.

DAY 6
25/05/24

Arrived at 9:00am.There was no rain.Everbody was busy

doing their work.Todays topic was the difference between two
types of engine; petrol and diesel engine.After some time one
of the man who works at the company arrived before us and

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started to explain the differences between those two types of
engine .The session ended at 6:pm.

DAY 7
26/05/24

As usual,arrived at 9:am.There was a car that was being

rebuild from. Scratch.Our curiosity piqued and went there.After
watching those parts many times over,the person who was
incharge explained about different types of module,it's
functions,positions,and about ECM which was the main control
unit in car.After successfully learning about modules ,the
session ended at 6:00pm.

DAY 8
27/05/24

Arrived at 9: am.That day was different from any other

day because it was the day they introduced us to OBD
SCANNER,a multifunctional device used for checking any
problems in car.It was rather intriguing.After doing many check
ups with it,the day was finally over and the session ended in
6:pm.

DAY 9
28/05/24

Arrived at 9:am.We laughed a lot while telling jokes with

the people present there.After laughing and joking, time passed
by,and we started a topic related to various types of sensors in

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car and it's functions and positions.We were genuinely
surprised by the number of sensors in the car.After carefully
observed the locations of sensors,time passed by,evening
came.As a result the session ended at 6:pm

DAY 10
29/05/24

As usual arrived at 9:am.It was a boring day

accompanied by heavy rain.We learned about different kinds of
services offered and their durations.After the we aimlessly
wandered around the workshop. The session ended with
discussing about paid services at 6:pm.

DAY 11
30/05/24

Arrived at 9: am.It was the day of heavy work.It was the day
of break pad replacement.Each of us got individual car and was
asked to replace the break bad.At the end of the we were so
tired.It was a rather exhausting day.The overall session ended
at 6:pm

DAY 12
31/05/24

At last, today was the last day of the internship

programme.We were a little bit worried for leaving benind
friends we made there.After the alignment of wheel,which was
today's session ,We decided to leave the centre by 5.30pm.It
was a rather funny and enjoyable internship programme which
benefitted us a lot.

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 CHAPTER 4
CONCLUSION

The 12-day internship at the Hyundai Service Centre has been an

enriching experience, allowing us to bridge the gap between
theoretical knowledge and practical application in the automotive
field. Throughout our time at the centre, we engaged in various
tasks, including vehicle diagnostics, routine maintenance, and
repair processes, which deepened our understanding of automotive
technology and service operations.

Working alongside experienced technicians provided invaluable

insights into the importance of precision and attention to detail in
automotive servicing. We also learned the significance of effective
communication and teamwork in ensuring customer satisfaction and
smooth operations within the service environment.

This internship not only enhanced our technical skills and

knowledge but also fostered a sense of professionalism and work
ethic essential for our future careers. It solidified our interest in
pursuing further opportunities in the automotive industry, inspiring
us to continue learning and developing our expertise.

We extend our gratitude to the staff at the Hyundai Service Centre

for their support, mentorship, and willingness to share their
knowledge. This experience has undoubtedly laid a strong
foundation for our future endeavours in the automotive sector.

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 CHAPTER 5
FUTURE SCOPE

The internship at the Hyundai Service Centre has opened several

avenues for future growth and development in the automotive
sector. First, the increasing reliance on technology in vehicles
suggests a strong demand for professionals skilled in advanced
diagnostics, electric and hybrid vehicle systems, and software
integration.

Additionally, as consumer expectations for quality service rise, there

will be an ongoing need for customer service training and effective
communication skills among technicians.

Further education and specialization in areas such as automotive

engineering, diagnostic technology, and management can enhance
career prospects and expertise.

Moreover, the insights gained from this internship can lead to

opportunities in research and development, contributing to
innovations in vehicle design and maintenance practices.

Overall, the foundation laid during this internship will empower us to

pursue various roles within the automotive industry, from service
management to technical development, ensuring a rewarding and
impactful career ahead.

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 CHAPTER 6
REFERENCES

● https://www.amgrotanahyundai.com/about/

● https://www.scribd.com/document/466518236/
● https://www.autozone.com/diy/trustworthy-advice/basic-parts-of-a-car-and-their-functi
ons

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