AMBO UNIVERSITY

HACHALU HUNDESSA
CAMPUS

DEPARTMENT OF MECHANICAL ENGINEERING

FINAL INTERSHIP REPORT
Company name: RIES ENGINEERING S. CO. (RESCO)
Final internship practice on:
Prep.by ID email
1. Nahom kacha A/UR27770/11 [email protected]
2. Fuad Abdulmalik A/UR28028/11 [email protected]
Period of internship: March to June /2022 GC.
Company supervisor: Seifu Bulcha
Academic supervisor: Mr Sine G.
June, 2022GC.

Ambo, Ethiopia
 Internship report, Ries Engineering S.Co 2015 E.C

Declaration

This paper is prepared by the students which are mentioned below. It contains the overall report,
benefit that is gained, problem identified and solution for the problem of the internship in briefly
and detail manner. And also, we like to declare that this paper is made originally by us and it is
not copied from any paper that had been done before.

Student name signature date

1. Nahom kacha -------------

2. Fuad Abdulmalik -------------

Approved by

Advisor name signature date

1. -------------- ---------------

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Acknowledgment

First of all, we would like to thank almighty GOD for helping to do this internship practice and
keep us safe from any kind of obstacle and hazard. Secondly, we would like to thank Ries
Engineering s.co(RESCO) for accepting us and paving the way to our job–training program by
facilitating suitable working conditions and also the workers of the company for sharing useful
skills, experiences, for their good interpersonal relationship and giving answers for the question
when we asked. Lastly we provide special thanks to our advisor Mr Sine G., for his useful comment
& advice.

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Executive Summary
This project mainly concerns the overall Four-month project done in Ries Engineering s.co(RESCO).
The project primarily deals with the benefits and experience advanced during the four-month internship
in terms of different working experiences and brief history of the company with its backgrounds, and
organizational workflow. During this time, we had the chance to work on different shops of the
company like: - main work shop and component rebuilding center (CRC). In this document we
presented project about our internship experience we get in RESCO, difficulties we face, how we pass
this challenge and also in internship time we were able to identify some problem and proposed a
solution for each problems, at this internship time we have experienced with practical skills, improved
theoretical knowledge, leadership skill, inter communicational skill and work ethics lastly we discussed
with conclusion and recommendation for the company and activities they must take to solve the
problem.

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Abbreviations

 RISCO = Ries Engineering share company.

 CRC = component rebuilding center.
 ET = Electrical Technician.
 SIS = software Information System
 CAT = caterpillar


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List of figures

No table of figures entries found.

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List of table

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Table of Contents
Contents Pages

Declaration ....................................................................................................................................... I
Acknowledgment ............................................................................................................................ II
Executive Summary ...................................................................................................................... III
Abbreviations ................................................................................................................................ IV
List of figures ..................................................................................................................................V
List of table ................................................................................................................................... VI
CHAPTER ONE ................................................................................................................. 1
1. Company profile ......................................................................................................................... 1
1.1 Brief history of the company ........................................................................................ 1

1.2 Mission, Vision and Values of the Company ............................................................... 2

1.2.1Mission of the company .................................................................................. 2

1.2.2 Vision of the company ................................................................................... 2

1.2.3 Value of the company .................................................................................... 2

1.3 Main Products of the company ..................................................................................... 3

1.3.1 In Construction sector .................................................................................... 4

1.3.2 In Agricultural sector ..................................................................................... 6

1.3.3 In Automotive sector...................................................................................... 7

1.4 End users of the company product ................................................................................ 9

1.5 Overall Organizational structure ................................................................................. 10

1.6 man power and equipment description ....................................................................... 11

1.6.1 Man power description ................................................................................ 11

1.6.2 Machineries and equipment of the company ............................................... 11

1.7 General workflow of the company ......................................................................................... 12

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CHAPTER TWO .............................................................................................................. 13

2. Overall Internship Experience .................................................................................................. 13
2.1 Brief how we get into the company ............................................................................ 13

2.2 Section of the company we have been working.......................................................... 13

2.2.1 Main Workshop ........................................................................................... 14

2.2.2 Component Rebuild Centre (CRC) .............................................................. 15

2.3 Work Flow in the Section ........................................................................................... 19

2.4 Tasks We Have Been Executed .................................................................................. 19

2.5. Major challenges encountered ................................................................................... 20

2.6. Solutions for the challenges ....................................................................................... 20

Chapter Three ................................................................................................................... 21

3. Overall Benefits I gained from the Internship .......................................................................... 21
3.1. Benefits we gained in terms of improving our practical skills .................................. 22

3.2. Benefits we gained in terms of upgrading our theoretical knowledge ....................... 23

3.3. Benefits we gained in terms of our interpersonal communication skills ................... 23

3.4. Benefits we gained in terms of improving our leadership skills ................................ 25

3.5 Benefits we gained in terms of understanding work ethics related issues .................. 25

CHAPTER FOUR............................................................................................................. 27
4. DESIGN OF OTC REVOLVER STAND PLATE FOR HYUNDAI DIESEL ENGINE ........ 27
INTRODUCTION ........................................................................................................................ 27
4.1 background of the study .............................................................................................. 27

4.2 Problem Statement ...................................................................................................... 28

4.3 Justification of the Study ............................................................................................ 30

4.4 Objective ..................................................................................................................... 30

4.4.1 General Objective ........................................................................................ 30

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4.4.2 Specific Objective ........................................................................................ 30

CHAPTER FIVE .............................................................................................................. 31

Literature Review.......................................................................................................................... 31
5.1 Literature review of engine stand ............................................................................... 31

CHAPTER SIX ................................................................................................................. 33

6. MATERIALS AND METHODS .............................................................................................. 33
6.1 Selection of Materials ................................................................................................. 33

6.2 Methodology ............................................................................................................... 34

6.2.1 Working Principle ........................................................................................ 35

6.3 Design of Engine Stand Components ......................................................................... 37

6.3.1 Design of mounting plate ............................................................................. 38

6.4.2 Design of bolts ............................................................................................. 39

6.3.3 Design of washers ........................................................................................ 40

6.3.4 Design of nuts .............................................................................................. 41

CHAPTER SEVEN ........................................................................................................... 43

CONCLUSIONS AND RECOMMENDATION ......................................................................... 43
7.1 Conclusion .................................................................................................................. 43

7.2 Recommendation ........................................................................................................ 43

Reference .......................................................................................................................... 44

APPENDEX ...................................................................................................................... 44

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CHAPTER ONE

1. Company profile

1.1 Brief history of the company

Ries Engineering share company (RESCo) started operation in 1961 as an

engineering department at one of its sister companies, paulries and sons
(Eth.Ltd,). It became an independent company in 1965. Since then it has
been developing continuously and today it represents well known and
reputable companies supporting the development of the country in
construction, mining, power and Agriculture sectors and also it is the
distributor of several world leading brands, and is a services provider in construction, automotive,
agricultural, and power industry in Ethiopia.

RESCO distributes products that provide the most value to its customers and supports them with
the highest standards of customer service. The brand we supply: Hyundai Construction equipment,
Massey Ferguson agricultural machineries, Dressta dozers, Ammann paving Equipment, Ford
automobiles, Cummins power generators, Fleet Guard, IPD, and BYG part sales.

Ries Engineering Share Company has opened four main branches in the areas of Bahir Dar, Dire
Dawa, Hawassa, Mekelle. These branch enables the company's service reachable by the customers
at their working site. It gives after sales customer support such as; Maintenance, Training,
Warranty and Parts delivery. Recently due to the government’s mega projects and foreign direct
investments; the construction, mining, power and agriculture sectors are highly in demand of the
RESCo's after sales support. So the motive of this research is to investigate the maintenance
practice of the component rebuilding center; so that to deliver best maintenance practices at the
head office and the four branches of the company. The frequent failure of machinery is one of the
major reasons that inhibits the company maximum provision of service and play its expected role
in customer satisfaction.

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1.2 Mission, Vision and Values of the Company

1.2.1Mission of the company

 To be the Total Solution Provider to its customers in the Construction, Mining, Power,
Agriculture and Transport sectors and to be the preferred partner in their journey to success.
 To become the most trusted partner and a leading knowledge transfer

1.2.2 Vision of the company

 To provide Reliable Quality Products to its customers.

 To have the best product support team that is motivated and skilled and provide the best
after sales support to customers.
 To be an active participant in the Country’s infrastructure development.

1.2.3 Value of the company

 Integrity
 Excellence
 Team Work
 Commitment
 Sustainability
 Responsibility
 Transparency
 Punctuality
 Safety

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1.3 Main Products of the company

Ries Engineering Share Company has opened four main branches in the areas of Bahir Dar, Dire
Dawa, Hawassa, Mekelle.These branch enables the company's service reachable by the customers
at their working site. It gives after sales customer support such as; Maintenance, Training,
Warranty and Parts delivery. Recently due to the government’s mega projects and foreign direct
investments; the construction, mining, power and agriculture sectors are highly in demand of the
RESCo's after sales support. So the motive of this research is to investigate the maintenance
practice of the component rebuilding center; so that to deliver best maintenance practices at the
head office and the four branches of the company.

RESCO represents the following internationally reputed companies at Present:

 HYUNDAI Construction equipment

 FORD automobiles
 MASSEY FERGUSON agricultural machineries
 DRESSTA dozers
 AMMANN paving Equipment

In 2010 the company expanded its operation to be major

player in the automotive sector representing the Ford Motor
Company. It now imports and distributes well known and
liked Ford products; like Ranger pick-up trucks and Everest
SUVs in Ethiopia. In order to reach its customers wherever
they are, it has increased its coverage through a branch
network that is fully staffed and equipped with required
resources to exceed customer expectations. Figure 1: RISCO

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1.3.1 In Construction sector

RESCO is the proud distributor of Hyundai Construction Equipment, AGCO, AMMANN

and DRESSTA. The services include pre-purchase advisory services, assembly, PDI, and
setting up new machinery. They provide troubleshooting management and the evaluation
and training of equipment operators and technicians.

RESCO’s brands are widely recognized as industry leaders for its use of advanced
ergonomic engineering and technology. Backed by highly advanced factory automation, a
zero-tolerance quality control inspection system, and innovative engineering.

RESCO currently represents the following construction companies:

 Hyundai Construction Equipment

Hyundai is widely recognized as an

industry leader for its use of advanced
ergonomic engineering and
technology. Backed by highly
advanced factory automation, a zero-
tolerance quality control inspection
system, and innovative engineering,
the division offers a wide range of
construction equipment.

Figure 1.4 Hyundai Construction Equipment

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 Ammann
Ammann is a world-leading supplier of mixing plants, machines and services to the
construction industry with core expertise in road
building and transportation infrastructure. Much
has changed in the 150 years of Ammann history.
Technology continues to evolve, and the plants and
machines deliver productivity that wasn’t even
dreamed of in 1869. The company now has a global
reach and expansive product line.

Figure 1.5 Ammann

 Dressta
Dressta has a rich heritage and has grown to
become a global manufacturer of heavy
Construction equipment, renowned for engineering
durable, powerful machines for the toughest
applications – from mining or landfill dozers, to oil
and gas pipelayers.

Figure 1.6 Dressta

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1.3.2 In Agricultural sector

Moving on, one of the biggest industries in Ethiopia is Agriculture. The agriculture mechanization
business department is aimed at providing solutions to different levels of agricultural industry in
Ethiopia. Subsequently, farm operations is a big part of what we build. RESCO has been the
official distributer of Massey Ferguson since the beginning of our business. Massey Ferguson
brand is designed, manufactured, and supplied by world renowned agriculture company AGCO.

 Massey Ferguson
MF tractors ensure that the performance
and efficiency of the engine,
transmission, and hydraulics are
optimized to minimize fuel use and
maximize output without
compromising the environment and
requiring a high operator workload.

Figure 1.7 Massey Ferguson

 Challenger

Seriously high-performance equipment

for people who are serious about
agribusiness. Serious means large scale.
Serious means maximum output.
Serious means always expanding your
revenue.

. Figure 1.8 challenger

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1.3.3 In Automotive sector

In the words of FORD founder Henry Ford, "To do more for the world
than the world does for you. That is success."
Throughout its 117-year history and today,
FORD strives to do more through its products
and services, delivering reliable premium
vehicles that keep Ethiopia moving.

FORD Ethiopia is committed to bringing

products that customers want and value.
Today, our product line-up offers a vehicle to
suit nearly every consumer's need, including a
wide range of petrol and diesel Vehicles & Car
models, from mid-size to larger SUVs ideal figure 1.9 automotive

for any terrain. Despite Ford's multi-faceted approach to offering better fuel
economy and exciting infotainment technology, the company has not
neglected its strong tradition of producing high-horsepower vehicles
suitable for rugged work environments.

Rental Service

Rental is a critical option for our clientele interested in temporary work related to their projects.it
is actually something that a lot of RESCO’s clients ask for. It is practical to rent a machine that
they need for a specific short-term contract rather than buying a new one. They may need
machinery for single use.to answer to this interest, RESCO offers reliable earth-moving equipment
at fair rental prices. This strengthens our Customers options to their satisfaction.

 At Ries Engineering there are various departments including the Workshops, Component
Rebuild Center (CRC), Body Works, Carpentry, Testing, Sales, Spare Parts, and many
more. We were stationed at the Component Rebuild Centre and later moved to the Main
Workshop.

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Sales of RESCO

Ries engineering is a trusted company supplying equipment and machinery across the full
spectrum of the construction, mining, and infrastructure industries. Amongst the brands we
represent are Hyundai construction equipment, ford, Massey Ferguson, Ammann group and
Dressta dozers.sales together with our marketing department have the mandate to promote business
after strong market presence, ensuring customer confidence and long-term clientele relation.
Promote products and services of the company, explore prospects, follow government construction
projects, and participate actively in tenders. Align our strategy to achieve the objectives of the
company.

Figure

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1.4 End users of the company product

Our services In order to serve our customers best, our ford vehicles maintenance and repair
workshop is organized and equipped with facilities that will enable us to deliver one window shop
service to our customers. It gives after sales customer support such as; Maintenance, Training,
Warranty and Parts delivery. Recently due to the government’s mega projects and foreign direct
investments; the construction, mining, power and agriculture sectors are highly in demand of the
RESCO’s after sales support.

1.3.1 Main customers

The RESCO customers could be governmental or non-governmental organizations. From those we

have listed below some.

 Different Machinery owner individuals

 Governmental organizations
 Ethiopian road Authority
 Addis Ababa city roads authority
 Ethiopian defense
 Ethiopian grand Renaissance Dam
 Construction Companies
 Rental and companies
 Agricultural based industries, etc.

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1.5 Overall Organizational structure

RIES is organized in a manner suited to best serve its customers. It has two main and two support
departments and all the necessary divisions under them. It has also setup two branches. One in Dre
Dawa and one in Mekelle and appointed four agencies in strategic location (Assela, Awasa,
Humera and Nazereth) to be close to its customers and to be able to be provide the support they
require promptly.

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1.6 man power and equipment description

1.6.1 Man power description

RESCO has been increasing its manpower and developing their skills since its establishment to
meet the growing needs of its customers. The company which started with 40 employees in 1965
has over 372 personnel today including contract employees. About 50% of the personnel are in
the Product Support Department. Over 60% of the company’s permanent employees are highly
qualified professionals (engineers and mechanics). These personnel have long years of hands on
experience on the products handled by the company and are given regular training to update
them with current technological development of the industry. All this is done to enable
customers get the best value from the machines and equipment they purchase from the company

1.6.2 Machineries and equipment of the company

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1.7 General workflow of the company

Figure

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CHAPTER TWO

2. Overall Internship Experience

2.1 Brief how we get into the company

Among different companies to collect information during the selection of internship hosting
company, there were several criteria’s that we had been put in that company. Such as; the
company has enough experienced to give training to student in many years, also give fixing,
inspection maintenance, repair and different service in masterwork. As a well-practical work is
done in fully equipped workshop which provides a realistic workshop environment. Based on the
above criteria, RESCO has been elected because it encompass workshops which provides the
following opportunities, Engine maintenance, Body repair, Machine shop and Welding.

2.2 Section of the company we have been working

We Have Been Working in Two Sections:-

 Main workshop
 Component rebuild center (CRC)

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2.2.1 Main Workshop

When there is an issue with an integral part of the machine, such as the wiring, brakes, tracks, they
entire machine will be transported into the main workshop and be repaired there. The facility
houses four heavy duty cranes, numerous toolboxes and wide-open passages for the transportation
of parts using a forklift. The work done here is usually helped with other machines such as forklifts,
cranes, Electrical Technician (ET) software, voltmeters and so on since the components to be
repaired are usually very heavy and difficult to work on. General servicing such as brake and oil
changes are also done here.

Figure 1.2 main workshop

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We are experience in general maintenance processes in main workshop of the company. The
main process are:

Disassembly process

In this work group the engine will be disassembled in its reverse order of assembly and the small
parts will be put in a table. The general housing will be hosted by a fork lift or overhead 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 and each element will be washed by using water and benzene

then dry by pressurized air.

Figure

2.2.2 Component Rebuild Centre (CRC)

This is where the engines and the hydraulic components of the vehicles come to be disassembled,
cleaned, repaired/replaced, and reassembled. The facility has all the necessary equipment for a full
rebuild of the engine and hydraulic components. Equipment such as: Worktables, Cranes,
Hydraulic Presses, Injection pump testing equipment, a compressor, cleaning apparatus, all the
necessary Spanners, Torque Wrenches and so on. Usually, an engine which has come for its regular
service will be inspected and disassembled in the main workshop, and then move to the component
rebuild centre where the worn parts will be replaced. To help the CRC crew, a Service Information
has been set up. The Service Information System (SIS) is a computer software where all the

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information regarding the Caterpillar (CAT) vehicles can be found. Starting from the
disassembling order to the amount of torque to be applied to a bolt. Through SIS any worker can
find detail reading material on the machines and better understand the components. A second SIS
system has also been set up in the Main Workshop.

Figure

The processes undertake in Component Rebuild Centre are:-

 Inspection process
 Assembly process

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Inspection process

Technical analysis inspection (TA) is an inspection procedure designed by caterpillar and a way
of machine condition monitoring. TA is performed both by visual inspection and by using
advanced measuring and diagnostic tooling (instruments) like the micrometer, Varner caliper,
and magnetic stand with a dial, dial gage and bore gage. In inspection process we will
recognize first if there are any problems like, crack and breakage on the engine housing and the
other parts. The engine parts that are inspected usually are the engine housing, the crankshaft, the
camshaft, journal/shell bearing and the valves in component rebilled work shop. TA inspection
helps to:

 Minimizing down time through schedule maintenance

 Locating potential problems
 Finding overlooked problems
 Lowering operating and lowing cost.

Fig

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Assembly process
The assembly section follows a set of procedures by using the caterpillar manufacturer manual
service information system (SIS) and special tools getting from tool store. SIS is the electronic
service tool that caterpillar dealer and customers rely on for their parts and service information
needs. The information in SIS is equivalent of over 825,000 books with over a million graphics,
more than 80,000 part numbers and contain thousands of parts and service documents.

Figure

There are also some rooms for testing and maintain process like:

 Engine Bay
 Hydraulic Bay

Engine Bay

As the name implies, this is where all the work regarding the engines is done. There is usually a
team of two people working on an engine at a time, there can be up to three teams working at the
same time.

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Hydraulic Bay

This is where all the work regarding the hydraulic systems is done. Hydraulic pumps, pistons,
lines, and so on are repaired, maintained and assembled here. There are also torque converters and
propeller shafts that come here for assembly and repair.

2.3 Work Flow in the Section

Depending on the type of damage the care is send to appropriate department and the chief
mechanic will distribute the work to the fellow worker. Also gat different accident or technical
problem on motor vehicle owners, the worker’s in the section will discuss over the problem and
on the task every worker will participate according to the fields of study and one person will take
the lead. Then term by term presentation within the given time will be taken and they discuss
with the worker’s. Then repair or alteration with proper time and retrieve to the owner.

2.4 Tasks We Have Been Executed

We have participated in various tasks: -

 Maintenance of engine, flywheel, gear box and differential.

 Maintenance of fuel system from starting from the tank to injector nozzle
 Air system.
 Electric circuit system.
 Body repairing system.

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2.5. Major challenges encountered

There are some challenges we have faced during our internship period in the company.

 There are no safety materials provided for the students.

 We could not get materials necessary for our project.
 There is no cafeteria for workers or there is no place to have lunch inside the company so
it leads us for extra payments outside the company.

2.6. Solutions for the challenges

For the challenges we have encountered we tried to give solutions as much as we can, some of
the solutions are:

 For the safety material problem, we tried to keep our self from harm, we used some shoes
that can be get by cheap price.
 The material shortage for our project is solved by searching materials in the compound
that are removed from vehicles after their service period and we made it fit to the
materials we needed by resizing them.

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Chapter Three

3. Overall Benefits I gained from the Internship

Internship have incomparable benefits. The benefits of internship are clear for person who have
get the opportunity. During internship we proof knowledge in terms of many activities or
situation. If you use these kinds of chance, you will learn many things that help you in your life
forever. Mainly we have taken internship for the purpose of exploration the practical operation
what we have learn in theoretical. Because some theoretical knowledge is incomprehensible and
be difficult to understand, but if they are supported by practice, they are so easy and you will
interpret and understand them easily.

At internship time we gain many benefits like; use of tools, procedure, technical works, safety
and so on. Those the above benefits are as it is and additionally during internship, we upgrade
our knowledge such as;

 Responsibility
 Punctuality.
 Reliability.
 Motivation.
 Tolerance.
 Good agreement with others.
 Disciplinary rules and Commitment, respecting other work.
 Honest
 Interest to teach others
 Availability at place on time they required etc.

In RESCo there are: multiethnic group workers, multi-religion follower workers, both sex
workers, different life style follower workers, those who have ability to create effective idea and
different level knowledge owner workers, those who have different level education certificate and
etc. However what glad you are, all workers work together without regard of these difference.
They also stand together during sad and help each other in case of difficult situation. Within annual
(a year) they also have meeting program with their branch depo. The workers of those branch come

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together and meeting each other’s as well as the come together and discuss on serious issue that
involve company’s development. All those activities are positive situation that we have to learn
from them and it develop our positive attitude. Internship was teaching us what are in RESCo and
around the company.

Generally, internship play vital role in case of develop our social, political and economic
knowledge beside to improving the practical skills of knowledge that we have learned in
theoretically.

3.1. Benefits we gained in terms of improving our practical skills

Internship is very important issue that help us to apply practically what we have been learned
theoretically in class. It helps to develop practical experience and how to handling the theoretical
knowledge when it changed into practical one. When we learn theory, it seems too difficult since
there is no more practical experience and lack of sufficient workshop availability in the campus.
In addition to this, in theoretical teaching and learning process of the course sometimes it is
difficult to interpreted and understand the subjects theoretically in a short period of time. But
practically in the internship or job training and practical work easily interpreted and understand.
As a whole the intern ship has excellent advantages for us, because of it deal with what we learned
theoretically again we seen practically.

Mechanical engineering most of the subjects are deals practical manner. However, except certain
course most of the course were not supported by practical activity up to we taken internship. This
renders me from the actual performance of the courses precisely. But in our internship, we got
sufficient knowledge and practical experience from the host internship company. So, that the
internship helps to gain different advantage and benefits. One of the most benefit was improvement
of our practical skills. After doing the internship we have improved our practical skill such as
speed of work, accuracy, confidence, independence in work and also technical skill on machine as
well as tools which are available in the company.

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3.2. Benefits we gained in terms of upgrading our theoretical knowledge

The internship was very helpful in up grading the theoretical knowledge since it was gained by
practical experience and observation. As all of us knew most of the field Study (mechanical
engineering) which we have been followed were theory. Certain theory of these were difficult to
understand easily and were forgettable within short period of time. But if all theoretical knowledge
were supported by practical activity by see and touch what we learn theoretically, they could be
easy to understand easily and we remember that knowledge at anywhere and when. This will
successful at a season like internship. So, the internship helps us in terms of upgrading our
theoretical knowledge development. During we join the company and doing our practice we
improve and change our knowledge which are from miss understand during field study.
Knowledge we have on how machines and mechanism of work and the system behind the
machines such as hydraulic, mechanical and pneumatic system were much clear to understand by
relating to the theoretical knowledge. Studying different kinds of process, machines and reading
manuals has also an important way for up grading my theoretical knowledge. In addition to this,
the internship has also helped as in how we can relate my knowledge to the working environment
and I think that this is very important for my future in that we won’t be new for working
environment.

Generally, up grading theoretical knowledge is important to participate in the internship and also
internship is a backbone to apply theoretically .so, internship is the most important for our future
opportunity to job requiring and to apply the practical experience that we gained during internship
time.

3.3. Benefits we gained in terms of our interpersonal communication skills

Since the most important thing for one employee is good and peaceful communication and for
sharing of idea with other employees, the internship has been of great help in improving our
communication skill. For example, to get different kinds of information about the company and its
function, to acquire knowledge about the mechanical system of each machine, to share one’s
knowledge with others peaceful communication was very important.

Interpersonal communication is important in order to work and to understanding each operation

on the machines and tools. This lead to gain the experience how to apply this into practical one.

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Additionally, to gained experience from the skilled professional workers. Due to this reason
through a time personal communication skill improves the knowledge and ability to approach the
workers by living with other peaceful. Personal communication skill improved depending on the
practical work and activities take place during the time.

To exchange, tools and other material during the work time with the workers. The interpersonal
communication skill plays a great role. To asking the operators how some machines perform its
tasks and the process performing on that machine communication is required. Even some workers
of RESCo use Italian name of materials and tools. This makes us confuse around the beginning
week. Sometimes we assist other material which we were not ordered, due to lack knowledge the
correct name of materials and tools in Italian name for a time. But after few weeks we were try to
know those names and able to identify names of materials and could assist the correct tools and
materials as we asked. Therefore, this knowledge is the result of interpersonal communication
from our internship. Some examples of those names are listed in the below table;

English name Italian name

Starter motor moterino
Hose Manicoto
Cylinder head Testate
Cylinder block Mano block
Oil sump Sotocopa
Crankshaft colo
Camshaft Alberocam
Gearbox Cambio
Injection pump Pompa
Alternator Denamo
Spark plug Candela
Table 3.1 Some examples of Italian names for engine parts

So, we were much benefited from internship by improving our interpersonal communication
skill.

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3.4. Benefits we gained in terms of improving our leadership skills

To improving leader ship skills internship is one of the basic criteria and plays vital role in order
to improving leadership skill. Through actively observe all the works how to perform and how to
flows by the supervisors of the company or the company time keeper. We have seen many things
related to leadership during our internship that we have passed in RESCo. The higher supervisor
arranges sub- supervisors in special way to control individual workers. Example RESCo
supervisor arrange maintenance supervisor, work shop supervisor, car wash section supervisor so
on. This type of responsibility division is good and easy for the flow of works. Unless otherwise
not all some employee shows them self as hard worker, but they waste time when there is no
manager. From internship we learn that absolute leaders are very important for any company like
RESCo.

The following are the benefits or advantages of internal ship improving leader ship skill. Those
are:

• To increase quality of work.

• To facilitate the manner and terminate on time.

• To increase product of company.

• To have confidence at any project activities.

• To have cost effective to the company.

Generally, we believed that my attitude has changed positively and so does our leadership.

3.5 Benefits we gained in terms of understanding work ethics related issues

Work ethics used to work with any person or to participate in any activity which take places
during work involving in a proper manner the work ethics is necessarily.

During our internship we were so understand and well knew many things what are work ethics
and their benefits for group and individual people as well as for company. Most of the company
workers were work together in order to simplify the activity. All those individual workers are

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respect and follow the work ethics. At the time we stay in RESCo sure we improve or update our
knowledge related to work ethics issues.

The work ethics is important in future because we will not be new this rule and by know that
respecting and trying to implement the rule is beneficial for once and countries development.

Generally, from my internship to improving the work ethics issues the basic work ethics issues
used in the work place that we obligate to know them as follows these are:

• Punctuality

• Reliability

• Respect others idea

• Tolerance

• Motivation

• Take care for properties and workers while use tools and machines

• Responsible for their works……etc.

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CHAPTER FOUR

4. DESIGN OF OTC REVOLVER STAND PLATE FOR HYUNDAI DIESEL

ENGINE

INTRODUCTION

In this chapter the definition of mounting plate, objective, the statement of problem on design of
mounting plate, significance of the study and the background view of engine stand will be
explained. Engine stands are the most essential devices for a company like the Infrastructure
Machinery Engineering Industry because this company deals with the manufacturing and
maintenance of earth-moving vehicles. Engine stand parts that are responsible for mounting the
engine are mounting plate and universal adapter plate. The mounting plate of the stand is easy to
use and allows attaching many types of engine to the stand, however it may be difficult to turn
the head of the stand with heavier engine stored , so for better movement of the head put same
grease on it after few uses.

4.1 background of the study

OTC revolver Engine Stands are used in the positioning and moving of automobile and light
truck engines in a wide variety of vehicle maintenance and service facilities. The OTC engine
stand include a 360° rotating head. It is very safe for both the engine and the operator; the engine
can rotate by using rotational mechanism that is by using handle bar. The operator can maintain
the engine in all position without dismantling the engine from the machine. Cylinders and other
internal components of the engine can be easily disassemble and maintain. It is movable from
place to place by using steel casters. Generally the OTC engine stand has the following
advantages for the company as well as the medium and small garages; reduce engine
maintenance time, improve the performance of the company, reduce human power with respect
to engine maintenance work. Most of its parts are constructed from steel. This paper present
important aspects: force analysis of each part, the assembling process of the machine, the
operation and instruction of the machine. Most automotive maintenance industries maintain the
engine by putting on a tire, earth and on table this requires additional and maximum human
power to rotate the engine, it takes time, it increase maintenance cost, it reduce the performance

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of the company and most especially the output is not efficient and etc… This project use to
reduce these problems in the company and other automotive maintenance establishment.

4.2 Problem Statement

Engine stands are the most essential devices for a company like the Infrastructure Machinery
Engineering Industry because this company deals with the manufacturing and maintenance of
earth-moving vehicles. Surprisingly, there are no proper engine stands for Hyundai diesel engine
in our component rebuild center (CRC) of the industry because of our company switches it’s
brand from caterpillar to Hyundai engine. Which directly led to the need for design and
manufacturing mounting plate for Hyundai diesel engine stand. The purpose of this project is to
design and manufacture mounting plate which is believed to greatly improve the current working
condition of the engine maintenance workshop. The current engine stands in the workshops are
fitting for caterpillar engine not for Hyundai diesel engine and also it’s not safe for both the
engine and the workers. Also, it does not allow for effortless and quick maintenance. If this
project is carried out it will have significant contribution for the improvement of engine
maintenance as well as productivity of the industry. The project will eliminate the probability of
engine damage during maintenance, increase workers motivation and productivity, and it will
reduce the number of workers involved in maintaining a single engine which will allow
more engines to be maintained simultaneously. These advantages will increase the overall
productivity of the workshops while decreasing production time. Regarding the cost of the
project, it is going to be carried out using low cost and available materials. The projects will cost
less than the cost of damages to engines during the current maintenance condition of the
company’s workshops. Therefore, our project is approved and manufactured in our company to
increase the productivity.

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The work in this study is in general described, OTC revolver stand plate for Hyundai diesel engine.
Designed for mounting engines, transmissions, or other components by using the universal
mounting plate or a mounting plate designed specifically for the application. The component may
be rotated 360 degrees by using the crank handle; the component may be raised by using the lifting
jack to increase swing radius for clearance when rotating the component.

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4.3 Justification of the Study

This study focuses on the mounting plate for Hyundai diesel engine. This design considers the
material characteristics, building construction and working mechanism regarding to proper
assembly with engine stand and engine itself. This study is needed because the company has not
engine stand for Hyundai diesel engine.

The study focused in the OTC engine stand mounting plate because of the following
characteristics:

 The presence of economic stray in country and that company.

 A loss of man power for a single task and lose of time etc.

4.4 Objective

4.4.1 General Objective

 The general objective of our project is to design Mounting plate for Hyundai diesel
engine.

4.4.2 Specific Objective

 To design the plate in the optimum manufacturing cost.

 Reducing time of assembly and disassembly.
 Reducing human effort.
 Single person is enough for assembling and disassembling of engine.
 For check and balance of our design in all aspects.

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CHAPTER FIVE

Literature Review

5.1 Literature review of engine stand

The GM Ecotec 2.2L engine on a swivel stand is designed for student instruction and practice
covering engine mechanical inspection, disassembly, measurement and reassembly. The engine
is securely mounted to a heavy duty rotating device equipped with an automatic lock to allow
full 360-degree rotation. A steel mounting plate is used for engine mounting that allows full
access for rear main seal and flywheel service. Each engine comes equipped with a manual
transmission flywheel. The engine starting station contains all components and systems
necessary for the starting and running of the GM 2.2L ECOTEC engine. All necessary engine
systems connections are provided to allow live operation of each swivel engine stand.

ARI-HETRA’s Model AH-06187 Diesel Engine Stand features a solid base structure for working
on heavy-duty diesel engines. This stand eliminates the need to struggle with rebuilding engines
on a bench or on the ground. The sturdy AH-06187 helps reduce the possibility of damaging
expensive diesel engines.

Torin T25671 engine stand has a square type sturdy design which is one of three most common
designs for engine stands. Construction consists of one base plate and two legs. The legs cannot
be folded. It means that the engine stand will take its space whole time and you can’t place it in
any other smaller size space. Engine stand is made out of high quality steel and construction is
very strong and durable. It is not recommended to place engines heavier than the maximum
capacity because it may cause bending of mounting arms or even construction.

The Rolls-Royce engine stand is ground based engine-built stand which has been designed on the
basis of two manipulators. It has its unique features such as 45-degree positioning wheel with
ball lock pin which secures engine giving eight angles of maintenance access, sturdy welded
steel construction, easy maneuvering with two swivel and two rigid heavyduty casters, center
foot operated grips firmly to stabilize stand during maintenance operation, and handy oil
recovery pan.

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Black Bull ES4W engine stand is made from heavy duty tubular steel that is painted in neutral
black color. Because of this material it is able to withstand weight that is up to ½ ton or 1000
pounds letting you hold most V8 type engine blocks on it while you are repairing the engine
itself or the car. The design of this engine also prevents even the heavy engines from tipping
forward.

Mountain MTN5138 engine stand is a perfect stand for small-type engines with weight up to half
a ton. It has a very strong and stable steel construction despite the small size. The size is a benefit
because this engine stand will mostly fit between legs of engine hoists. This Mountain engine
stand has a very good and durable steel construction that is perfectly suited for holding engines
up to 0.5 tons (1000 lb.). It has the square type shape and construction can be very stable if even
heavier engines are placed on it. Two support plates and other construction parts help to hold the
heavy engines and doesn’t face any kind of problems.

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CHAPTER SIX

6. MATERIALS AND METHODS

6.1 Selection of Materials

The selection of a proper material, for engineering purposes, is one of the most difficult problems
for the designer. The best material is one which serves the desired objective at the minimum cost.
The following factors should be considered while selecting the material:

1. Availability of the materials,

2. Suitability of the materials for the working conditions in service, and

3. The cost of the materials.

There is also number of factors that affecting the material selection. They are properties of
materials, performance requirements, material’s reliability, safety; Physical attributes
environmental conditions, availability, disposability and recyclability, and finally economic
factors. In these properties,

1) One of the most important factors affecting selection of materials for engineering design is the
properties of the materials. The important properties of the materials are mechanical, thermal,
chemical properties etc.

2) The material of which a part is composed must be capable of performing a part’s function
(always it must be possible or not) without failure.

3) A material in a given application must also be reliable.

4) A material must safely perform its function.

5) Physical attributes such as configuration, size, weight, and appearance sometimes also serve
functional requirements can be used.

6) The environment in which a product operates strongly influences service performance.

7) A material must be readily available, and available in large enough quantity, for the intended
application.

8) The cost of the materials and the cost of processing the materials into the product or part. The
development and manufacture of satisfactory products at minimum cost is to make a sound,
economic choice of materials.

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In material selection, the following requirements are focused. They are:

1) High material stiffness is needed to maintain optimal shape of performance.

2) Low density is needed to reduce gravity forces,

3) Long-fatigue life is needed to reduce material degradation. By having the above properties in
mind steel selected as general material.

6.2 Methodology

When we start our project, we gathered general information about RESCO previous methods
that used to stand the engine. To gather this and other general information we used primary
and secondary data collection method. This project is designed by calculating different
calculations and by arranging of the components properly. The data’s we use in our
calculation are collected by different methods of data collection. These are:

Primary source

During primary data collection time we use different mechanism by observation, interview
with worker, communicating with my enterprise advisor, and also we take different
measurement data collection from service information system, SIS (software information
system). In this time, we try to identify the main problem of this enterprise is lack of engine
stand for Hyundai engine.

Secondary source

As a secondary data, we use text books like mechanics of materials, design of machine
elements, accessing websites, documents of material specification, journals, and literature.
These data have played significant role in developing and assisting our project through the
following way:

 To complete the cost analysis

 To assure the quality and reliability of the product
 To calculate the strength of raw material
 Material selection
 Mounting plate Component analytical and software design

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 Assembly design of mounting plate

 Conclusion and Recommendation
 Analytical Design and Material Selection
 Software application in this project we use solid work software for making the 2D
and 3D DWG exploded, and for the assembly drawing.

6.2.1 Working Principle

Before attaching the engine to the stand check that its weight does not exceed the stand
maximum capacity, and then determine the tread type and length of the bolt depends on the
screw of engine block. After determine the bolts align the mounting arms with the mounting
location of the engine by rotating the mounting arms 360 and sliding the mounting arms. After
this place the bolt through the mounting plate and securing them with mounting plate, then
secure all bolts of the mounting arm. After this slowly lower the hoist (engine crane) until the
entire engine weight is held by the stand. Then safely release from the engine crane, by removing
the pin of hallow shaft slowly rotating the engine to the desired angle by using handle, after get
the required position of the engine lock the pin. During rotation of engine not have sudden
engine moment before removing pin. For our engine stand there is a terry that is used to caring
tools like bolts and others it also use a soil reserves. After finished our work we remove the
engine from the stand. To remove the engine from stand first rotates the engine to its initial
position; secure the engine properly to the crane. Once the engine is properly supported by the
crane remove the bolt securing the mounting arm to the engine, then take the engine from the
engine stand. Because of engine stand is movable you can take from place to place.

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Procedure to assemble with engine

1. Verify the handle locking mechanism on the

engine stand is engaged before mounting an
engine.

2. Select an engine adapter plate that has the

correct bolt pattern for the engine to be serviced.
Use the application chart provided with the adapter
plate to determine which bolt holes adapt to the
specific engine model.

3. Bolt the engine adapter plate to the engine using

the spacers, bolts, and washers specified in the
application chart. Wrench tighten the bolts.

4. Attach side plates to the engine adapter plate,

but leave the cap screws and nuts loose.

5. Align the engine (with side plates attached to the adapter plate) with the universal adapter
plate on the engine stand. Raise or lower the engine until its center of balance is in-line with the
rotating shaft of the engine stand. Note: The engine's center of balance (greatest concentration of
weight) is usually about 50.8 mm (two inches) above the center of the crankshaft.

6. Align the closest tapped holes in the universal adapter plate with holes in the side plates.
Securely tighten the side plates to the engine adapter plate on the engine and to the universal
adapter plate on the engine stand.

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6.3 Design of Engine Stand Components

Material required for Hyundai diesel engine stand mounting plate design

 Mounting Plate
 Bolts
 Washer
 Nut

Mounting Plate:-These are the parts of the engine stand where the engine is going to be
bolted and held. The arrangement can be rotated 360-degree with the help of a handle which
makes every part of the engine easy to reach.

Bolts:-A bolt is s form of threaded fastener with an external male thread. Bolts are used to hold
the engine through the mounting arm. They are fitted on the engine through the fly wheel
mounting internal threads.

Washer:-Washer is simply a flat, doughnut-shaped part that serves to increase the

area of contact between the bolt head or nut and the clamped part. A washer is a thin
plate (typically disk-shaped) with a hole (typically in the middle) that is normally used
to distribute the load of a threaded fastener, such as a screw or nut. In general they are
used for the purpose of:

o To prevent the loosening of the associated screw, bolt, and nut

o To distribute the compressive force over areas larger than that of the head or the nut,
o In order to decrease the friction that occurs when nut is tightened, especially when
the surface of the part is having poor surface finish.

Nut:-Is a threaded fastener used to hold two parts together and Nuts in general are
square or hexagonal in shape. The nuts with internal threads engage with the
corresponding size of the external threads of the bolt. For nuts, hexagonal shape is
preferred to the square one, as it is easy to tighten even in a limited space. This is
because, with only one-sixth of a turn, the spanner can be re-introduced in the same
position.

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6.3.1 Design of mounting plate

The plate transfers the universe of plate torque to the engine.

Torque on plate = 42
Moment on plate (M) = load × distance
M= 3000Nm × 330 mm = 990 Nm
The moment of inertia for rectangular plate about the centroid (I) = bℎ3 /12
h= 251mm
b= 152mm
I= 251mm × 1523 mm⁄12
I= 73455317.33𝑚𝑚4
The polar moment of inertia for rectangular plate (J) = bh /12√(𝑏2 + ℎ2 )
J = bh /12√(𝑏2 + ℎ2 )
J =251mm × 152mm⁄12 √(251𝑚𝑚2 + 152𝑚𝑚2 )
J =121297925.3𝑚𝑚4
From equation
T/J=T/y where T=torque
J= polar moment of inertia
T= torsional shear stress
Y=h/2
Find T
T=Ty/J
=42000Nmm × 76𝑚𝑚⁄121297925.3𝑚𝑚4
T=0.0263MPa
From M/I=𝜎𝑏 /y
Finding bending stress
𝜎𝑏 =M × y/I
= 990000Nmm × 76𝑚𝑚⁄73455317.33 𝑚𝑚4
𝜎𝑏 = 1.0243Mpa

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Then find 𝑇𝑚𝑎𝑥

𝑇𝑚𝑎𝑥 = 1⁄2 √(𝜎𝑏 2 + 4𝑇 2 )
= 1⁄2 √(1.02432 + 4× 0.02632 )
𝑇𝑚𝑎𝑥 = 0.5123Mpa
The material selection for plate is the same as universe of plate that is high carbon steel which
have 262.5Mpa shear stress (262.5MPa > 0.5123 MPa).

6.4.2 Design of bolts

Material selected for the bolt is 304 stainless steel with yield strength:
𝜎𝑦 = 215
Safety factor assumed is F.S = 2
Number of bolts, 𝑛 = 8
Engine weight 𝑃 = 2000𝑙𝑏 = 8900𝑁
The internal thread found on the engine for fitting the bolt is 12mm.
Therefore, diameter of bolt d = 12mm.
Considering shearing of the bolt, shearing strength is,
𝜋𝑑 2 𝜏𝑏𝑜𝑙𝑡
𝑷𝒍𝒐𝒂𝒅 =
4
Load on each bolt
𝑃 8900
𝑷𝒍𝒐𝒂𝒅 = = = 1112.5 𝑁
𝑛 8
Therefor shearing strength will be,
π122 𝜏𝑏𝑜𝑙𝑡
1112.5 =
4
4 ×1112.5
𝜏𝑏𝑜𝑙𝑡 = = 9.84 𝑀𝑃𝑎
π122
But allowable shear stress is,
𝜎𝑦 215
𝜏𝑎𝑙𝑙 = 2𝐹.𝑆 = = 53.75 𝑀𝑃𝑎
2 ×2

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Since 𝜏𝑏𝑜𝑙𝑡 = 9.84 𝑀𝑃𝑎 is less than 𝜏𝑎𝑙𝑙 = 53.75 𝑀𝑃𝑎, the design is satisfactory. Considering
crushing of the bolt, crushing strength is,
Torque transmitted
𝑇 = 𝑘 𝑥 𝑑 𝑥 𝑃𝑒𝑎𝑐ℎ = 0.2 𝑥 12 𝑥 1112.5 𝑁 = 2670 𝑁. 𝑚𝑚
k = 0.2 for non-lubricated bolts
∴ crushing strength is,
2𝑇 2 ×2670
𝜎𝑐 𝑏𝑜𝑙𝑡 = π 3 = π 3 = 3.934 𝑀𝑃𝑎
𝑑 12
4 4

But allowable crushing stress is,

𝜎𝑦 215
𝜎𝑐 𝑎𝑙𝑙 = = = 107.5 𝑀𝑃𝑎
𝐹.𝑆 2
Since 𝜎𝑐 𝑏𝑜𝑙𝑡 = 3.934 𝑀𝑃𝑎 is less than 𝜎𝑐 𝑎𝑙𝑙 = 107.5 𝑀𝑃𝑎, the design is satisfactory.

6.3.3 Design of washers

Material selection in our design we select low alloy steel to design the washer because of:

 It has high working stress compared to others,

 Has high atmospheric corrosion resistance capacity
 Suitable to welding.
To calculate the outer diameter of the washer we can use the following formula:

𝐷𝑂 𝑤𝑎𝑠ℎ𝑒𝑟 =1.5𝐷𝑂 𝑠𝑐𝑟𝑒𝑤 + 3mm Where outer diameter of the screw is=28mm

DO washer= 1.5*28mm+3mm=45mm

To calculate the thickness of the washer we use the following formula.

𝐷𝑂 𝑠𝑐𝑟𝑒𝑤 28
𝑡𝑤𝑎𝑠ℎ𝑒𝑟 = = =3.5mm
8 8

Therefore the outer diameter of the washer is = 45mm.

The thickness of the washer is = 3.5mm.

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6.3.4 Design of nuts

We select mild steel material to design Nuts because of:

 easily workable
 very hard
 yet malleable
 good for construction
 easy to shape and machine
 Very flexible and can be harden
Table material selection for nut design [2].

Steel grade Measured direction Yield strength(Mpa) Tensile strength(Mpa)

Mild steel A 452 497

To design nuts we have taken all necessary parameter from Table. 7- Basic
dimensions for square threads in mm (normal series) according to IS: 4694-
1968 (Reaffirmed 1996)
Table 6 Basic dimensions for square threads in mm (normal series) according to IS:
4694-1968 (Reaffirmed 1996) [1].

Nominal Major Minor Pitch(p) Depth of Area of

diameter(𝑑1) diameter(D) diameter(𝑑𝑐) thread(H) core(𝐴𝑐)

32 32.5 26 6 3.25 531

Let n is the number of threads in contact with the screw Let us assumed that the
load is uniformly Distributed over the cross sectional area of the nut. Let Pb be the
Allowable Bearing pressure between the threads. Bearing pressure is assumed as
65 N/mm2

Pb = (2 ∗ T)/((π/4) ∗ (do² − dc²) ∗ n)

65 = (104914.26)/ ((π/4)*(282-252)*n)

𝑛 = 12.925

Number of threads, n = 12.925 ≈ 13

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In order to have good stability let

n=13 Thickness of Nut

= 8*p=13*3=39mm

Width of Nut b =1.5*do=1.5*28=42mm

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 Internship report, Ries Engineering S.Co 2015 E.C

CHAPTER SEVEN

CONCLUSIONS AND RECOMMENDATION

7.1 Conclusion

This internship project contains the overall experiences that we gain from the internship program.
We concluded that the program is very good to know the real world life and work way comparing
with class study subjects. We can say that this internship was successful by acquiring sufficient
knowledge and practical skills. Here during this period (as an intern) the hosting company satisfied
with the activities of our performance especially theoretical understanding in every moment. On
the internship period, we have understand so many skills that was the job environment and what it
meant to be a worker, what and why ethics we need to have at the work place and outside. It was
also very effective in developing team playing, interpersonal and leadership skills. Generally, we
were able to learn and experience different practical lessons. We were also able to find out different
problems and tried our best to resolve the problems. In this time, we also experienced our self with
the problems a vehicle can mostly occur to and we also did different maintenances. We have done
a major service and also minor services in Ries Engineering share company. We get satisfactory
knowledge and more benefited at internship period. This internship program is real, necessary and
important to all engineering students.

7.2 Recommendation

As internship program gave an opportunity to change the student to change theoretical knowledge
into practical or real world and exposes the student to exercise the real world life, we strongly
recommended to be continue in a manner that it achieves its goal. From the time we spent in the
Ries Engineering share company for internship practice we have seen things that should be
modified and we gave recommendations on those issues these are: -

 To make the working area organized.

 To provide services necessary for the workers.
 To satisfy the internship students material request for projects.

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 Internship report, Ries Engineering S.Co 2015 E.C

 Finally, our design of Hyundai diesel engine to mount with OTC revolver engine stand has
to be implemented to solve problem that present in company.

Reference

[1] Shigley’s Mechanical Engineering Design, Eighth Edition Budynas−NisbettMcGraw-Hill

[2]Text book of machine design, 2005, R.S. KHURMI and J.K. GUPTA,EURASIA
PUBLISHING HOUSE

[3] Machine Elements INMechanical Design,Fourth Edition, Robert L. Mott, Pearson education

[4] Mechanics of material, six editions, Ferdinand P. Beer

[5] Internet :- https://www.vehicleservicepros.com

[6] Mechanical engineering design-9th-edition-Shigley

[7] Literature review Source: - GM Ecotec, ARI-HETRA Model AH-06187, Torin T25671, Rolls-
Royce, Black Bull ES4W, Mountain MTN5138.

APPENDEX

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