Chevrolet

IN PLANT TRAINING REPORT 2014-2015
ACKNOWLEDGEMENT
First of all I would like to praise the god almighty for blessing me to
complete the training successfully.
I am deeply thanks to Mr. S.N.M. Basil (Head of department in

Automobile Engineering SSMPTC (Tirur) for providing me the opportunity
to undergo an INPLANT TRAINING in such a prestigious institution.
I express my sincere and profound thanks to Mr. Gasali (Branch
Manager) and to Mr. Venugopal (Asst. Service manager) Mr. Vinod
(Supervisors) who encouraged and provided me a lot of creative ideas about
this training which I have done.
I extended my unexplainable gratitude towards all of the staff and
techniques of GM motors.
Dept. of Automobile Engg.
S.S.M. Polytechnic College
CONTENTS
INTRODUCTION
ABOUT THE COMPANY
WORKSHOP LAYOUT
WORK REPORT
REPORT 1
REPORT 2
REPORT 3
WARRANTY
PCR
CONCLUSION
INTRODUCTION
This INPLANT TRAINING is in connect with the syllabus of 5th
semester diploma in AUTOMOBILE for duration of two weeks. It aims for
students touch with automobiles servicing in direct exposure.
German Motors dealers of CHEVROLET and OPEL passenger car,
proves to be the correct platform such training.
ABOUT THE COMPANY

German motors are a part of large business group based in Calicut. It
has a world class showroom and focuses providing total-customers, delight.
The main service centers under the German motors Calicut, Perinthalmanna
and Kannur, Kasargod, Kottakkal & Wayanad.
Since 1996, the German motors a dealer of general Motors in north
Kerala have been rewriting the conventional automobile industry that was
prevalent in Kerala this innovativeness has given them an extra inch in the
arena of sales and service.
Started on 511 march 2001 German Motors Calicut is partnership
concern with Capt.D.A Sebastian & Mrs. Theresa Sebastin as the partners. A
German motor. Calicut with a stunning series of world class best sellers, has
scaled new heights in sales and service. The coveting Bestseller award in
Customer satisfaction and the big finish sales contest 2003 award have
added more glory to the unique sales performance presented by word class
dealer of German motors Chevrolet & Opel.
In the initial stage we are dealing with Qpels products like Corsa,
Vectra, Astra etc then came Chevrolet products like Captiva, Cruze, Optra,
Tavera, SRV, Aveo, U-VA, Spark and Beat.
Greeyem Cochin, Vythiri resort, Madikkeri Resort etc are some of
our sister concerns. At present German motors is a 100 crore turn over
company. So be happy as you are also a part of this company.
WORKSHOP LAYOUT
1. PARKING
2. SECURITY
3. PARKING
4. CAR DISPLAY
5. OFFICE OF SALES MANAGER
6. SALES
7. SALES
8. ADVISER ROOM
9. ACCOUNTING
10. OFFICE OF SERVICE MANAGER
11. SUPERVISOR CABINE
12. SPARE PARTS
13. TOOL ROOM
14. ELECTRICAL ROOM
15. PAINTING STORE ROOM
16. BATH ROOM
17. DRESSING ROOM
18. WORKSHOP
19. ALLIGNMENT
20. PAINTING BOOTH
21. PAINTING
22. SERVICING
23. DENDINGROOM
24. GENERA TOR ROOM
25. WELL
26. ACCIDENT VEHICLES AREA
27. P D I
28. CANTEEN
29. CUSTOMER LAUNCH
WORKSHOP PROCESS
The two important elements involved in workshop process are
1. ITEMS
2. ACTIONS
INSPECTION JOB CARD REPAIR FINAL INSPECTIONS
The following procedures are followed when a vehicle enter for a
service.
1. CUSTOMER RECEIVING
Service adviser receives the receiver.
Using relevant information about the vehicle job card is
issued.
2. PROBLEM IDENTIFICATION
Service adviser enquires about complaints if any of the
vehicle.
The complaints of the vehicle are entered into the job card.
3. VEHICLE INVENTORY
Vehicle body is checked for any scratch ardent.
Extra necessaries inside the vehicle are noted and entered into
the job card.
Fuel level is also checked and also entered in to the job card
4. PRE-ORDER
The information's obtained from (he above three are entered in

to the pre-order sheet of the job card and signed by the
customer.
5. WORKSHOP ORDER
Vehicle entered into the bay concerning the complaints.
Technician check the vehicle shares his infertance with the
service advisor.
6. CUSTOMER COMMUNICATION
Service adviser informs customer about the work to be done
and a rough estimate.
Customer confirms the work if to be done.
7. SERVICING
Work Allocation:
Service adviser allocates respective works to specific machine.
Servicing of mainly
Kilometer/duration type of service
Electrical repair
Mechanical repair
Accident repair
Body repair
A/C related works
Technical places the fenter cover, seal cover, steering wheel cover
and gear lever cover etc.
Technicians diagnosis the problem with the help of "star"
Technicians rectifiers the problem one by one using tools and
necessary space from the store of company.
A technician verifies that the fault codes are removed.
The works done and parts replaced are entered in the job card and
technician signed in it.
8. TEST DRIVE
Technician took the vehicle for a test drive and ensured that
the problems are properly rectified.
9. FINAL CONTROL
Check fluid levels in engine, transmission, radiator, battery etc.
Check the functions of brakes, steering, A/C, wiper etc.
Take the vehicle for visual check out of engine, transmission,
arches, steering, tyres, body and paint damages.
Check the inventories had been in the vehicle.
10. BILLING AND DELIVERY
H O D of service, bills the work throw online using the software
GMI.
Three copies of bills are issued of which one is to customer, one
for dealer and third one is to send to the production plant at
HALOL.
Customer pays the bill and obtains the gale pass which also issued
with the bill.
After showing the gate pass top security officials customer takes
the vehicle out.
11. CUSTOMER FEED BACK
Always after a service a repost will be kept which will show the
customers opinion about service and other feedback.
WORK REPORT 1
RECEIVING THE CUSTOMER
The customer is received by the service advisor and enquires about
the problem of vehicle.
PRE ORDERING VEHICLE DETAILS
Regn.No
KL 53 F 895
Model
Tavera 2.5 L Diesel
Receiving lime
09.00 AM
Receiving date
07/04/2014
CUSTOMER COMPLAINT
1.
12 month/10000 km service.
2. Wheel changing.
3.
Rattling.
VEHICLE INVENTORY
10
1.
The scratched and dents are not in the job.card. There is a

scratch on the left door and small dent on the front bumper.
2. The fuel level in the fuel is noted.

3.
There are toolkit, music player cigar lighter, bonnet sot

warning triangle, key chain, etc.
4. Job card is signed by customer.

WORK SHOP ORDERING
Service adviser prepared the job card by checking the vehicle
and list out the problem in it.
Then hand over the vehicle to corresponding section and
technician.
CUSTOMER COMMUNICATION
Service adviser communication with customer about the total
problems of vehicle and gives a rough estimate.
Customer gives a positive replay.
WORK 1
12 MONTH/10000KM SERVICES
Park the vehicle on service floor.
Start the vehicle and check the component like A/C, wiper, music
system, mirror, lighting system.
Drain the engine oil and top up the engine oil.
Replace oil filter.
Check and adjust A/C belt change.
Lubricate door ,door stop, hood release, tail gate, hinges.
Replace transmission oil and differential oil.
Check and adjust fan belt.
Check and top up coolant level.
Check and inspect drive pulleys and grooves.
11
Check and correct wheel attachment, tire condition, inflation

pressure, balancing etc
Rotate the tire softens.
Check the wind shield wash system and washer fluid.
Check exhausts emission.
Check visually for leakage of engine transmission AC compressor
etc.
Check and record damage in service booklet.
Visually check and fore wheel & disk brakes an drear wheel drum
brakes.
Visually check the brake pipe brake pressure hoses fuel line and
exhaust system.
Lift the vehicle using power lifter.
Check the ones shaft and boots.
Bring down the vehicle from lift.
Now the 12 month/ 10000 km service work is completed.
After this we have to change the vehicle for the next work. The next
work is the changing front wheel (right side).
WORK 2
WHEEL CHANGING
The front right side tire of the vehicle is seemed to bulge. The main
possible reasons are given below.
Due to driving in bad road condition.
Faulty driving method.
The material quality of tire.
12
To get the opinion of customer service adviser contracted with he and he

suggested installing space wheel instead of bulged lire wheel.
The procedure of changed tire is as given below
Lift the vehicle in the proper level using lift.
Fix proper socket on the gun and remove the wheel bolls, take out the
wheel and check it properly.
We find that there is only one bulging in the tire.
Open the dick and take out the spare wheel.
Fit the space wheel on the wheel hub and tight the bolt with proper
tool in steer wise.
Interchange the wheels from front to rear.
Bring down the torque of the torque wrench.
WORK 3
RATTLING
Rattling is a noisy sound producing from the vehicle especially from
engine sound. If there is any breakage in the metal parts or joints.
There will be a sound from suspension, extra vibration of engine are
other example of rattling. To know the exact place of rattling, we inspect the
vehicle carefully at starting. Then accelerate the vehicle for some time. So
we noticed the sound is coming from the engine side.
Procedure of eliminating this problem is,
Lift the vehicle, removed the undercover and check the components
like ball joints, bushes etc.
Support the engine with hydraulic jack.
13
Loosen the engine mounting bolts from under, the side of the engine
and take out it.
Inspect the mounting by shaking strongly.
No defects noticed.
Refit the mounting bolts properly.
Remove the hydraulic jack, refit the under cover and bring down the
vehicle.
During the bonnet and take the vehicle for a test drive.
During test drive there is no rattling sound.
RESULT OF CORRECTION
12 month/10000km servicing is done.
Bulged lyre is replaced by fitting the spare wheel.
Rattling is also eliminated.
Work done and parts replaced are entered in the job card and signed
by the technicians.
The vehicle is then delivered into the washing section and washed
neatly.
FINAL INSPECTION
The tire pressure is settled into 30 PSI or 2 bar is each tire.
Service adviser checked the vehicle neatly.
He checked all the inventories in the proper order.
BILLING
The service advisor prepares the bill through online.
"German Motors" (IIPL) software is used to prepare bills.
The copies of bill are issued one for the customer and one for the
German motors pvt Ltd Company.
14
Customers pay the bill and receive the gale pass.

Customers show the gate pass to the gate keeper and take out the
vehicle.
CUSTOMER FEED BACK
The opinion of the customer about the servicing of his vehicle in German
Motors is entered to the feedback.
WORK REPORT 2
The customer is received by the service advisor and enquires about the
problem of vehicle.
Regn. No
KL 53 F 5653
15
Model
Spark
Receiving time
10:00 AM
Receiving date
10/04/2014
CUSTOMER COMPLAINT
1. 6 month/ 5000 km service.
WORK 1
6 MONTH/ 5000 KM SERVICE
system, mirror, lighting system etc.
Fill the new engine oil into the engine after replacing the old oil filter.
Check and inspect the spark plug.
Change the brake fluid.
Check and top up gear box oil and power steering oil.
Check and adjust the V ribbed belt.
Check and correct top up the coolant and anti freezer.
Check and correct the wheel attachment, tire combination and
inflation pressure.
Check and correct the clutch pedal adjustment.
Check and adjust the head lamp aiming.
Check the leakage of engine, transmission and compressor.
Check the front wheel disc brakes and rear wheel drum breakage.
Visually check the brake pipes, brake pressure hose fuel lines and
exhaust system.
Check axle shaft and tic rod and boots.
Bring from the vehicle from lift.
16
After that we have to change the vehicle for the new work.
Now the 6 month/ 5000 km serving work is completed.
Take the vehicle for the test drive to check more complaints.
6 month/ 5000km servicing is done.
by the technicians.
neatly.
WORK REPORT 3
The customer is received by the service advisor and enquires about the
problem of vehicle.
17

Regn. No
KL 53 D 6623
Model
Beat
Receiving time
09:30 AM
Receiving dale
17/04/2014
CUSTOMER COMPLAINT
1.
1 year/ 10000 km service.
2.
Sound producing from left rear view mirror.
WORK 1
1 YEAR/ 10000 KM SERVICING
system, mirror, lighting system.
Check the clutch fluid and brake fluid.
Replace the pollen filter.
Check and adjust A/C and fan belt.
Check and adjust the coolant level and freeze level.
Check and inspect the drive pulley and grooves.
Check and correct the wheel attachment condition inflation pressure
balancing etc.
Check the light and signaling drives.
Fill the windshield wash wipe system.
Check the axle shaft and lie rod end boots.
Visually check brake pipes, brake pressure hose fuel lines and
exhaust system.
18
Check the front wheel disc brakes.

Check the rear wheel drum brakes.
Lubricate the door hinges, door stop. etc.
Check the exhaust emission.
Bring down the vehicle from lift.
Now the I year/ 10000 km servicing completed.
WORK 2
SOUND PRODUCING LEFT REAR VIEW MIRROR
A disturbing sound is coming from the mirror when it operated the
key factor of this problem may be the rust in the mirror causing otherwise
any damage in the mirror causing the procedure for rust elimination is as
below.
Put the mirror a completely closed position.
Remove the out casing of the mirror assembly.
Rust is noticed to avoid rust we should clean it using compressed air.
Apply rust off spray in to the rusting places.
Fit the outer casing.
1 year/ 10000km servicing is done.
Sound from the mirror I eliminated.
by the technicians.
neatly.
WARRANTY
19
Warranty is an obligation of manufacture and provided to enhance the

customer confidence in products.
TYPES OF WARRANTY
In German motors in India, two types of warranties are provided,
there arc
1) PERIODS OF WARRANTY
Different duration of warranties are divided like 2 year/ 50.000 km,
3year/ 1,00,000 km etc.
2) OPTIONAL WARRANTY
Optional warranties are two types they are. El- 1 year, E2 - 2 year
REGISTRATION FOR WARRANTY
A copy of warranty card duly filled in by costumer having to be
submitted to warrant within 15 days from the date of sale for registration the
vehicle in company record.
SOME MODEL VEHICLES AND THEIR WARRANTIES
GIVEN
CHEVROLET
1. OPTRA 1.8
OPTRA 1.6
2. OPTRA MAGNUM
3. TAVERA
4. AVEO
5. SPARK
6. S.R.V
7. CAPTIVA
8. BEAT
9. CRUZE
: 2Year/40,000 km optional warranty

: 2Year/40,000 km optional warranty
: 2 Year/40,000km no optional warranty
: 2Year/50,000km optional warranty
: 3 Year /10,000km no optional warranty
: 3 Year/10,000km no optional warranty
: 3Year/ 10,000km no optional warranty
: 3Year / 50,000km no optional warranty
: 3Year/10,000km no optional warranty
: 3Year/1,00,000km no optional warranty
20
PARTS COVERED UNDER OPTIONAL WARRANTY
21
Engine parts excluding
Starter motor
Transmission part
Alternator
Switches
Compressor
AC part
Radiator
Window filler
Accelerator and clutch
Condenser
cable DIS
Electronic modules
Fuel tank
Actuators
Fuel gauge
All pumps
Sensor
Steering gear
Wiper motor and mechanism
Steering column
Condenser fan
Cluster
Caliper ass
Wheel cylinder
Master cylinder
Radiator fan
Seat belts
Booster
Klining harness
Locks
Resonator
PARTS NOT COVERED UNDER OPTIONAL WARRANTY

Oil filter
Battery and audio system
Fuel filter
Weather STNO
Air filter
Rubber parts, sleeves, Hoses and bush
Oils ,fluids &A/C gas
Seats and gasket kits
Spark plug
Engine maints
Drive belts and timing belts

Bulbs
Bearing and bushes
Any accessories fitting

Dash board
Any plastic parts
Break pad/shoes
Fuses
Seats
"o" ring
Shock absorber
Brake disc &brake drum
Tie rod and tie rod ends

Wiper blades
Catalytic converter and muffler Glass
22
Ball joint
Clutch and pressure plate
Tire and rims
Torsion damper
Shock absorber
Also warranty
Mirror
Door pads and trims
Body shell or body parts
Door steps
Paint defect
does not cover the accident, axial damage, crush to
external force etc.

TERMS AND CONDITION FOR IN WARRANTY GOODWILL
WARRANTY IS INVALID
Vehicle is not serviced by authorized sensation
Prescribed regular service or yearly main ones
Improper repair
Usage of non original parts
Damage caused due to natural and environmental things
If the complaints is not repealed immediately
If the total repair cost is less than RS.450
Warranty does not cover to wing costs transportation changes, travel
and hotel and communication expenses.
23
PRODUCTION COMPLAINT REPORT (PCR)

The product complaint report (PCR) is the data amount the vehicle
complaint with in warranty period. The PCR is prepared by the warranty
section officer. It is send to Chennai (head office) by the help of GMI
software. The PCR consists of details of the vehicle. Customer complaints,
technical observation photo of the complaint part, suspected rescue,
correction action etc.
No
Vehicle
1. CORSA
2. AVEO
3. CAPTIVA
4. U-VA
Customer
complaints
Technicians
information
Abnormal
sound
From
engine
On inspection found
Abnormal sound
from engine
compartment On
further inspection
Found the sound
was
Coming from A/C
Compressor clutch
bearing.
Brake
Checked the run out
juddering
Of both FRI, RH&
While
LR Rotor, it was
braking
found to be with the
Inspection. Checked
by replacing with
new rotor and the
problem-found to be
solved.
Coolant
Pressure tested the
Vehicle found the
level
coolant was leaking
getting low
through the
thermostat gasket
outlet pipe to HSG
Hand brakes On inspection the
Problem was due to
lock not
The low spring
Working
Tension of hand
brake lever Lock.
properly.
24
Suspected
root case
A/C
Correction
taken
Need to
compressor
replace
Magnetic
magnetic
clutch
clutch bearing-
Bearing
defective
Suspecting
the
juddering
was Due to
failure of
Disc brake
rotor.
Replace
LH&RI IC
brake rotor
Poor quality
of material.
Replaced
gasket or pipe
top the
coolant rested
Poor product
Replaced hand
quality.
brake lever.

5. TAVERA
Oil leakage
6. AVEO
Shock
leakage
7. TAVERA
Rear ac
poor
cooling
8. AVEO
Black
smoke
9. AVEO
STURT
leakage
10. TAVERA
Water
entering
into
The LH
head
Lamp
(visible
complaint)
Tail lamp
not
working
11. BEAT
12. TAVERA
Seat
rattling
While doing service

Pound oil leakage
From engine Fly
wheel side, after
Removing
transmisson assy
found oil leaking
through the crank oil
seal.
While doing service
Found oil leaking
Trough rear LH
Shock assembly.
On inspection AC
Gas leak from
Evaporator core pipe
At the location of
Heat sensing
Element of
expansion Valve.
Poor
material
quality.
Product
failure
The leak is
due to
Biome telic
Corrosion
on the Pipe
at the
Location of
heat sensing
element
On inspection Found Suspecting
oil entering into the
Internal
inlet manifold
failure of
through PCV Valve. PCV
While doing service Product
Found oil leaking
failure
FRTRH strut
On inspection found
Water entered into
The LH HEAD
LAMP ASSY there
is no External
impact or broken
noticed
Checked all airing
Hardness &routings
On diagnosing the
t relay coil was
found To be open
circuit
On inspection the
noise was due to the
Excessive play on
Seat rail of assembly
25
Suspecting
Due
To poor
Adhesive
/process
between
glass and
doom
Electrical
Complaint
failure
Product
failure
Replaced
crank
oil
As prediction
for
zonal.
Replace RR
LH
shock
assembly
Need to ac
edit
Evaporator
Replace PCV
valve
Replaced the
FRT
Strut
assembly
Need place
atlas assy
Replace tell
pa day
Replace stick
empty
CONCLUSION
From the training I am able to understand about most of the possible
complaints and works done in an automobile. The staffs and technicians are
so talented to complete the work in time. I think that the staffs and
technicians play a good roll in making GERMAN MOTORS PVT
LIMITED a world class service centre. I conclude that the interactions with
them help a lot in my future.
26

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IN PLANT TRAINING REPORT 2014-2015

I am deeply thanks to Mr. S.N.M. Basil (Head of department in

Dept. of Automobile Engg.

S.S.M. Polytechnic College

IN PLANT TRAINING REPORT 2014-2015

Dept. of Automobile Engg.

S.S.M. Polytechnic College

IN PLANT TRAINING REPORT 2014-2015

Dept. of Automobile Engg.

S.S.M. Polytechnic College

IN PLANT TRAINING REPORT 2014-2015

ABOUT THE COMPANY

Dept. of Automobile Engg.

S.S.M. Polytechnic College

IN PLANT TRAINING REPORT 2014-2015

Dept. of Automobile Engg.

S.S.M. Polytechnic College

IN PLANT TRAINING REPORT 2014-2015

S.S.M. Polytechnic College

IN PLANT TRAINING REPORT 2014-2015

29. CUSTOMER LAUNCH

Dept. of Automobile Engg.

S.S.M. Polytechnic College

IN PLANT TRAINING REPORT 2014-2015

The information's obtained from (he above three are entered in

S.S.M. Polytechnic College

IN PLANT TRAINING REPORT 2014-2015

S.S.M. Polytechnic College

IN PLANT TRAINING REPORT 2014-2015

Tavera 2.5 L Diesel

Dept. of Automobile Engg.

S.S.M. Polytechnic College

IN PLANT TRAINING REPORT 2014-2015

The scratched and dents are not in the job.card. There is a

2. The fuel level in the fuel is noted.

There are toolkit, music player cigar lighter, bonnet sot

4. Job card is signed by customer.

S.S.M. Polytechnic College

IN PLANT TRAINING REPORT 2014-2015

Check and correct wheel attachment, tire condition, inflation

Dept. of Automobile Engg.

S.S.M. Polytechnic College

IN PLANT TRAINING REPORT 2014-2015

To get the opinion of customer service adviser contracted with he and he

S.S.M. Polytechnic College

IN PLANT TRAINING REPORT 2014-2015

S.S.M. Polytechnic College

IN PLANT TRAINING REPORT 2014-2015

Customers pay the bill and receive the gale pass.

S.S.M. Polytechnic College

IN PLANT TRAINING REPORT 2014-2015

S.S.M. Polytechnic College

IN PLANT TRAINING REPORT 2014-2015

S.S.M. Polytechnic College

IN PLANT TRAINING REPORT 2014-2015

PRE ORDERING VEHICLE DETAILS

1 year/ 10000 km service.

Sound producing from left rear view mirror.

Dept. of Automobile Engg.

S.S.M. Polytechnic College

IN PLANT TRAINING REPORT 2014-2015

Check the front wheel disc brakes.

S.S.M. Polytechnic College

IN PLANT TRAINING REPORT 2014-2015