St workshop visit auto 2048 - final versionf ooter

Page 1

Page 1

AIM: The basic motive for visit to GSRTC workshop was to clear the idea of the production of buses, used for transportation.

INTRODUCTION: GSRTC, also known as Gujarat State Road Transport, is the

passenger bus transport service provided by the Indian state, Gujarat.

For manufacturing of this transportation buses a workshop has been introduced in Naroda since, its existence.

GSRTC was established on 1st May 1960. It started with 7 divisions, 76 depots and 7 divisional workshop

among which the workshop in Naroda, Ahmedabad is considered to be the main branch.

The GSRTC workshop at Naroda is considered to be the Asia’s largest workshop as per its manufacturing of business is concerned.

Page 1

DEPARTMENTS:

1. Air compressor department

2. Cylinder head department

3. Engine washing and anti-rust treatment department

4. Crankshaft grinding department

5. Rotary pump testing department

6. Injector testing department

7. Engine testing center

8. Tyre molding department

9. Boiler room

10. Body fitting department

11. Welding department

12. Coach section

13. Bus body repair department

14. Painting department

15. Engine parts storage department

16. Oil storage department

17. Office work

18. Training centre

Page 1

1. AIR COMPRESSOR DEPARTMENT:

This department consists of air compressor.

The supply of air to entire workshop where it is needed for any work is done through this department.

Its main application is to supply air to tyre, machine and engine shop.

The following photographs explains in brief about the department:

Page 1

2. CYLINDER HEAD DEPARTMENT:

This department’s main application is to fit the cylinder head of

engine.

It even concentrates on proper dimensioning of inlet and exhaust

valves by grinding and polishing it by bare hands.

After proper finishing and fitting of valves the cylinder head is

mounted.

Page 1

The following department gives an idea of working of this

department:

3. ENGINE WASHING AND ANTI- RUST DEPARTMENT:

After dismantling all parts of engine it should be washed properly.

It may consist of dust particles stuck in the corners.

First the engine is washed with diesel and all dust particles are

removed with a scraper.

After this process engine is washed with water and the water is

allowed to dry.

Page 1

And after the entire fitting of engine components is done the

engine is lubricated and anti-rust treatment is given to the engine.

The following photograph show the process done by this

department:

4. CRANKSHAFT GRINDING DEPARTMENT:

This department’s main purpose is to grind the crankshaft with

boring machine.

Grinding of crankshaft is required due to improper dimensions, due

which it cannot properly fit into the crankcase.

G.S.R.T.C has proper fixed dimensions in it manual for every part of

engine, according to which every parts are made efficient.

Page 1

Following photograph shows the working of this department:

5. ROTARY PUMP WORKING DEPARTMENT:

This department assembles the rotary pump with its appropriate

parts and method.

After completion of this process it is tested according to method.

G.S.R.T.C. has a machine for testing of this pump.

It shows the reading of accuracy of this pump.

Page 1

It even shows how much the pump pressurizes the diesel for

injecting diesel through injector.

The reading is shown on a digital display.

The following photographs show the machines and rotary pump:

6. INJECTOR TESTING DEPARTMENT:

The fuel injectors of engine are sent to this department for their

testing.

It contains an equipment for testing which has a reservoir in which

diesel is stored.

After cleaning the injector it is placed on the injector holder.

Page 1

And as the pump is compressed, diesel reaches up to injector and it

is injected through holes in the injector.

As the diesel sprays from injector’s holes the accuracy of that

injector is decided.

Following photograph shows the work of this department:

7. ENGINE TESTING CENTRE:

This department checks the proper working of engine after it is

completely ready to work.

There about 8 to 10 machines in this department on which working

of engine is tested.

Page 1

Some connections are needed to be made on engine and when

power is supplied the engine runs.

The following photograph indicates the workingofthisdepartment:

8. TYRE MOLDING DEPARTMENT:

The old and worn out tyres whose grip/ pattern have been damaged are remolded by this department.

This department has large machines which contain a space for the tyre to be fixed and remolded.

Page 1

A dye containing the pattern to be made on the tyre is placed in the machine along with the tyre.

After machine is closed with its cover and power is supplied to it, it produces immense heat due to which the tyre is heated and the pattern on the dye is formed on the tyre as it dissolves at high temperature.

The following photograph shows the working process of this department:

9. BOILER ROOM:

This is a room where boiler is kept.

It consists of heating equipments and the heat produced is

supplied into the tyre molding department.

Page 1

The tyre molding department uses this heat to heathen up the tyre

for making its surface/ grip perfectly as per the decided pattern.

Boiler even generates power for various departments which

require heating processes.

The following photograph is of a boiler:

10. BODY FITTING DEPARTMENT:

This department consists of assembling of the frame and body of

the bus.

Page 1

The total assembling of frame and body is with welding the joints

and applying nut and bolts on required spaces.

An entire different team of expertise is allotted for this work who

join the body and frame;

The following photographs show the working of this department:

11. WELDING DEPARTMENT:

This department focuses on welding of the frame and body of

buses.

Page 1

Each and every joint in the bus are welded by the experts so no

joints separate or breakdown.

Mig welding is preferred for this process.

The following photographs show the work done by the

department:

12. COACH SECTION:

This is a department which completely concentrates on the interior

of the bus.

Page 1

The fitting of seats and luggage carriers are done in this

department.

They even put the rivets and screws which fit with the panels in

interior and holds it in its position so the seats can be fitted

according to them.

These rivets are fitted by using hammer.

Following photograph consists of work of this department and

even rivets are displayed in it.

13. BUS BODY REPAIR DEPARTMENT:

Page 1

This department has to deal with the buses which have met with

an accident.

These buses are repaired as per their damage; it may be major or

minor.

The dents created in the bus body are removed by the washer

welder method.

If any kinds of glass of bus or head lights are broken then they are

also changed.

The working of department is as shown in the figure:

14. PAINTING DEPARTMENT:

Page 1

The main motive of this department is painting the body of bus.

For a better result of painting, before starting the work primer is

applied on the bus body.

Primer helps from corrosion prevention and even smoothen the

surface to be painted.

After completing the process the technicians apply paint with help

of spray gun.

Following photographs show the working process of this

department:

15. ENGINE PARTS STORAGE DEPARTMENT:

This department is specially used for storing the parts required for

engine tuning.

Page 1

It consists of different sections at different at various places for

crankshaft, cam shaft, connecting rod, engines, oil sump, etc.

Proper records of storage as per availability are maintained by

G.S.R.T.C.

The following photographs show the storage department of

various engine components.

16. OIL STORAGE DEPARTMENT:

The waste oil achieved from engine is stored in oil tankers.

Page 1

The tankers consist of burnt oil which is useless.

G.S.R.T.C. has a separate department for this work.

The following photographs show the oil storage department:

17. OFFICE WORK:

The office area is entirely located away from the workshop.

Page 1

This department has to maintain the records of workshop and

delivery of ready buses.

It even manages the account of the expenditures of the workshop

18. TRAINING CENTRE:

Page 1

This department is for training the learners with the entire process

of working of the G.S.R.T.C. workshop.

Prototypes of some engine parts and buses components are kept in

this department.

The trainees are trained by help of these prototypes

The following are some photographs of the training centre:

Page 1

(FRAME OF ROOF OF BUS)

(MIG WELDING)

Page 1

(OPEN FRONT VIEW OF BUS)

(GEAR BOX OF BUS) (DIFFERENTIAL)

Page 1

(ELECTRIC CIRCUITS ON DASH BOARD)

(RADIATOR) (FUEL TANK)

Page 1

(BUS BODY FRAME)

(BUS BODY FITTING) (ENGINES)

Page 1

(CAM SHAFTS) (ENGINE TESTING CENTRE)

(CYLINDER BLOCK BEING LIFTED)

Page 1

Page 1

(G.S.R.T.C. WORKSHOP LAYOUT) (KEY FEATURES SHOWN BELOW)

KEY FOR WORKSHOP LAYOUT:

1. OFFICE

2. DIESEL

3. WASHING

4. CHANNEL

5. SHEET METAL

6. ROOF

7. SCRAP WHEEL AND DISK

8. RIM

9. CRANK SHAFT

10. GLASS

11. ENGINE

12. GEAR

13. ELECTRIC SUPPLY

14.

15.

16. GLASS

17. STORAGE CHASSIS

18. NEW BUS PARKING

19. PAINT SHOP

Page 1

20. TRAINING CENTRE

21. NEW TRAINING SHOP

22. GARDEN

23. CYLINDER HEAD

24. ENGINE STORAGE

25. ENGINE TUNING DEPARTMENT

26. AIR COMPRESSOR ROOM

27.

28. ENGINE TESTING CENTRE

29. CYLINDER BLOCK

30. RE- POWER

31. ENGINE DISMANTELING

32. INJECTOR TESTING

33. CRANK AND CAM SHAFT

34. PISTON AND CONNECTING ROD

35. MACHINES AND EQUIPMENTS

36. TYRE STORAGE

37. TYRE MOLDING

38. HEATING CHAMBER

39. BOILER ROOM

40. ASSEMBLING OF ROOF

Page 1

41. BUS BODY ASSEMBLING

42. HALF BODY

43. FULL BODY

44.

45.

46.

47.

48. ARC WELDING

49. ARC WELDING PARTS STORAGE

50. OFFICE

51.

52.

53.

54.

55.

56. MIG WELDING

57.

58. SHEETS

Page 1