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1. GOVERNMENT POLYTECHNIC , AHMEDNAGAR Industrial Training Presentation On TATA Motors Industrial Training (315004) Under Guidance of: Prof. S. V. BANDGAR

2. INTRODUCTION ⯈ Introduction ⯈ Training Organization: Tata Motors Showroom & Workshop, Ahmednagar ⯈ Training Duration: 12 Weeks (From 9 June 2025 to 25 Aug 2025) ⯈ Guided By: Prof. S. V. Bandgar ⯈ Participants: 13 Students (Diploma – Production Engineering) ⯈ Objective: To gain practical exposure to automobile servicing, maintenance, and diagnostic procedures.

3. GROUP MEMBERS ⯈ 1. Borkar Parth Paresh (23610230820) ⯈ 2. Kawat Om Pravin (23610230842) ⯈ 3. Aher Prathmesh Shivaji (23610230812) ⯈ 4. Timkare Adinath Bahiru (23610230873) ⯈ 5. Kharad Sanket Parmeshwar (23610230843) ⯈ 6. Lakudzode Yashvant Vilasrao (23610230849) ⯈ 8. Karale Siddharth Ranganath (23610230838) ⯈ 9. Kurapati Shreyash Vinayak (23610230847) ⯈ 10. Jahagirdar Mayur Rajendra (23610230835) ⯈ 11. Athare Santosh MhatarDev (24610230874) ⯈ 12. Manware Shubham Dilip (24610230879) ⯈ 7. Mehetre Kartik Vikram (23610230853) ⯈ 13. Rawade Rushikesh Vijay (24610230882 )

4. OBJECTIVES OF INDUSTRIAL TRAINING ⯈ 1. To gain practical knowledge of car servicing and maintenance. ⯈ 2. To understand the use of diagnostic tools and workshop equipment. ⯈ 3. To learn the standard servicing procedures followed in Tata Motors. ⯈ 4. To develop hands- on skills in tasks like oil change, wheel alignment, battery testing, etc. ⯈ 5. To understand safety practices while working in automobile workshops. ⯈ 6. To bridge the gap between theoretical knowledge and industrial practices. ⯈ 7. To improve problem- solving ability and teamwork during real workshop conditions. ⯈ 8. To enhance communication and professional skills while working with experts.

5. INTRODUCTION OF ORGANISATION ⯈ 1. Established in February 2018 by Mr. Nikhil Karachiwala . ⯈ 2. One of the leading automobile dealerships in Ahmednagar . ⯈ 3. Offers sales, servicing, and spare parts under one roof . ⯈ 4. Provides complete customer support from booking to after-sales . ⯈ 5. Information on vehicle models, features, prices & finance options. ⯈ 6. Vehicle display & test drive facility available . ⯈ 7. Assistance with insurance, registration, and documentation. ⯈ 8. Focus on customer satisfaction and reliable service.

6. TATA CAR - SCHEDULED SERVICING DETAILS 1st Service (1,500 - 2,000 km / 2 months) Free service (labour free, only consumables charged if needed) General vehicle inspection Engine oil level & top-up check Coolant, brake fluid, washer fluid check Tyre pressure & wheel inspection Battery check Lights, horn & wiper operation check Cleaning & washing of vehicle

7. 2nd Service (5,000 - 7,500 km / 6 months) Free service (labour free, consumables extra) Engine oil replacement (if required depends on model) Oil filter check/replacement Brake system inspection & cleaning Clutch, steering & suspension check Air filter cleaning Wheel balancing & alignment check

8. 3rd Service (10,000 - 12,000 km / 12 months) Free service (labour free, consumables extra) Complete engine oil change Oil filter replacement Fuel filter inspection Brake fluid check/top- up Air filter replacement/cleaning Cabin (AC) filter cleaning/replacement Wheel rotation, alignment & balancing Full underbody & chassis inspection Diagnostic scanning & software updates Car wash & polishing

9. Diagnostic Instruments OBD (On- Board Diagnostics) Scanner Battery Tester & Charger Multi- Meter (for electrical systems) MAJOR EQUIPMENT Wheel Alignment Wheel balancing

10. OBD- II Scanner (On- Board Diagnostics Version 2) Purpose: Standardized tool to read vehicle computer data. Functions: Reads & clears Diagnostic Trouble Codes (DTCs) Monitors live data: engine RPM, coolant temp, O2 sensor, fuel trims. Detects emission- related faults.

11. Battery Tester & Charger Purpose: Tests condition and charges vehicle batteries Functions: Tests battery voltage, capacity & Cold Cranking Amps (CCA). Diagnoses alternator & starter motor performance. Smart charging (prevents overcharging, maintains battery health)

12. Multimeter (Digital Multimeter - DMM) Purpose: General electrical diagnostic tool. Functions: Measures DC/AC voltage (e.g., battery 12V, alternator 14V). Current measurement (starter, alternator). Resistance testing (sensors, wiring, ignition coils). Continuity test (fuses, wiring harness). Advanced models measure frequency & cycle.

13. WORKSHOP MAJOR EQUIPMENT :- Wheel Alignment Machine Used to check and adjust wheel angles (camber, caster, toe). Ensures proper steering & handling. Improves tyre life and fuel efficiency. Uses laser / computer sensors for accuracy.

14. Wheel Balancing Machine Used to detect imbalance in tyres & wheels. Ensures smooth driving and reduces vibration. Prevents uneven tyre wear. Balancing weights are added for correction. Essential after tyre replacement or puncture repair

15. THANK YOU Tata Punch Tata Nexon Tata Altroz Tata Harrier EV

16. HYDRAULIC CAR LIFTER A hydraulic car lifter is a device used to lift cars off the ground using hydraulic pressure.

17. CAR SERVICING PROCESS 1. Spark plugs - How It Works The primary function of a spark plug is to ignite the compressed air- fuel mixture within the engine's cylinders. Here's a simplified breakdown of the process: High Voltage: The ignition coil or magneto generates an extremely high voltage, often between 12,000 and 45,000 volts.

18. CAR SERVICING PROCESS Current Flow: This electrical current is sent down the heavily insulated wire to the spark plug. Spark Gap: The spark plug has a central electrode and a side or ground electrode, separated by a small gap.

19. CAR SERVICING PROCESS 2. Oil change - Purpose of an Oil Change Engine oil is crucial for the proper functioning and longevity of a car's engine. Its main roles are: Lubrication: It creates a protective layer between the many moving parts of the engine, preventing metal- on-metal friction that can cause wear and tear.

20. CAR SERVICING PROCESS Cooling: It absorbs heat from the engine's combustion process, helping to regulate its temperature and prevent overheating. Cleaning: The oil picks up dirt, debris, metal particles, and other contaminants as it circulates through the engine. The oil filter then traps these impurities. Protection: It contains additives that prevent corrosion and rust on engine components.

21. CAR SERVICING PROCESS 3. Brake inspection - Brake Pads – Replace if less than 3mm thick or if squealing/grinding. Rotors – Check for deep grooves or warping. Brake Fluid – Should be clear; flush if dark or over 2 years old. Hoses/Lines – Look for cracks or leaks. Test Drive – Car should stop smoothly without pulling or vibration .

22. CAR SERVICING PROCESS 4. Check the tyre pressure - Find correct PSI – On driver’s door sticker or owner’s manual. Use a pressure gauge – Check when tires are cold. Adjust if needed – Add or release air to match recommended PSI. Don’t forget the spare tire!

23. CAR SERVICING PROCESS 5.Examining wheel alignment Check Tire Wear – Uneven wear on inner/outer edges = misalignment. Drive Test – On a flat road, does the car pull left/right? Steering Wheel – Is it centered when driving straight?

24. CAR SERVICING PROCESS 6.Cabin filter replacement Steps to Replace: Open glove box and remove limiting arm (if needed). Release the tabs or cover holding the filter. Pull out old filter – note airflow direction! Insert new filter – match airflow arrows. Reassemble glove box or cover.

25. CAR SERVICING PROCESS 7.Air Filter Steps to Replace: Open the hood. Locate the air filter box (usually a black plastic box with clips or screws). Open the box and remove the old filter. Insert new filter – match orientation. Close the box and secure clips/screws.

26. CAR SERVICING PROCESS 8.Check wipers What to Look For: Streaking or Smearing – Leaves lines or haze? Time to replace. Chattering or Skipping – Wipers bounce or make noise? Could be wear or a bent arm. Cracks or Tears – Visibly damaged rubber = replace immediately. Poor Contact – Parts of the windshield stay dry? Blades may not be pressing evenly. .

27. CAR SERVICING PROCESS When to Replace: Every 6–12 months or sooner in harsh weather conditions.

28. CAR SERVICING PROCESS ⯈ 9.Check coolant levels ⯈ How to Check Coolant Levels ⯈ Wait for the engine to cool down! (Never open the coolant reservoir or radiator cap when hot— risk of burns.) ⯈ Locate the coolant reservoir ⯈ Usually a translucent plastic tank near the radiator.

29. CAR SERVICING PROCESS Check coolant levels Check the level Look for “MIN” and “MAX” marks on the side of the reservoir. Coolant should be between these marks. Add coolant if low Use the type specified in your owner’s manual. Don’t overfill! Close the cap tightly after checking or adding coolant

30. CAR SERVICING PROCESS 10.battery replacement car Steps to Replace a Car Battery PreparationTurn off the car completely and remove the key.Apply the parking brake.Wear safety gloves and safety glasses. Locate the BatteryOpen the bonnet (hood). In some cars, the battery may be in the trunk.Identify the terminals: + (positive, red) and – (negative, black).

31. STEPS TO REPLACE A CAR BATTERY Disconnect the Old BatteryAlways disconnect the negative (–) terminal first to avoid short circuit.Then disconnect the positive (+) terminal.Loosen the battery clamp/holder with a spanner if needed Remove the Old BatteryLift the battery carefully (it is heavy).Clean the battery tray (remove dust, dirt, and corrosion ).

32. STEPS TO REPLACE A CAR BATTERY Install the New BatteryPlace the new battery on the tray.Secure it tightly with the clamp/holder.Connect the positive (+) terminal first.Then connect the negative (–) terminal. Final CheckMake sure the terminals are tight.Apply a little grease/vaseline on terminals (to prevent corrosion).Start the car to check if everything works.

33. CAR SERVICING PROCESS New oil and filter Oil & Filter Change Steps Warm up the engine for a few minutes (helps oil drain faster), then turn off. Lift the car safely using a jack and stands or ramps. Locate the oil drain plug underneath the engine. Place a drain pan under the plug, then unscrew the drain plug to drain old oil.

34. CAR SERVICING PROCESS Remove the old oil filter (use an oil filter wrench if needed). Lubricate the new oil filter’s rubber seal with fresh oil. Install the new oil filter by hand, snug but not over- tightened. Replace and tighten the drain plug securely. Add the correct type and amount of new oil through the oil filler cap on top of the engine.

35. CAR SERVICING PROCESS Add the correct type and amount of new oil through the oil filler cap on top of the engine. Check oil level with the dipstick, add more if needed. Start the engine , check for leaks, and re- check oil level. Dispose of old oil and filter properly at a recycling center.

36. HANDS- ON EXPERIENCE DURING THE TRAINING, WE PRACTICALLY PERFORMED AND OBSERVED: ⯈ 1. Engine Oil & Filter Change – Removing old oil, replacing filter, adding new oil. ⯈ 2. Battery Testing & Replacement – Checking battery voltage, capacity and installing new battery. ⯈ 3. Tyre Pressure Check & Adjustment – Using digital pressure gauge, filling air to correct PSI. ⯈ 4. Wheel Alignment & Balancing – Observed and assisted in adjusting camber, caster, toe angles. ⯈ 6. Coolant & Fluid Levels Check – Refilling coolant, brake fluid, washer fluid. ⯈ 7. OBD- II Scanner Usage – Connecting scanner, reading error codes, basic troubleshooting. ⯈ 8. Air & Cabin Filter Replacement – Opening housing, replacing filters, reassembling. ⯈ 9. Wiper Blade Check & Replacement – Inspecting worn blades and fitting new ones. ⯈ 10. Car Washing & Cleaning – Exterior wash, polishing and interior cleaning.

37. SKILL DEVELOPMENT ⯈ Technical Skills ⯈ Car servicing procedures (oil change, filter replacement, wheel alignment & balancing) ⯈ Use of diagnostic tools (OBD- II scanner, battery tester, multimeter) ⯈ Hands- on practice with workshop equipment (hydraulic lifter, wheel alignment machine) ⯈ Preventive maintenance techniques (tyre pressure, brake inspection, coolant check) ⯈ Troubleshooting and minor fault detection in vehicles ⯈ Soft / Professional Skills ⯈ Teamwork & coordination during servicing tasks ⯈ Communication with mentors and co- trainees ⯈ Time management in workshop environment ⯈ Safety awareness and discipline while handling tools & machines ⯈ Problem- solving & decision- making in real workshop conditions

38. ADVANCED DRIVER ASSISTANCE SYSTEM (ADAS) ⯈ ADAS refers to sensors, cameras, and radars integrated into vehicles to make driving safer and easier. ⯈ Tata Motors’ latest models (Harrier EV, Safari facelift) come with ADAS features. Key Features: ⯈ 1. Adaptive Cruise Control – Adjusts vehicle speed according to the car ahead. ⯈ 2. Lane Departure Warning & Lane Keep Assist – Alerts the driver if the car drifts out of lane and provides steering correction. ⯈ 3. Automatic Emergency Braking (AEB) – Applies brakes automatically if an obstacle or vehicle appears suddenly. ⯈ 4. Traffic Sign Recognition – Reads road signboards using cameras and displays them to the driver. ⯈ 5. Blind Spot Detection – Warns the driver if there is a vehicle in the blind spot area. ⯈ 6. 360° Camera & Parking Assist – Provides a 360° view around the car to support safe parking.

39. Benefits: ⯈ Helps prevent accidents. ⯈ Reduces driver fatigue on long drives. ⯈ Improves vehicle safety ratings (useful for NCAP tests). ⯈ Provides a smart and modern driving experience. In Tata Motors : ⯈ ADAS features are available in Tata Harrier and Safari (2023 onwards). ⯈ More advanced ADAS features will be included in upcoming EV models.

40. Industrial Uses (after processing) ⯈ As a fuel in cement factories, brick kilns, and furnaces (after treatment). ⯈ In boilers or large industrial burners. ⯈ As a raw material in manufacturing lubricants again. Local Uses (NOT directly recommended) ⯈ Some people use waste oil for: ⯈ Rust prevention on metal parts or farm tools. ⯈ Wood treatment (like fence posts). ⯈ Lubrication for heavy chains, hinges, etc. ⯈ But these practices can be toxic and polluting if oil is not properly treated.

41. Importance of Warranty & Service History Warranty Coverage ⯈ Free repairs/replacements within warranty period ⯈ Builds customer trust in company Service History ⯈ Record of all past services & repairs ⯈ Helps in accurate fault diagnosis ⯈ Increases resale value of vehicle

42. CONCLUSION ⯈ The industrial training at Tata Motors provided us with valuable practical exposure to real workshop conditions. ⯈ We learned about modern diagnostic tools, servicing procedures, and safety practices in automobile workshops. ⯈ This training helped us to bridge the gap between theory and practice and improved our technical as well as professional skills. ⯈ It also developed our teamwork, communication, and problem- solving abilities. ⯈ Overall, the experience has prepared us for future challenges in the automobile industry and enhanced our confidence to work as skilled engineers.

43. THANK YOU