2017

INDUS MOTOR
CORPORATION

INTERNSHIP REPORT
MUHAMMAD YASIR ABBAS
[2017]

UNIVERSITY OF SARGODHA | [BS MECHANICAL ENGINEERING TECNOLOGY]

0
1
2
 UNIVERSITY COLLEGE OF ENGINEERING TECHNOLOGY
DEPARTMENT OF TECHNICAL EDUCATION

Supervised industrial training

It is submitted that I have completed my one month internship at indus motor company Karachi located
near bin qasim.

Learning objective
Bachelor of Engineering Internship Objectives fall under two major categories, namely, program
objectives defined by the College of Engineering as general conditions which all internships must meet,
and personal objectives defined by the intern for an internship. Personal objectives should be consistent
with program objectives. It is intended to establish that this experience meets the objectives of the
Bachelor of Engineering Technology internship. Following an examination of the internship objectives,
IMC organizational structure, approach, and management philosophy are overviewed. The major project
undertaken during the internship is introduced and its technological basis briefly discussed. The author's
specific work assignments and contributions in Maintenance Department, all in project control
engineering, are then presented. The work assignments include process instrument diagram of the Utility
department including Chiller, Cooling Towers, Compressors, Hot Water generation, Fire Fighting
System in Paint shop on a segment of this project assignment the internship was involved with; and
manpower utilization and productivity studies. Finally, aspects of project management to which the
intern was exposed through association and observation during the internship are discussed. It is thus
demonstrated that both the program and personal objectives are met.

Signature:
Student name; Muhammad yasir abbas
Registration No: BSMTF13E028

Signature:
Supervisor Name:
Dated:

Counted signature:
Head of department:

3
 Acknowledgement:

All the praises for the Almighty, Allah who bestowed us with the ability and potential to complete this
internship. I also pay my gratitude to the Almighty for enabling me to complete this Internship report
within due course of time.

The internship opportunity I had with INDUS MOTOR COMPANY Ltd was a great chance for
learning and professional development. Therefore, I consider myself as a very lucky individual as I was
provided with an opportunity to be a part of it. I am also grateful for having a chance to meet so many
wonderful people and professionals who led me though this internship period.

Bearing in mind previous I am using this opportunity to express my deepest gratitude and special thanks
to the Mr. JAMSHED KHAN, Mr. SHOAIB and MR. HANEEF of INDUS MOTOR COMPANY
Ltd who despite being extraordinarily busy with their duties, took time out to hear, guide and keep me
on the correct path and allowing me to carry out my internship at their esteemed organization.
I express my deepest thanks to Mr. Islam ud din (GM Administration) for providing me requisite
information and arranged all facilities to make life easier. I choose this moment to acknowledge his
contribution gratefully.

I perceive as this opportunity as a big milestone in my career development. I will strive to use gained
skills and knowledge in the best possible way, and I will continue to work on their improvement, to
attain desired career objectives. Hope to continue cooperation with all of you in the future.

4
 SUMMERY

This report documents my internship experience with INDUS MOTOR COMPANY Ltd., during the
period March 9, 2017 through April 8, 2017. It is intended to establish that this experience meets the
objectives of the Bachelor of Engineering Technology internship. Following an examination of the
internship objectives, IMC organizational structure, approach, and management philosophy are
overviewed. The major project undertaken during the internship is introduced and its technological basis
briefly discussed. The author's specific work assignments and contributions in Maintenance Department,
all in project control engineering, are then presented. The work assignments include process instrument
diagram of the Utility department including Chiller, Cooling Towers, Compressors, Hot Water
generation, Fire Fighting System in Paint shop on a segment of this project assignment the internship
was involved with; and manpower utilization and productivity studies. Finally, aspects of project
management to which the intern was exposed through association and observation during the internship
are discussed. It is thus demonstrated that both the program and personal objectives are met.

5
Chapter #01

1.1

Introduction--------------------------------------------------------------------------------------------------------- 01

1.2 Internship objectives-------------------------------------------------01

1.3 Organizational structure and operations-------------------------------02

1.4Vision----------------------------------------------------------------03

1.5 Mission--------------------------------------------------------------04

1.6 Slogan---------------------------------------------------------------04

1.7 Safety Policy---------------------------------------------------------04

1.8Pakistan Automobile Market------------------------------------------05

1.9Organization chart----------------------------------------------------05

chapter #02

2.1 Work and contribution-----------------------------------------------06

2.2 Basic Knowledge about Piping and Instrumentation Diagram ----------06

2.3 Symbols of P & ID----------------------------------------------------07

2.4 Work project and contribution-----------------------08

chapter #03

Suggestions & conclusion-------------------------------------------------------------------12

REFERNCE-------------------------------------------------------------------------------14 6
7
Figures title pages
1 structure 01

2 organization chart 05

3 unity is strength 05

4 PID symbols 08

5 PID of Fire fighting system 08

6 PID of cooling tower 09

7 PID of compressor 10

8 PID of Hot water generator 11

8
Chapter #01

1.1 Introduction
PURPOSE
This report relates the author's one month internship experience with
Indus Motor Company, Ltd. to establish that the objectives of the
internship have been met.

POSITION
The internship was served in the Maintenance Utility Department, with
the formal designation of Associate Engineer, under the direct
supervision of Engr Mr. Shoaib as Control Team Manager. Appendix A
contains brief descriptions of process and instrument diagram. Mr.
Jamshed Khan, Manager of Maintenance., was the intern supervisor
through much of the one-month life of the the internship. He was
subsequently assigned projects in my internship.

1.2 Internship objectives

Bachelor of Engineering Internship Objectives fall under two major
categories, namely, program objectives defined by the College of
Engineering as general conditions which all internships must meet, and
personal objectives defined by the intern for an internship. Personal
objectives should be consistent with program objectives.
[2017]

1
Program Objectives

Identifies two objectives for Bachelor of Engineering internships, namely:

To enable the student to demonstrate his ability to apply his

knowledge and technical training by making an identifiable
contribution in an area of practical concern to the organization
or industry in which the internship is served, and

To enable the student to function in a non-academic environment

in a position where he will become aware of the
organizational approach to problems in addition to traditional
engineering design or analysis. These may include, but are
not limited to, problems of management, labor relations,
public relations, environmental protection

Personal Objectives

Program objectives above emphasize contribution and broad exposure, respectively. Accordingly, the
following final objectives were defined to reflect the general guidelines.
Become familiar with the Process Industry Technology.
Take responsibility for cost engineering on one aspect of a
project.
Develop a manual of major cost reports.
Learn the essence of scheduling engineering.
Observe management practices at the project level.

1.3 Organizational structure and operations

Corporate Level
Indus Motor Company Limited (IMC) was incorporated in 1989 because of a joint venture agreement
among some companies of House of Habib of Pakistan, Toyota Motor Corporation and Toyota Tsusho
Corporation of Japan. The Company manufactures and markets Toyota brand vehicles in Pakistan. The
main product offerings include several variants of the flagship Corolla in the passenger cars category,
Hilux in the light commercial vehicles segment and the Fortuner Sports Utility Vehicle. The
manufacturing facility and offices are located at a 105-acre site in Port Qassim, Karachi, while the
product is delivered to end customers nationwide through a strong network of 43 independent 3S
Dealerships spread across the country. In its 25 years history since inception, IMC has sold more than
600,000 CBU/CKD vehicles and has demonstrated impressive growth, in terms of volumetric increase
from a modest beginning of 20 vehicles per day production in 1993 to 240 units daily at present through
the development of human talent embracing the Toyota Way of quality and lean manufacturing.
Over the years, IMC has made large scale investments in enhancing its own capacity and in meeting
customer requirements for new products. Today, Corolla is the largest selling automotive brand model in
Pakistan and it also has the distinction of being # 1 in Toyotas Asian market. The Company invests
heavily in training its 2,300 plus workforce of team members & management employees and creating a
culture of high performing empowered teams working seamlessly across processes in search of quality
and continuous improvement. The core values of the Company encourage employees to pursue high
standards of business ethics and safety; communicating candidly by giving bad news first and to respect
people. The bi-annual TMC morale surveys show that employees rate IMC high on work environment
and level of job satisfaction.

The Company has played a major role in the development of the entire value chain of the local auto
industry and is proud to have contributed in poverty alleviation at the grass root level by nurturing
localization that, in turn, has directly created thousands of job opportunities and transferred technology
to over 60 vendors supplying parts. IMC is also a major tax payer and significant contributor to the GOP
exchequer.

Figure 1

1.4 Vision

To be the most respected and successful enterprise, delight customers with a wide range of products
and solutions in the automobile industry with the best people and best technology.

The most respected.

 The most successful.
Delighting customers.
Wide range of products.
The best people.
The best technology.

1.5 Mission

Mission of Toyota is to provide safe & sound journey. Toyota is developing various new technologies
from the perspective of energy saving and diversifying energy sources. Environment has been first and
most important issue in priorities of Toyota and working toward c

1.6 Slogan

ACT#1: Actions, Commitment and Teamwork to become No.1.

reading a prosperous society and clean world.

1.7 Safety Policy

Indus Motor Company Ltd is committed to provide a safe workplace to all its employees and to ensure,
so far as is reasonably practicable, the safety of its contractors, suppliers, vendors and all members of the
public that may be affected by its business operations.

The company will strive to prevent all accidents and injuries through the active participation of every
employee as well as the commitment to put in continuous efforts to identify, eliminate or manage safety
risks associated with its actions.

Our Philosophy:

Safety is everyones responsibility,

All accidents are preventable,
All employees are empowered to stop any unsafe job or act, and
No task is so important that risk of injury to people is justified.

At Indus Motor Company Ltd.,

SAFETY WILL ALWAYS TAKE PRECEDENCE OVER PRODUCTION

1.8 Pakistan Automobile Market

The demand for automobiles remained robust throughout the first quarter stemming from the favorable
macroeconomic indicators and positive consumer sentiment in the country. The prevailing environment
of low interest rates, sustainable inflows of record inward remittances, lower fuel costs and stability in
the selling prices of cars contributed towards upbeat demand in the market place. This trend augurs well
for automotive industry performance for the new fiscal
year 2016-17.
Industry wide sales of the locally manufactured PC/LCVs at 47,645 units represent an impressive
volume compared to any other first quarter sales, except for the last year, which was heavily influenced
by a onetime boost from the Apna Roger Scheme of the Punjab Government which resulted in 1Q
quarter sales of 54,812 units. The recent launch of the new model Honda Civic has added to the vibrancy
in the market.

1.9 Organization chart

Figure 2
Unity the strength

figure 3

Chapter #02

2.1 Work and contribution

The project assign to me during my internship was process and instrument diagram of different sections
in maintenance utility section I have worked on cooling towers, chiller, oil free, oil injected
compressors, hot water generation and Firefighting system of the paint shop. First have a look at process
and instrument what is it what are symbols related to it and how they work in my drawing

2.2 Basic Knowledge about Piping and Instrumentation

Diagram
Piping and instrumentation diagram, also called P&ID, illustrates the piping processes and interactions
with other installed equipment and instrumentation. P&IDs are often used in the process industry to
show the process flow and other installed equipment and instrument.
Piping and instrumentation diagram plays a crucial role in the design and engineering of process plants
and piping systems, by showing the interaction of process used to control the process. P&ID is a
schematic illustration of functional relationship of piping, instrumentation and system equipment
components
P&ID is a very common term used in the world of process industries. A process engineer in a
manufacturing plant need to create new and/or modify the already existing P&ID to the as-is plant
modifications. All the Chemical Engineering and related Engineering students have also learned about it
or at least heard. A P&ID is a detailed graphical representation of a process including the hardware and
software (e.g., piping, equipment, instrumentation) necessary to design,
construct and operate the facility. As defined in the PIC001: Piping and [Type the sidebar title]
Instrumentation Diagram Documentation Criteria by Process Industry
[Type the sidebar

content. A sidebar is a
Practice (PIP) - a consortium of process industry owners and
standalone
engineering construction contractors who serve the industry.
supplement to the
A P&ID Should Include:
Instrumentation and designations; main document. It is
Mechanical equipment with names and numbers;
often aligned on the
All valves and their identifications;
Process piping, sizes and identification; left or right of the
Miscellaneous - vents, drains, special fittings, sampling lines,
reducers, increasers and swaggers; page, or located at the
Permanent start-up and flush lines;
Flow directions; top or bottom. Use the
Interconnections references;
Drawing Tools tab to
Control inputs and outputs, interlocks;
Seismic category; change the formatting
Interfaces for class changes;
Quality level; of the sidebar text
Annunciation inputs;
Computer control system input; box.]
Vendor and contractor interfaces;
Identification of components and subsystems delivered by
others;
Intended physical sequence of the equipment;
Equipment rating or capacity.

A P&ID Should NOT Include:

Instrument root valves;
Control relays;
Manual switches;
Primary instrument tubing and valves;
Pressure temperature and flow data;
Elbow, tees and similar standard fittings;
Extensive explanatory notes

2.3 Symbols of P & ID

Figure 4
Some more symbols of vessels and instruments

2.4 Work project and contribution

After the orientation of maintenance department from engr. Musheb I have assigned different projects in
maintenance utility department head engr. Mr. Shoaib first I ask to make some rough sketches and then
draw them on the paper so I started my work following

Chiller section
Chiller in IMC provided chilled water to the paint shop because its necessary for the paint these chillers
are outside the paint shop I made their rough drawing and then draw it on the software.

2.4.1 Firefighting system

Firefighting slentem I IMC namely Fokada is used for any un attentional hazards when fire erupt this
system work

Figure 5

2.4.2 Cooling towers

Five cooling towers working in the IMC maintenance utility section which gives cooled water to the
welding shop as it necessary for the cooling in the spot welding hot water then return in the cooling
tower which after process goes towards the welding shop the cooling towers lines also goes toward the
compressors rooms where cool water also needed for cooling as refringent in the compressors every
tower has two pump which are working at the 5barr pressure their pressure must be seen through the
pressure gauges. First I make the drawing on the drawing pages then manipulate it on the software as
shown in figure.
 Figure 6

2.4.3 Compressor
There are two types of compressors used in the IMC maintenance utility department

Oil free compressor for the paint shop and oil injected compressors for the the welding shop in
compressor there are also some dryer which are used to dry the air and control the humidity at the
control temperature oil free compressor having two compressed air reservoirs for compressed air before
the dryer and compress air after the dryer and three compressed air reservoir foot oil injected compressor
one before dryer and two for after the dryer
 Figure 7

2.4.4 Hot water generation

Necessity of hot water in paint shop is as pessary as blood for the heart for hot water generation three
generators are used a storage mixing tank and feeding and process pumps feeding pump injected water
from the tank and give it to the generator and generator after the process give hot water again towards
the tan from tank by using process pump the hot water goes to different section of paint and towards the
co-generation and towards the engine shop.
 Figure 8

Chapter #03

3.1 Suggestions & conclusion

As we know that The successful conversion of a conceptual idea into actual execution of process
industry is the basic aim of any process engineer .Normally a project passes through various phases ,
basic engineering , detailed engineering equipment fabrication /procurement , civil/structural work ,.The
conceptual idea , either from the process development cell (for new processes) of from the marketing
engineer (as per the customer) requirement , is converted to executable documents during basic
engineering stage , and thus governs the successful completion of the project.

Piping & Instrumentation Diagram (P&ID) is one of the important basic engineering documents in the
form of drawing , which truly represents the process plant It shows pipelines interconnecting all
equipment , instruments , control systems, valves , etc. for the completeness of the process plant .Since
detailed engineering work for any process plant depends more on the P & ID , its correctness and
completeness is very much essential .Any wrong information provided in the P&ID at the initial stage
may to a big disaster or may entail heavy expenses later .Hence , great attention is required for
the preparation of error free P&ID .Good quality P& ID may deistically cut the engineering man hour
requirement for the successful completion of a project .

Normally process plants have static equipment like storage tanks, columns, heat exchangers, etc. and
rotating equipment like pumps, blowers, etc. This equipment is connected to each other by a
complicated pipeline network for the completeness of the process. Measuring instruments like
thermocouple for temperature measurement, and controlling devices like temperature control valve, are
mounted on the equipment or pipelines for operating the plant at desired conditions. Although a single
step process like blending of two compounds can be represented in a single Piping & Instrumentation
Design (P & ID) , a process having a large number of processing steps like reaction , filtration , drying ,
etc. would need to have many P & IDs for the complete representation of the process plants .For ease of
understanding , the complete process plant is functionally divided into various units .For example a
reactor with the other related equipment , pipelines and instruments required for carrying out a reaction
process may be covered in one unit while filtration operation may be specified with another unit number
accordingly the individual units.

In a big process industry, the processing units are spread over a large area. Although two different units
may be far away from each other they are connected by pipelines or the continuous flow of fluid from
one unit to another Interconnection between two units is represented by Interconnecting P & IDs
Similarly, another engineering document, Utility P & IDs, provides information regarding the
distribution of utilities like water, steam fuel etc. in the required locations. This article deals only with
preparation of Process P & ID.

Process P & ID provides detailed information of the process plant like type of equipment, the details of
pipelines, i.e., size material, identification number, types of instruments and controlling devices etc.
Operation, start-up, maintenance, safety and aesthetic aspects are mainly considered during the
preparation of process P & ID.

3.1.1 Maintenance
Maintenance is an important aspect to be considered during the preparation of Process P & ID. For
example, Bypass line with regulating valve for control valve is provided for talking it out for
maintenance without affecting the running plant. Sometimes it is marked in the P & ID to provide
sufficient room for cutout in the floor above the vertical tube bundle from the heat exchanger body. If
such type of information is not provided initially, it may be missed out in the various engineering stages
and may lead to problems at the later stages. To avoid such possibilities, Process P &ID, should be
critically examined from the maintenance point of view during preparation stage.

3.1.2 Safety
For the safe operation of any process plant , safety measures cannot be overlooked .Hence, the
preparation of Process P & ID needs the attention of safety aspects also .HAZOP study is carried out
keeping in view each and every safety and operation step .For example , the exhaust of obnoxious gases
near the plant operators is harmful to their health .Such gases are diffused in the atmosphere at a higher
elevation .These safe elevations are normally marked in the process P & ID Safety interlocks are
provided to ensure safe operation of the process plant .For example, failure of a running pump for a
critical operation may disturb the complete process plant . To avoid this situation, the stand -by pump
should be started without any time lag. - Necessary interlock is shown in the process P & ID. Some
metallic pipelines and equipment handling hot fluids are insulated for body protection. Here heat saving
may not be an important criterion for the selection of insulating, but it is essential for the operators
safety.

Such safety requirements are clearly marked in the P & ID. Requirement of safety valves in pressurized
system, minimum flow lines for centrifugal pumps, high and low alarms etc., are to be critically seen
during the preparation of Process P & ID.
 REFERNCEs:

www.toyota-indus.com

www.edrawsoft.com

www.pipingguide.net

Indus motor company ltd. Annual report 2015

Guide on piping and instrumentation chapter 12

Guide for drafting and P&ID by Sebrina Durant

Head of department.
Mechanical engineering technology
UCET University of Sargodha, Sargodha

Dear Sir,

Muhammad Yasir Abbas completed his one-month internship at INDUS MOTOR COMPANY Ltd on
April 8, 2017. His internship was a success and in my opinion he
achieved his internship objectives. He was assigned to a task force set up to engineer. For your
information, a task force within IMC is a group of professionals dedicated to a specific project. As such,
there is a lot of intermingling of various aspects and types of tasks required to achieve a common goal,
His role on the task force was that of an engineer having primary responsibility for drawing the process
instrument Diagram. In his primary responsibility his work involved interface with process engineers,
mechanical engineers, design engineers, and project management, which basically covers the whole
gamut of the project task force concept. This responsibility gave him a clear insight on how all task force
operations work and are managed.

The experience gained will serve him well. In addition to his primary responsibility, Muhammad Yasir
Abbas also worked directly under my supervision.

These special studies challenged Muhammad Yasir Abbas abilities to solve unique problems on the job
and he did an outstanding job in this regard. Muhammad Yasir Abbas demonstrated a strong ability to
communicate his work plan and
methods concisely and precisely to management. In all cases he met his deadlines on various
assignments and displayed a consciousness for proper planning and efficient use of time, which is very
important in our business.

In summary, I have no hesitation in stating that Muhammad Yasir Abbas met his internship objectives. I
also believe that he has demonstrated the technical ability required from a practicing engineer as well as
a good awareness of the multitude of variables that bear on project management.

I appreciate the opportunity to serve on Muhammad Yasir Abbas internship committee and look forward
to meeting you again at his final examination.

Sincerely,