St workshop visit auto 2048 - final versionf ooter

PROJECT BY ARTHAR SILVESTER 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.

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

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:

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.
 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.
 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.
 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.
 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.
 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.
 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.
 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.
 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.
 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.
 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.
 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:
 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:
 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.
 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.
 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.
 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:
 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:

(FRAME OF ROOF OF BUS)
(MIG WELDING)

(OPEN FRONT VIEW OF BUS)
(GEAR BOX OF BUS) (DIFFERENTIAL)

(ELECTRIC CIRCUITS ON DASH BOARD)
(RADIATOR) (FUEL TANK)

(BUS BODY FRAME)
(BUS BODY FITTING) (ENGINES)

(CAM SHAFTS) (ENGINE TESTING CENTRE)
(CYLINDER BLOCK BEING LIFTED)

(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
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
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

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