Transcript
Lab Specifications Automotive – 4 Wheeler Repair An initiative of Ministry of Skill Development & Entrepreneurship, Govt. of India and National Skill Development Corporation
02 LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
If we have to promote the development of our country then our mission has to be ‘skill development’ and ‘skilled India’. Shri Narendra Modi Honourable Prime Minister
03 LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
OVERVIEW The lab standardization guidelines envisions to standardize the lab infrastructure for automotive – 4 wheeler repair trades across sectors. The document intends to ensure industry linked training with state-of-art infrastructure.
04 LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
AUTOMOTIVE – 4 WHEELER REPAIR SECTOR 1. Description of Lab 2. List of Tools & Equipment Automotive – 4 Wheeler Repair 3. 3D Representation of Automotive – 4 Wheeler Repair 4. Illustrative Architectural Layout of Lab 5. Illustrative Pricing of Tools & Equipment 6. Safety Instructions
05 LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
1 DESCRIPTION OF LAB 1. 4 Wheeler Service Technician – Level 4 2. AC Specialist 3. Brake Specialist 4. Automotive Electrician Level - 4
Lab Specifications for the Listed Sectors / Job Roles
5. Clutch Specialist 6. Chauffeur-cum-Taxi Driver 7. Automotive Sales Head (Retail) 8. Sales Representative 9. Showroom Hostess 10. Service Office Executive 11. 4 Wheeler Service Technician – Level 3 Some of the above mentioned job roles may be done with planning and delivery methodology.
Proposed Batch Size
25
Machine - Man Ratio
1:5
06 LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
2 LIST OF TOOLS & EQUIPMENT AUTOMOTIVE – 4 WHEELER REPAIR S. No.
Equipment Name
Qty
Unit Type
1
Service Technician Tool Kit
15
Set
2
Drive Socket Set
2
Set
3
Lever Type Grease Gun
2
Nos
4
Chisel - Drop Forge 16 x 22 x 20
10
Nos
5
Oil Can - Wesco Type
4
Nos
6
Centre Punches
10
Nos
7
Two Leg Puller
1
Nos
8
Hammer Ball Pin
15
Nos
9
Single - Arm Torque Wrench Covering 1 - 7 mkg
1
Nos
10
Single - Arm Torque Wrench Covering 3 - 14 mkg
1
Nos
11
Single - Arm Torque Wrench Covering 5 - 23 mkg
1
Nos
12
Cross Wheel Spanner (17 x 18 - 19 x 21 mm)
5
Nos
13
Bench Vice (100 mm x 4")
2
Nos
14
Working Bench Wooden
2
Nos
15
Vernier Callipers
4
Nos
16
Micrometer (Size: 0 to 25 mm)
4
Nos
17
Digital Multimeter with Various Lead Sets
2
Nos
18
Work Bench Wooden (Two) Size: 4*3*2.5" in Feet
2
Nos
19
Hacksaw (300 mm) with Blade
15
Nos
20
Tyre Pressure Gauge
2
Nos
21
Steel Rule
15
Nos
22
Tape Measure
15
Nos
23
Depth Gauge
2
Nos
24
Hydro Meter
2
Nos
07 LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
2 LIST OF TOOLS & EQUIPMENT AUTOMOTIVE – 4 WHEELER REPAIR S. No.
Equipment Name
Qty
Unit Type
25
Tyre Pressure Gauge
2
Nos
26
Plastic Hammer
5
Nos
27
Filter Adjustable Remover
1
Nos
28
Spark Plug Sockets 67 mm Drive Size 16/21 mm
2
Nos
29
Magnetic Pickup Tool (Bar)
2
Nos
30
Dial Gauge (Mahr 10 mm Range)
5
Nos
31
Wire Brush
5
Nos
32
Hydraulic Jacks 3 Ton
1
Nos
33
Air Compressor and Hoses
1
Nos
34
Tyre Inflator
1
Nos
35
Battery Charger
1
Nos
36
Universal Battery Tester and Probe
2
Nos
37
Creeper
2
Nos
38
Drain Pans / Engine Tray 12" x 18", 18" x 24"
6
Nos
39
Screw Extractor Set
2
Nos
40
Temperature Sensing Device
2
Nos
41
Wheel Chocks
6
Nos
42
Measuring Can
2
Nos
43
Two Post Lift
1
Nos
44
Neon Timing Light
3
Nos
45
Battery & Charging System Tester
1
Nos
46
Injector Tester and Cleaner
1
Nos
47
Air Tester Filter Machine
1
Nos
48
A/C Leakage Tester
1
Nos
08 LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
2 LIST OF TOOLS & EQUIPMENT AUTOMOTIVE – 4 WHEELER REPAIR S. No.
Equipment Name
Qty
Unit Type
49
Diagnostic Tool
1
Nos
50
Brake Bleeder, Pressure or Vacuum
1
Nos
51
Wheel Balancer (Optima D - 6111)
1
Nos
52
Tyre Changer (Trufit)
1
Nos
53
Head Light Focusing
1
Set
54
Pneumatic Tools
1
Set
55
Wheel Aligner
1
Nos
56
Goggles
15
Nos
57
Ear Plugs
15
Nos
58
Gloves
15
Nos
59
First Aid
2
Nos
59
Powder - Based Fire Extinguisher Class ABC, 500 gms
4
Nos
60
Water Stored Pressure Fire - Extinguisher Class A, 9 ltr
2
Nos
61
Safety Sign
1
Nos
62
Complete Car Cut Section
1
Nos
63
Petrol Vehicle - Minimum Maruti Alto
1
Nos
64
Diesel Vehicle - Minimum Indica / Indigo
1
Nos
64
Aggregate Car Petrol ( Engine, Transmission System, Brake System, Suspension System, Steering System, Electrical System, etc. Mounted on Chassis) Minimum Maruti Alto
1
Set
65
Special Maintenance Tool for Maruti Suzuki Alto
1
Set
66
Diesel Engine Mounted on Stand Four Cylinder Inline Engine 1200 CC Tata Sumo (Preferred)
1
Nos
67
Clutch System Gypsy or Tata Sumo
1
Nos
09 LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
2 LIST OF TOOLS & EQUIPMENT AUTOMOTIVE – 4 WHEELER REPAIR S. No.
Equipment Name
Qty
Unit Type
68
Gear - Box Mounted on Stand Gypsy or Tata Sumo (Synchromesh)
1
Nos
69
Propeller Shaft - Gypsy or Tata Sumo (Preferred)
1
Nos
70
Differential Mounted on Stand - Gypsy or Tata Sumo (Preferred)
1
Nos
71
Starter Motor - Lucas or Equivalent 12 Volt / 1 kW
1
Nos
72
Alternator Lucas or Equivalent 12 Volt / 70 amp
1
Nos
73
Steering System Rack Travel 136 mm Rane Male or Equivalent
1
Nos
74
Air Assisted Brake System
1
Nos
75
Brake System Hydraulic any 4 - Wheeler
1
Nos
76
Fuel Pump (12 V Electrical Fuel Pump) - Maruti or Tata Motor Preferred
3
Nos
77
Water Pump
3
Nos
78
Radiator for 4 - Wheeler
3
Nos
79
Fuel Filter
3
Nos
80
Oil Filter
3
Nos
81
Almirah for Keeping Tools 6'' Height x 3'' Width x 1.75'' Depth and 18 Gauge
2
Nos
82
Tool Board
1
Nos
10 LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
3 3D REPRESENTATION OF AUTOMOTIVE – 4 WHEELER REPAIR LAB
List of Equipment Entry
Store Room
Engine Cut Section and Aggregates
Auto Electrician Cut Section and Work Area
Vertical Hydraulic Hoist
Service Area
Work Benches for Observers
Classrooms
Diagosnistic Equipment
Transmission Cut Section Area
Chassis with Gear Box and Steering Section
Air Compressor
Vehicle Service Area
11 LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
4 ILLUSTRATIVE ARCHITECTURAL LAYOUT OF LAB
12 LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
5 ILLUSTRATIVE PRICING OF TOOLS & EQUIPMENT S. No.
Equipment Name
Qty
Unit Type
Unit Price* (INR)
Amount (INR)
Brands**
1
Service Technician Tool Kit
15
Set
10,000
1,50,000
Multi Branded
2
Drive Socket Set
2
Set
4,000
8,000
Multi Branded
3
Lever Type Grease Gun
2
Nos
340
680
Non Branded
4
Chisel - Drop Forge 16 x 22 x 20
10
Nos
140
1,400
Non Branded
5
Oil Can - Wesco Type
4
Nos
110
440
Non Branded
6
Centre Punches
10
Nos
70
700
Non Branded
7
Two - Leg Puller
1
Nos
1,798
1,798
Non Branded
8
Hammer Ball Pin
15
Nos
171
2,565
Non Branded
9
Single Arm Torque Wrench Covering 1 - 7 mkg
1
Nos
3,700
3,700
Taparia or Equivalent
10
Single Arm Torque Wrench Covering 3 - 14 mkg
1
Nos
4,200
4,200
Taparia or Equivalent
11
Single Arm Torque Wrench Covering 5 - 23 mkg
1
Nos
4,600
4,600
Taparia or Equivalent
12
Cross Wheel Spanner (17 x 18 - 19 x 21 mm)
5
Nos
320
1,600
Taparia or Equivalent
13
Bench Vice (100 mm x 4")
2
Nos
3,000
6,000
Multi Brands
14
Working Bench Wooden
2
Nos
8,000
16,000
Fabricated
15
Vernier Callipers
4
Nos
900
3,600
Mitutoyo or Equivalent
16
Micrometre (Size: 0 to 25 mm)
4
Nos
1,200
4,800
Mitutoyo or Equivalent
17
Digital Multimeter with Various Lead Sets
2
Nos
475
950
Mitutoyo or Equivalent
18
Work Bench Wooden (Two) Size: 4*3*2.5" in Feet
2
Nos
7,500
15,000
Fabricated
19
Hacksaw (300 mm) with Blade
15
Nos
300
4,500
Non Branded
20
Tyre Pressure Gauge
2
Nos
210
420
Multi Branded
21
Steel Rule
15
Nos
75
1,125
Non Branded
22
Tape Measure
15
Nos
75
1,125
Multi Branded
23
Depth Gauge
2
Nos
180
360
Mitutoyo or Equivalent
24
Hydrometer
2
Nos
200
400
Multi Branded
*Price is indicative for the major brands, similar tools/equipment may be used **Brands are illustrative, other brands with same specifications may be used
13 LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
5 ILLUSTRATIVE PRICING OF TOOLS & EQUIPMENT S. No.
Equipment Name
Qty
Unit Type
Unit Price* (INR)
Amount (INR)
Brands**
25
Tyre Pressure Gauge
2
Nos
210
420
Multi Branded
26
Plastic Hammer
5
Nos
326
1,630
Non Branded
27
Filter Adjustable Remover
1
Nos
390
390
Non Branded
28
Spark Plug Sockets 67 mm Drive Size 16/21 mm
2
Nos
270
540
Non Branded
29
Magnetic Pickup Tool (Bar)
2
Nos
545
1,090
Non Branded
30
Dial Gauge (Mahr 10 mm Range )
5
Nos
385
1,925
Mitutoyo or Equivalent
31
Wire Brush
5
Nos
120
600
Non Branded
32
Hydraulic Jacks 3 Ton
1
Nos
1,13,000
1,13,000
Multi Branded
33
Air Compressor and Hoses
1
Nos
1,50,000
1,50,000
Atlas Capco or Equivalent
34
Tyre Inflator
1
Nos
18,000
18,000
Multi Branded
35
Battery Charger
1
Nos
3,825
3,825
Multi Branded
36
Universal Battery Tester and Probe
2
Nos
899
1,798
Multi Branded
37
Creeper
2
Nos
3,000
6,000
Non Branded
38
Drain Pans / Engine Tray 12" x 18", 18'' x 24"
6
Nos
1,000
6,000
Non Branded
39
Screw Extractor Set
2
Nos
394
788
Non Branded
40
Temperature Sensing Device
2
Nos
150
300
Multi Branded
41
Wheel Chocks
6
Nos
445
2,670
Non Branded
42
Measuring Can
2
Nos
450
900
Non Branded
43
Two Post Lift
1
Nos
1,65,000
1,65,000
Multi Branded
44
Neon Timing Light
3
Nos
4,200
12,600
Multi Branded
45
Battery & Charging System Tester
1
Nos
13,500
13,500
Non Branded
46
Injector Tester and Cleaner
1
Nos
19,500
19,500
Bosch or Equivalent
47
Air Tester Filter Machine
1
Nos
12,490
12,490
Bosch or Equivalent
*Price is indicative for the major brands, similar tools/equipment may be used **Brands are illustrative, other brands with same specifications may be used
14 LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
5 ILLUSTRATIVE PRICING OF TOOLS & EQUIPMENT S. No. 48
Equipment Name A/c Leakage Tester
Qty
Unit Type
Unit Price* (INR)
Amount (INR)
Brands**
1
Nos
4,490
4,490
Bosch or Equivalent
49
Wheel Balancer (Optima D - 6111)
1
Nos
1,14,000
1,14,000
Multi Branded
50
Tyre Changer (Trufit)
1
Nos
1,08,000
1,08,000
Multi Branded
51
Head Light Focusing
1
Set
34,950
34,950
Multi Branded
52
Pneumatic Tools
1
Set
35,320
35,320
Taparia or Equivalent
53
Wheel Aligner
1
Nos
5,61,000
5,61,000
Multi Branded
54
Goggles
15
Nos
119
1,785
3 m or Equivalent
55
Ear Plugs
15
Nos
132
1,980
3 m or Equivalent
56
Gloves
15
Nos
71
1,065
3 m or Equivalent
57
First Aid
2
Nos
2,000
4,000
Non Branded
58
Powder Based Fire Extinguisher Class ABC, 500 gm
4
Nos
2,500
10,000
Cease Fire or Equivalent
59
Water Stored Pressure Fire Extinguisher Class A, 9 ltr
2
Nos
2,500
5,000
Cease Fire or Equivalent
60
Safety Sign
1
Nos
5,000
5,000
Non Branded
61
Complete Car Cut Section
1
50,000
50,000
Multi Branded
62
Petrol Vehicle - Minimum Maruti Alto
1
Nos
1,00,000
1,00,000
Maruti Alto or Equivalent
63
Diesel Vehicle - Minimum Indica / Indigo
1
Nos
1,50,000
1,50,000
Indica / Indigo or Equivalent
64
Aggregate Car Petrol (Engine, Transmission System, Brake System, Suspension System, Steering System, Electrical System, etc. Mounted on Chassis) - Minimum Maruti Alto
1
Set
1,00,000
1,00,000
Non Branded
65
Special Maintenance Tool for Maruti Suzuki Alto
1
Set
15,000
15,000
Taparia or Equivalent
66
Diesel Engine Mounted on Stand Four Cylinder Inline Engine 1200 CC Tata Sumo (Preferred)
1
Nos
20,000
20,000
Gypsy or Tata Sumo
*Price is indicative for the major brands, similar tools/equipment may be used **Brands are illustrative, other brands with same specifications may be used
15 LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
5 ILLUSTRATIVE PRICING OF TOOLS & EQUIPMENT S. No.
Equipment Name
Qty
Unit Type
Unit Price* (INR)
Amount (INR)
Brands**
67
Clutch System Gypsy or Tata Sumo
1
Nos
4,000
4,000
Gypsy or Tata Sumo
68
Gear Box Mounted on Stand Gypsy or Tata Sumo (Synchromesh)
1
Nos
4,500
4,500
Gypsy or Tata Sumo
69
Propeller Shaft - Gypsy or Tata Sumo (Preferred)
1
Nos
2,500
2,500
Gypsy or Tata Sumo
70
Differential Mounted on Stand - Gypsy or Tata Sumo (Preferred)
1
Nos
4,500
4,500
Gypsy or Tata Sumo
71
Starter Motor - Lucas or Equivalent 12 Volt / 1kW
1
Nos
3,000
3,000
Lucas or Equivalent
72
Alternator Lucas or Equivalent 12 Volt / 70 amp
1
Nos
2,500
2,500
Lucas or Equivalent
73
Steering System Rack Travel 136 mm Rane Male or Equivalent
1
Nos
3,000
3,000
Rane or Equivalent
74
Air Assisted Brake System
1
Nos
2,590
2,590
Bosch or Equivalent
75
Brake System Hydraulic any 4-Wheeler
1
Nos
3,500
3,500
Bosch or Equivalent
76
Fuel Pump (12 V Electrical Fuel Pump) Maruti or Tata Motor Preferred
3
Nos
1,800
5,400
Multi Branded
77
Water Pump
3
Nos
1,500
4,500
Multi Branded
78
Radiator for 4-Wheeler
3
Nos
3,000
9,000
Multi Branded
79
Fuel Filter
3
Nos
500
1,500
Bosch or Equivalent
80
Oil Filter
3
Nos
600
1,800
Multi Branded
81
Almirah for Keeping Tools 6' Height x 3' Width x 1.75' Depth and 18 Gauge
2
Nos
10,000
20,000
Fabricated
82
Tool Board
1
Nos
2,750
2,750
Fabricated
Total 22,92,509
*Price is indicative for the major brands, similar tools/equipment may be used **Brands are illustrative, other brands with same specifications may be used
16 LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
6 SAFETY INSTRUCTIONS Given below Safety Instruction posters should be placed at appropriate places in the lab. The posters should be digitally printed and pasted on sun board.
Power Tools Precaution
CAUTION SLIPPERY
When in Fire Situation, Please Remember PASS PULL... the pin. Some extinguishers may require releasing of a lock latch, pressing a puncture lever or other motion
AIM... low, pointing the extinguisher nozzle (or it's horn or hose) towards the base of the fire
SQUEEZE... the handle. This releases the extinguishing agent
FLOOR
SWEEP... from side to side at the base of the fire until it appears to be out. Watch the fire area in case fire breaks out again and repeat use of extinguisher, if necessary
17 LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
6 SAFETY INSTRUCTIONS Electrical Hazards • •
Do not work in wet work areas or cramped up work spaces Do not leave naked or loose wires in the lab
Electrical exposure may lead to falls, fractures and other accidents. A small shock can cause brain damage while death can occur from large shocks.
ELECTRICAL HAZARDS
Electrical Safety • • • • • •
Use dry gloves Wear rubber soled shoes Protect yourself from surfaces that conduct electricity Keep insulation on all equipment Components must be dry and in good condition Do not do wiring with bare hands, wet gloves or while standing on wet or ungrounded surfaces
18 LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
Shri Rajiv Pratap Rudy Minister of State (I/C) for Skill Development & Entrepreneurship Govt. of India
We are a youthful nation. Our youth is our strength. The world and India need a skilled workforce and we are committed to achieve this mission.
19 LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
www.fulki.co.in
