1.

Introduction

1.1. Overview of organization

Continental Trading Enterprises has been under operation for over two decades
delivering the best in class brands and unbridled service to Nepal. It represents famous
brands like Komatsu construction and mining equipment, Kia passenger vehicles, Otis
elevators and drilling equipment like Furukawa. It also has its stake in manufacturing
concerns, financial institutions and housing development. Over the course of our long
history and vast experience, it has been able to create its name as a valuable brand in
Nepal.
1.1.1. KIA: Passenger and commercial vehicle division
For the last ten years, it has been distributing the Kia passenger cars and commercial
vehicles (mini buses) in Nepal. Kia is a Korean company which is renowned worldwide
for its products meeting the needs of people of various classes. Kia products are known
for reliability as well as value for money. In Nepal it has been offering Kia brands like
Cerato, Rio (Sedan and Hatchback), Carens and Picanto cars, Sorento and Sportage
SUVs and Pregio micro buses. All these models have earned good reputation in Nepal
in terms of their performance and service provided through our dealers across the
nation.
1.1.2. KIA motors Nepal
KIA motors Nepal is one of the service centers of Continental Trading Enterprises
located at Dhumbarahi, Kathmandu. It takes pride in the competence of its after-sales
staff, who are well-trained and fully qualified to look after customers’ Kia vehicle. Its
team is always kept up-to-date with the latest developments in the automotive industry,
thanks to a rigorous ongoing training programmed conducted by its in-house trainers,
as well as trainers from the manufacturer. It aims to deliver the genuine product and
service at reasonable price taking customer satisfaction as their primary goal. It has
been providing quality service with guarantee with genuine spare parts. There are 25
staffs paid with handsome salary. The service center has been providing services as
follows:
 Services and maintenance,
 Replacement of battery, tires, rims and other minor components,
 Repairs and replacements of suspension, brakes and steering components,
 Air, non-electrical and audio system repairs,
 Accident repairs/motor vehicle insurance claims,
 Restoration/renewal of trims and upholstery,
 Overhaul of engine, transmission and axles,
 Complimentary shuttle service,
 Panel beating/welding
 Body alignment using the latest technology
 Car grooming including express (wash & wax) standard (machine polish) and
luxury (machine polish and leather treatment)
 Paintless dent removal

1
1.1.3. Vision
KIA motors Nepal envisions of providing value addition to its people, customers,
community and the nation as a whole through innovative products and quality service.
1.1.4. Mission
Its mission is to excel in providing quality service to the satisfaction of its customers.
It takes care of customers’ interest by committing to deliver the best of the
technologies, considering the need of the time, in the most efficient manner.

1.2. Organizational Structure

Since KIA Motors Nepal is one of divisions of Continental Trading Enterprises, each
and every task is conducted according to policy and order of Continental Trading
Enterprises. Continental Trading Enterprises has six divisions under which KIA motors
is one.

Continental Trading Enterprises

Komatsu OTIS KIA

Pramac Furukawa Sakai
construction elevators motors
equipment

Figure 1: Divisions of Continental Trading Enterprises

The organizational structure of KIA motors, Dhumbarahi is given below.

President, (Continental
Trading Enterprises)
KIA
motors
Service and Spare Parts
Sales Division
Division

Manager

Assistant

Superviser

Mechanics Washers Painters

Figure 2: Organizational structure of KIA motors, Dhumbarahi

2
1.3. Form of Ownership
It is a private organization.
2. Personnel Management
It deals with the human resources for recruitment, skills, knowledge and towards
motivating the personnel for achieving the common goals of an organization or
production system or services.
2.1. Personnel Policy
It is used as the medium for the effective use of manpower, to provide the medium to
work in full potential for workers and harmonize the overall functions of any
organization. In KIA motor, Dhumbarahi, Kathmandu; different policies and approach
are used for different personnel at different departments.
Personnel Management mainly deals with the following things:
1. Manpower Planning
2. Recruitment
3. Selection
4. Training and Development
5. Wages and Incentives

2.2. Manpower Planning

It mainly concerns with the planning, analyzing, and creating the best environment for
the proper and efficient use of human resources. It is the process of putting the right
number of people, right kind of people at the right place, at right time, doing right things
for which they are best suited to achieve the common goals of an organization described
by its policies. It is the system approach and is carried out in a set of procedure. In KIA,
it uses following procedure for this process:
1. Analyzing the current manpower inventory
2. Forecasting future manpower
3. Applying employment programs and designing training programs

2.3. Recruitment
It makes decisions about who to select and not to select by applying different criteria
as the medium for checking their requirements which is planned by organization.
Recruitment begins with the advertising the vacancy announcement in newspapers with
criteria in Kia motors by Continental. Then the CV of the applicants are analyzed and
if needed, tested for their verifications. After this screening of applicants as best suited
is done and interview is held for the selection.
2.4. Selection
Selection is the process of eliminating the unnecessary applicants. It starts with
screening the applications, written examination for their understandings in the
respected job and finally the short listing of applicants from direct interview through
the managerial head and supervisors. After this the list of selected employees are
published through the media and their placement are defined.
2.5. Training and Development of Manpower
KIA motors is one of the top companies in the city and to remain at that level the
manpower of this organization must be highly skilled in their respective field. As they
3
recruit highly competent technicians and employees with the advent of latest
technologies the employees are trained regularly to keep them in pace with the
requirements of the modern market.
New recruitments are trained for several months under heavy supervision to make them
familiar with their work. The technicians and workers are made familiar with new tools
and equipment as well as latest problem solving techniques. Employees who are in
management and sales division are made familiar with latest technologies as well as the
changing market of automobiles. It is done in following ways:
a) Demonstration
In this method, trainer/specialist demonstrates the method of operating the
machines, tools, causes of defects & malfunctions, process of eliminating the
problems for different conditions and cases. This method is employed when new
technology and latest problems are to be dealt with as the current manpower
may not be familiar with it.

b) Off the job training

It is the process of training the workers and employees at different associated
facilities around the city. The workers and employees are trained in a different
environment than that of their current workplace.

c) On the job training

This training process is actually implied for those workers who actually works
i.e. not for the beginners but for the experienced workers. It deals with the latest
developing cases and machines because everything is evolving. So, to match
this, training is conducted every year to keep their employees up to date with
the latest technology. For this, a specialist from South Korea trains the
employees.

2.6. Job Evaluation

Personnel are evaluated on the basis of their sincerity, working intentions, experience,
and punctuality. Also, manager submits annual performance sheet of employees to the
central office every year which is then evaluated by the central office. This performance
sheet is the evaluation of the efforts put in and the work done by the employees.
2.7. Wages and Incentives
Salaries of employees are distinguished according to the hierarchy of their position in
the organization. Contracts are made with the workers/employees according to the
company’s policy in KIA which states increment of salary after every two years.
Incentives are distributed among the workers usually in Dashain.

2.8. Motivation
KIA motors takes the task of motivating its employees very seriously as it directly
impacts their performance and the overall performance of the organization. Every year,
bonus shares are provided to employees according to the profit which the organization

4
has made. New working uniforms are provided twice a year. Sometimes, KIA motors
organizes picnic for amusement.
3. Management Information System
A Management Information System (MIS) is a computerized database of organizational
information organized and programmed in such a way that it provides regular reports
on operations for every level of management in a company. A management information
system organizes all company data in a computerized database. Authorized Personnel
can retrieve data from all sections of the company including sales, maintenance and
inventory to see how efficiently each department is operating.
For an automotive company, getting correct vital information at the right time is
essential in the competitive nature of market today, therefore reducing costs, enhancing
productivity and maximization of profits. This is achieved by the use of MIS by the
automotive company and KIA Motors is no exception.
Managers of KIA Motors have to administer the complications of the operations, supply
chain, internal control and maintenance as well as meeting the customer and distribution
demands. In today's business environment administrators are forced to make effective
decisions on a regular basis with the limited information system. KIA Motors has
employed various information systems for its departments to assists in day to day
operation of the company as well as in making strategic decisions.

Figure 3: MIS Block Diagram

3.1. Application of MIS in KIA Motors
Operations
The operations of KIA Motors is heavily influenced by the development of technology.
The application of MIS in this department has significantly improved the process
structuring and planning for smooth flow of operations. The manager use MIS to plan
the whole operation from the arrival of the vehicle to its delivery after it has been
serviced/repaired. The software also stores all the information about the vehicle which
include the specifications of the car, ownership details and most importantly previous
5
problems and the list of operations done on the car. This enables the manager to predict
the next service date and possible areas of problems. The MIS also helps to properly
forecast and plan for the requirement of parts.
Sales/ Marketing
The sales manager also use MIS to keep record of the cars sold and imported over a
span of time. The MIS analyzes the present market trend and helps the manager to
predict which model of cars the customers are most likely to buy. The system also keeps
record of the number of car sold over a period and determine the period where most of
the cars are sold. By using the information generated by MIS, the sales manager at KIA
can forecast the demand of cars of various models at different periods and launch
attractive marketing schemes.
Finance
The Finance department at KIA motors also use MIS to evaluate the financial
transactions of the company. The financial MIS generate the records of profits and
losses of KIA Motors, which reflect the current position of KIA Motors in the market
and eventually correct decisions regarding control of the cost and spending of funds can
be made. The people of the finance department of KIA Motors analyze previous and
current financial figures, anticipates future financial outputs, and handle the utilization
of capital over time by making use of the information generated by the MIS.
Inventory
MIS is also used to manage the inventory of KIA Motors. MIS is used to monitor the
inventory level and the value of the inventory. A software (Swastik) keeps the record
of all the present parts and its quantity along with its price. The system automatically
detects the re-order point and generates the Economic order quantity of the most used
parts keeping a healthy safety stock to prevent shortage and hamper the operations.
Attendance / Payroll Management
KIA Motors use MIS to monitor employee attendance and payroll management. The
software includes MIS reports on attendance management, leave balance and summary,
and payroll management. Biometric attendance system is used to keep records of each
employees’ arrival time, shift time and departure time. This system is integrated with
the payroll management system which evaluates the attendance, wage structure,
bonuses and automatically generates the salary of each employee. This results in
efficient operation by reducing the time and effort required.

6
4. Production system design
4.1.Locational Analysis
KIA Motors is located in Dhumbarahi, Kathmandu. Since it is nearer to ring road, this
locations is an ideal location for any automobile sales and service center. It is about 10
meters below the road level. KIA motors is availed with facilities like communication,
transport, power, etc. Being
located in urban area, KIA
motors has advantage of
proper market, higher traffic
flow, skilled labors,
availability of required
parts and equipment, etc.
Despite having direct ring
road access, there is the
flooding problem in rainy
season since it is situated
below the ring road surface.
Figure 4: KIA motors, Dhumbarahi
4.2. Factory building
KIA motors, Dhumbarahi has a single storeyed building which allows cheaper and
efficient material handling, efficient supervision, use of natural light and ventilation,
and has greater flexibility.
4.3.Plant layout
All similar machines are grouped together and sections are divided accordingly in KIA
motors. KIA motors has process or functional or job type of plant layout.
The figure below shows the layout or KIA motors.

Figure 5: KIA Motors plant layout

7
4.4.Flow pattern
The job flow pattern in KIA motors is O-flow among horizontal flow patterns.

Figure 6: Flow Pattern

4.5.Material handling equipment and tools

Various material handling equipment are used throughout the workshops that simplifies
the work far easier. The following equipment are used in day to day work in KIA
Motors.
1. Lifting equipment:
There are different kinds of lifts that are used that are used for different purposes
like for washing or for maintenance. Some of them are listed below.

i. Hydraulic Washing Lift: It is the hydraulic system which is used for lifting
of automobiles for washing purpose.

Figure 7: Hydraulic washing lift

ii. Four post lift: This type of lift contains four post for mechanical support and
base for vehicle. It is driven by hydraulic pressure which drives rope and
pulley. It is generally used for lifting automobiles for gear box and clutch
maintenance. A four post lift makes it much easier to load and position the
vehicle. The runways of the four post lift make it easy for the operator to just
drive onto the lift.

8
 Figure 8: Four post lift

iii. Two post lift: The working of two post lift is similar to four post lift but it
comes in high voltage single phase motor.

Figure 9: Two post lift

9
 iv. Hydraulic Jack: A jack is a device that uses force to lift heavy loads. This
is movable anywhere and has capacity of lifting up to 5 ton.

Figure 10: Hydraulic Jack

v. Hydraulic tappet: It is a hydraulic lifter which is used to lift automobile

engines.

Figure 11: Hydraulic tappet

2. Toolbox
The toolbox is the box where the technicians put all the necessary materials like
wrench, ratchet wrench, screw driver, pliers, hammer, all kinds of sockets,
extensions and so on. All the technicians have their own toolbox.

10
 Figure 12: Tool box

3.Impact gun:
It is used to tighten or loose bolts and nuts. It is driven by high speed motor and
high torque motor which rotates the socket.

Figure 13: Impact gun

4.Air compressor:
It is used to compress the air for different purposes like cleaning of air filter and
other parts. Its pressure range is 0.5 to 10 bar.

5.Air dryer:
It is used to dry out the wetted parts of automobiles by flowing compressed air.
11
6.Vertical Stand:
It is used to hold the uplifted vehicles for safety purpose from falling down due
to equipment failure.

Figure 14: Vertical stand

7.Ramp:
It is used to put the vehicle in inclined position so as to change the lubricant
easily.

Figure 15: Ramp

12
 8.Washing Gun
It is used to create powerful water jet to wash vehicles.

Figure 16: Washing gun

9.Others:
Other equipment used in workshops are grinder, vice, cutter, welding and so on.

5. Production, planning and control

5.1.Routing
If a customer wishes to repair or service his vehicle then the vehicle is sent to
repair/maintenance section. After the completion of repair or servicing task, the vehicle
is sent to washing section.
If a customer just wishes to repaint or repair dents on his car, the vehicle is routed
directly to dent paint section.
5.2.Scheduling
Generally, the repair tasks are performed on first come first service basis. But in case
of unavailability of specific parts, those repair tasks are halted and other vehicles are
taken into consideration. Also, the task which takes very less time such as changing
engine oil are done instantly to avoid overcrowding of vehicles in the workshop.
5.3.Product research and development
Product research and development are done in main factory of KIA which is located in
Seoul, South Korea. However vehicle data are automatically updated through internet
whenever a vehicle is connected with GDS (Global Diagnostics System). In this way
product performance are evaluated and required improvements are done for better
quality of parts.

13
5.4.Process planning
Following steps are followed in KIA motors to repair a vehicle.
a. Entry
Before the vehicle is entered, the guard makes entry and provides tag.
b. Job card
An employee prepares the job card. It includes customer complaints and the task
to be carried by the technician. The details about the customer are maintained in a
software named Auto Boom.
c. Supervisor
After the job card is made, the supervisor handle the job card to the technician and
allocate the bay depending on the nature of job.
d. Trial
The technician performs a short trial before carrying the job to identify the
problems in the vehicle.
e. Ordering of parts
The technician after trial gives the list of parts to the supervisor and the supervisor
tells to the service advisor to enter the list into the job card so that it becomes easy
for preparation of bill.
f. Quality assurance
The vehicle is taken for test drive after the maintenance is done to ensure proper
performance of the vehicle.
g. Billing
After the technician completes the job, the customer collects the job card with
amount from the service advisor and makes the payment in the account section.

14
Figure 17: Job card

15
 Entry

Job Card

Supervisor

Trial

Ordering of parts

No
Hold Parts
availabilit

Yes

Start repair

Quality assurance

No

Performance
met?
Yes

Billing

Payment

Figure 18: Process flow chart

16
6. Inventory Control
Inventory is one of the most important section at KIA motors. The Inventory holds all
the parts and materials that are required for daily operation of the service center. The
Inventory Management at KIA is responsible for replenishment of spare parts,
managing and maintaining healthy inventory levels and predicting expected supplies
over time. Apart from these basic functions the Inventory Management at KIA also
monitor

 Maximum items in the stock

 Minimum items in the stock
 Delivery time
 Order package amounts or the number of items required for smooth operations

Figure 19: Inventory of KIA

The Inventory at KIA holds goods which fall under three general categories.
1. Fast Moving Parts (Most Common Parts): These parts are used at a high rate and
are always in demand. The Inventory at KIA ensures that these parts are always
available and maintains a good safety stock. These parts cover majority of items in
the inventory. Examples of such goods at KIA Inventory are brake pads, engine
lubricants, oil filters, clutch discs, pressure plates etc.
2. Special parts: These parts are not used as frequently as the fast moving parts but
over a period of time are consistently used. These parts have longer delivery time
so KIA holds a quite sufficient inventory level. These parts are ordered at certain
points when the company finds appropriate. Examples of such goods at KIA
inventory are engine parts like piston pin, piston head, chamber bolt, engine bolts,
tire bolts, fuel filter etc.
3. Rare parts: The Inventory at KIA Motors also holds rare parts which are not usually
used during the general operations and are only required in few cases. The Inventory
Management at KIA places an order only when such parts are required. The delivery
17
 time is usually very long and operations dealing with such parts also take quite some
time to complete. The cost of placing an order is quite high but the cost of holding
such goods is very low as the inventory does not necessarily hold the part over time.
Example of such parts are parts required in accident cases,
Inventory Control at KIA Motors is assisted by the use of MIS and computers. A
software called Swastik assists to handle all the operations of Inventory Management.
The operations include monitoring inventory level, determining EOQ, placing an order,
receiving the order, allowing access to the goods when required and logging the data.

7. Material Requirement Planning

Material requirements planning (MRP) systems is a prominent approach to manage the
material flow and components on the factory floor. MRP technique- is used to explode
bills of material, to calculate net material requirements and for production planning.
The master production schedule and bill of materials indicates the materials to be
demanded, order scheduling, cycle time production and supplier lead times then these
all factors jointly determine when orders should be placed. It is a time phased priority-
planning technique that calculates material requirements and schedules supply to meet
demand across all products and parts in one or more plants and used to optimize the
inventory. It controls the system that attempts to keep adequate inventory levels to
assure that required materials are available when needed.
In KIA Motors, MRP is used for procuring spare parts to reduce the servicing time of a
vehicle. The demand is forecasted for the materials based on actual demand and this
gives the expected levels of goods or services. Based on the forecasted demand material
requirement planning is done and orders are released to purchase materials and the
materials are stocked. The objective of this work is to reduce the idle time and cost of
materials and by procuring materials in right time.
The actual demand long with forecasted demand is shown above. In KIA Motors, the
material which are commonly in use such as the materials used in servicing like air
filter, oil filters, break pad, lubricants, etc. are preordered before the materials runs short
on inventory. This is done with the help of the software called “SWASTIK” which
gives a warning alert when the materials runs short in inventory. Also the some
materials are ordered after the complete estimation of the required parts. This is done
for the vehicles which are damaged in accident case or the serious maintenance case
where the vehicle parts are to be replaced.

8. Forecasting
Forecasting at KIA motors plays a major role in effective operations of the company.
The managers at KIA motors use the reports generated by MIS and analyze the present
market trends and tentatively forecast the future market demands. The managers also
evaluate the occurrence of problems in the various models of KIA vehicles which helps
them to forecast the possible failures that may occur and prepare themselves to solve
those problems as well as report to the higher authorities to eliminate the problems in
the upcoming models.

18
9. Plant Maintenance
KIA Motors has various machine, equipment and system which are in operation all year
round. These systems and devices assist in effective operation of the service center and
hence must be kept at a good condition to optimize the company productivity. KIA
motors follows in general two specific types of maintenance procedures.
1. Breakdown Maintenance: Some equipment at KIA Motors are only maintained
and repaired if necessary only when the equipment is out of order. This results
in downtime and hampers the operations of the service station. These types of
maintenance often cost less but pose a safety threat to the workers, staff and
customers. Typical cases of breakdown maintenance at KIA motors are:
a. Failure of electric pump at washing section.
b. Failure of tools (fatigue failure).
c. Failure of Air Compression Unit
2. Annual Inspection and Overhaul: This maintenance process involves restoring
the equipment, machine, or system at KIA Motors in a functional condition. The
Overhauling technique may involve
a. Partial or complete disassembly
b. Detecting worn, defective and damaged components
c. Repairing/replacing such parts
d. Reassembly, testing and trial before resuming normal operations.
At KIA Motors this overhauling techniques for maintenance of
a. Two post lifts
b. Air Compressor Unit
c. Washing Unit
d. Tools and equipment
e. Denting and Painting equipment

10. Quality Management

Consistency of performance and quality of service is mandatory for any company in
nowadays competitive environment. Quality according to KIA motors is not only what
they provide but also what the customer gets. At KIA Motors, the quality of the parts
that are acquired from suppliers are checked for conformance with the specifications
and design. The parts that are used in the service at KIA Motors are genuine KIA parts
as well as genuine Hyundai-KIA spare parts. The quality of the parts are exact to the
standards.
The quality of service provided is also good and carefully supervised. The technicians
do the job without interfering with other fully functioning parts of the car and only
address the problem of the car. By doing so unnecessary problems do not arise however
they follow routine inspection to ensure that the car is safe and reliable to use.
After the car is attended to, the car is taken for a test drive to check the performance of
the car in actual field conditions. The technician fully evaluate the performance of the
car. The car is delivered to the customer only when the technician and the manager are
assured that the car is now ready to hit the road.
Quality of service offered by KIA Motors is not assured until the customer is satisfied
with the service. The employee at KIA Motors follow up on the customer few days after

19
the delivery to ensure that the car has been functioning and has not shown sign of further
problems.

Figure 20: Quality Management

20
11. Case study
Case 1:
Problem Statement: Engine overheating
Possible Causes:
Damaged thermostat
Damaged fuse and relay
Defective Fan resistor
Damaged cylinder head gasket
Diagnosis:
The vehicle was checked with GDS. DTC analysis displayed the cooling fan to be
operating but in real it was not. Following tasks were followed:
a. Thermostat was checked and found working properly.
b. Cooling fan resistor and relays were replaced with new ones but the
problem remained same.
c. Finally, the cylinder head was faced and gasket was changed which
solved the problem
Finding:
Cylinder head gasket was found damaged.
Solution:
The cylinder head was faced and cylinder head gasket was changed.
Root Cause:
Operation of vehicle despite of leakage of coolant was found to be the root cause.
Days Required:
12 days
Conclusion:
The customer was suggested not to drive the vehicle ignoring the problems seen.

21
Case 2:
Problem Statement: Engine speed did not increase despite pressing the accelerator
pedal fully.
Possible Causes:
a. Problem in accelerator wire
b. EGR sensor defect
Diagnosis:
GDS was used to inspect the vehicle. DTC analysis showed problem with EGR sensor.
Finding:
One of the wires in EGR sensor was found broken.
Solution:
The wire was reconnected.
Root cause:
Disconnected EGR sensor wire
Days required:
1 day

22
Conclusion
We are grateful to have been a part of KIA Motors as intern/trainee for a duration of
one month. KIA Motors located at Dhumbarahi, Kathmandu is a well-established
company which follows modern management principles and has vowed to provide
extremely satisfactory services to its customers. KIA motors Nepal is one of the service
centers of Continental Trading Enterprises located at Dhumbarahi, Kathmandu. It aims
to deliver the genuine product and service at reasonable price taking customer
satisfaction as their primary goal. KIA Motors has highly competent staffs working for
them and the employees are well trained and guided. KIA also has latest technologies
at its disposal and employs MIS and computers to assist in its operation. It manages its
inventory well and rarely the inventory goes out of stock. KIA also focuses on providing
quality services to its customer and undertakes various steps to achieve it.
It was a very fruitful experience having been attached at KIA Motors for the duration
of our internship. The friendly and welcoming environment at KIA Motors enabled us
to gain an insight of the operations and management at KIA Motors. During the course
of our internship, we got to see how the company is managed and operated to stay at
the top of the competitive market. We were mainly focused on the technical section of
the company where we spent the most time observing, learning and practicing the actual
operations performed by that department. We got familiar with various components of
an automobile, common problems and the probable solutions. We gained a lot of
practical knowledge about the various automobile systems which has boosted our
knowledge and confidence regarding the subject.
Recommendation
However, we found the company to be lagging behind at some specific section which
is poor management of time given to each car. No definite time is allocated for each car
which results in poor management. It also reduces the efficiency and effectiveness of
the service. Hard and fast format of time schedule is not necessary but a slightly lenient
time allocation could be done. Also there is no scheme to drive the spirit of the workers
who complete the work efficiently saving a lot of time. There is no difference between
the workers who work efficiently and those who work unwillingly. This decrease the
morale of enthusiastic workers. KIA has multi location inventories which results in
delay of delivery of some parts and eventually the repairing task. The facility location
is quiet ideal but during rainy season it can get flooded due to poor drainage system.

23
References

1. M. Mahajan, “Industrial Engineering and production Management” ,Dhanpat Rai and Co. (P)
Ltd. , Delhi, 2002

2. O. P. Khanna, “Industrial Engineering and Management” , Dhanpat Rai Publications (P) Ltd.,
2007

3.

24
Appendix A
Work Summary by Day
Days Summary of work done
Separating gear box from engine and changing the clutch plate set of an
1
AWD SPORTAGE model KIA vehicle (CI engine).
Opening and repairing of gear box of RWD PICANTO of 2004/05 and
2
replacing four brake pads of RIO.
Continued work on PICANTO to change the bush of alternator set and
lubrication alongside the servicing (replacing engine oil and oil filter with
3-4
clearing air & AC filters) and aligning the timing belts of SPORTAGE
vehicle.
Removing the axles of the vehicle and replacing all bushes and link rods
and reassembling the parts, also checking the condition of silencer, sensor,
5-8 radiator, and coolant of a SPORTAGE (SI engine).
Servicing a RIO model car; changing brake pads, air filter, AC filter and
lubricants.
Separating gear box from engine and changing the clutch plate set of 4
9-14 vehicles (2 AWD SPORTAGE, 1 RWD PICANTO, 1 RIO) and changing
the brake pads as well as routine servicing.
Complete disassembling of gear box and replacing the second gear due to
15-18 its misalignment and auto gear shift of PICANTO model vehicle along
with its routine servicing
Changing of 2 AWD SPORTAGE vehicles clutch plate set, replacing of
19-21 spark plug, replacing of old brake cylinders and brake pads with new ones,
repairing the fuel pump and aligning the chain belts.
Opening cylinder head and cleaning engine parts of a SPORTAGE car.
22 Replacing the clutch cylinder and clutch wire and clutch master of a RIO
car.
Replacing the gasket and radiator sensor (thermostat).
25-26 Separating gear box from engine and changing the clutch plate set of a
RIO car.
Repairing EGR sensor wire and reassembling the engine cylinder heads
with its components and testing for the fan used in cooling the coolant.
27-28
Separating gear box from engine and changing the clutch plate set of a
SPORTAGE.
Test drive of the vehicle and testing of coolant fan in running condition of
29
vehicles.

25
Appendix B
List of vehicles available at KIA Motors, Dhumbarahi, Kathmandu
Models Variants Price (NRs.)
LX I 24,99,000
EX I 27,49,000
Picanto 1.0
EX I (Sunroof) 27,49,000
EX II 30,49,000
EX I 41,00,000
ALL new Rio H/B 1.4
EX II 47,00,000
EX I 42,00,000
All new Rio N/B 1.4
EX II 48,00,000
GSL 55,95,000
New Soul 1.6
DSL 59,95,000
EX I 56,00,000
Soul EV
EX II 58,00,000
Petrol LX I 78,95,000
Petrol EX I 83,95,000
Petrol A/T 93,95,000
Sportage 2.0 Diesel LX I 83,95,000
Diesel EX I 90,95,000
Diesel EX II 94,95,000
Diesel A/T 96,95,000
Sorento 2.2 EX A/T 1,25,00,000
Carnival 2.2 EX I 75,00,000

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Appendix C
Maintenance of Two post lifts
These car handling equipment are used almost regularly and must be maintained
regularly. The routine procedure followed for maintenance are
 Always keep bolts tight. Check periodically.
 Always keep lift components clean.
 Always, if oil leakage is observed, call responsible service authorities.
 Always, if electrical problems develop, call responsible service authorities.
 Daily: Check cables and sheaves for wear. Observe for frayed cable strands.
Wipe cables with a rag to detect hard to see small broken cable strands.
Replace cables showing any broken strands. Replace worn parts as required
with genuine parts.
 Daily: Inspect adapters for damage or excessive wear. Replace as required
with genuine parts.
 Monthly: Check equalizer cable tension. Adjust per lift installation
instructions. If there are no more threads available for adjustment, replace the
cable. Do not use washers to stand off the nut to use previously used threads.
 Monthly: Lubricate the four inside corners of the columns with heavy duty
bearing grease.
 Monthly: Lubricate locking latch shafts. Push latch handle several times for oil
to penetrate pivot points.
 Every 3 Months: Check anchor bolts for tightness. Anchors should be torqued
to 120Nm.
 Semi-Annually: Check fluid level of lift power unit and refill if required per
lift installation instructions.
 Replace all caution, warning or safety related decals on the lift if unable to
read or missing.

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Appendix D
Questionnaires

1. What is the objective/goal of your organization?

…………………………………………………………………………………
………………………………………………………………
2. What type of organization structure do you have?
…………………………………………………………………………………
………………………………………………………………
3. What is the form of ownership of your organization?
…………………………………………………………………………………
………………………………………………………………
4. How do you plan for manpower requirement and tell us about recruitment and
selection process.
…………………………………………………………………………………
………………………………………………………………
5. How do you analyze the work of your employee and what are the evaluation
process?
…………………………………………………………………………………
………………………………………………………………
6. How do you motivate your employee and what are the wages structure and
incentives that you offer?
…………………………………………………………………………………
………………………………………………………………
7. How is your organization influenced by MIS and how do you benefit from
them?
…………………………………………………………………………………
………………………………………………………………
8. Tell us about the scheduling and loading techniques that you use.
…………………………………………………………………………………
………………………………………………………………

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9. How do you do your product research and contribute towards development
and design?
…………………………………………………………………………………
………………………………………………………………
10. What Inventory control techniques do you use?
…………………………………………………………………………………
………………………………………………………………
11. How do you plan for material requirement?
…………………………………………………………………………………
………………………………………………………………
12. How do you forecast for the future demands?
…………………………………………………………………………………
………………………………………………………………
13. What type of plant maintenance principle do you use and why?
…………………………………………………………………………………
………………………………………………………………
14. How do you approach quality management in your organization?
…………………………………………………………………………………
………………………………………………………………

29