REPUBLIC OF THE PHILIPPINES

CITY GOVERNMENT OF ZAMBOANGA

COLEGIO DE LA CIUDAD DE ZAMBOANGA

Automotive 201
(Shop Management)
Self-Learning Module 2
RYAN D. ABANICO
Instructor
COURSE DESCRIPTION:
This course deals with the knowledge and skills in managing automotive service shop.
It covers topics such as Maintenance Work, Maintenance Shop, Building and Service facility
lay out.

COURSE OBJECTIVES:

At the end of the course the students will be able to:

1. Classify the different maintenance work
2. Compare the different maintenance Shop
3. Understand building and service facilities lay out.
4. Demonstrate workshop safety and preventive procedure in the shop

COURSE OUTLINE:
Lesson 1: Maintenance Work
1.1 Classification of Maintenance Work
1.2 Shop Terminologies
1.3 Auto repair shop

Lesson 2: Maintenance Shop

2.1 Types of maintenance shops
2.2 Nature of operation

Lesson 3. Building and Service facility lay out

3.1 Shop location
3.2 Buildings Design and Facilities Layout
3.3 Interior Layout Consideration

Lesson 4. Workshop Practice

4.1 Workshop Safety and Preventive Procedures in The Auto- Workshop
4.2 When Working with Vehicles on the Roadside
4.3 When Working with Lifting Equipment

1
Lesson 1 Maintenance Work

2
3
4
5
An automobile repair shop (also known regionally as a garage or a workshop) is an establishment where
automobiles are repaired by auto mechanics and technicians.

Auto body repair

Some repair shops offer both mechanical and bodywork repair. Automotive repair shops that
specialize in bodywork repair are known as body shops. They offer paintwork repairs to scratches,
scuffs and dents, as well as repairs to the bodies of vehicles damaged by collisions. Many body shops
now offer paintless dent repair.

6
Name: _______________________________________ Date: ___________________________
Year and Course: ______________________________ _Score: __________________________

Formative Exam 1.

1. What is the main difference between preventive and corrective maintenance work?

2. Why it is necessary to equip a depot for maintenance service?

3. What is the difference between the term yard and the word depot?

4. What are the two methods of maintenance practices which have been the result of modern
management technique?

5. List the five main classification of maintenance work?

Lesson 2 Maintenance Shop

7
\
8
9
10
11
12
13
Name: _______________________________________ Date: ___________________________
Year and Course: ______________________________ _Score: __________________________

Formative 2

1. Enumerate the six different nature of shop and their nature of operation?

2. What is the difference between the long distance service and milk run
delivery?

3. Give an example of each of the following.?

a. Production machinery

b. Materials handling equipment

c. Marketing

4. What are the different passenger transport fleet?

5. Compare the two types of heavy equipment maintenance yard?

Lesson 3 Building and Service Facilities lay out

14
15
16
Name: _______________________________________ Date: ___________________________
Year and Course: ______________________________ _Score: __________________________

Formative Exam 3 Building and Service Facilities Lay out

1. Enumerate the important factors to consider in planning the layout of a

maintenance shop?

2. Give at least four basic considerations in a building lay out?

3. List the kinds of roof structure used?

4. What are the common types of construction materials?

Lesson 4 Workshop Practice

Automotive Engineering

17
 This is a part of Mechanical Engineering that deals with the design and operation of
vehicles that move on land, sea and air.
What is an automobile?
An automobile is a basically a four wheeled, self-powered motor vehicle which runs
on road and it is used to transport passengers (the driver with an addition of passengers with
numbers ranging from 1 to 7) and a little amount of load.
What is an automobile workshop?
An automobile workshop is a place where repairs and servicing of automobiles and
automobile systems are done.

1.0 WORKSHOP SAFETY AND PREVENTIVE PROCEDURES IN THE

AUTO- WORKSHOP
In an auto-workshop various services are rendered by the technical staff during repairs
and servicing of automobile systems and parts. The technical staff and others in the workshop
are expected to observe some laid down rules to be safe and to ensure the safety of others in
the workshop.
The rules to obey are peculiar to the activities and services being rendered and are to
be obeyed while working on automobiles in the workshop or outside the workshop. They are
grouped as follows:
(i) When working with vehicles in the workshop
(ii) When working with vehicles on the roadside

(iii) (iii)When working with lifting equipment

18
1.1.1 When Working with Vehicles in the Workshop
Hazards: Moving vehicles may cause injuries to employees and members of the public.
Therefore, appropriate measures must be taken to guard against this.

Figure 1.1: Low risk workshop: A neat and tidy workshop area

Table 1.1: When Working with Vehicles in the Workshop

TASK / ACTIVITY RULES/SAFETY MEASURES

i Management in workshop  Customers are to drop their vehicles at the
car park/pickup area.
 Customers are not allowed to drive
their vehicles within the workshop.
 Serviced/repaired vehicles are to be moved
to the customer car park/pickup area by an
employee.

ii Work Areas  The vehicle route is marked out from the

route of service personnel and
pedestrian.
19
iii Planning for pedestrian traffic  They should be designated customer
parking bays
 A sign that reads “No unauthorized access”
should be in place at all entry points of the
workshop.

20
iv Vehicle Handling (Driving)  Employees are to drive vehicles within their
licence and competency.
 Earth moving equipment and farm vehicles
are to be moved to the designated repair
areas from the vehicle drop off areas by
licensed operators with appropriate
experience.
v Preventing vehicles from moving Vehicles in the workshop are prevented from
moving using atleast three methods:
 The vehicle keys are removed from
the ignition.
 The hand brake is to be engaged.
 Vehicles are raised on a pillar hoist with all
wheels off the ground.
 The vehicle’s wheels are chocked on both
sides of the vehicle’s wheel with
serviceable purpose-built chocks.

vi Slip and trip prevention  All leads are stored out of the ways e.g.
retractable reels.
 Power and pneumatic outlets are located
close to the service area.

 Spill on the workshop floor are covered

with absorbent material and immediately
cleaned up.
 Potentially slippery surfaces are coated
with non-slip coatings.

vii Vehicle payload stability  Vehicle is unloaded or load is reduced to

safe level before the start of brake servicing
or tyre changing.
viii Availability of the lifting  Manual handling aids are made available to
equipment for the lifting and technical staff while undertaking repair or
management of heavy objects servicing work.
ix Communication with isolated  Constant communication with technical
worker/s staffs working in isolated areas should be
maintained by the supervisor.
 Emergency/panic alarm must be made
available in such places.

21
1.1.2 When Working with Vehicles on the Roadside:

The hazards include: high speed traffic, poor visibility and weather conditions, loose, soft or
sloping ground conditions. Employees may be struck by a passing vehicle or crushed by the
vehicle moving off jack. The rules and control measures below apply to all vehicles.

Figure 1.2a: Low risk workshop: Visible warning signs for approaching drivers

Figure 1.2b: Low risk workshop: Highly visible vest and warning lights
Table 1.2: When Working with Vehicles on the Roadside

TASK / ACTIVITY RULES/SAFETY MEASURES

22
i Traffic control at the site of the  Service personnel are to be competent in risk
broken-down vehicle assessment and traffic control at the scene of
a broken down vehicle.

23
 The control measure may include:

 Calling the police or other appropriate

authorities e.g. Road safety
officials.

 Arranging for the towing of the vehicle to a

safe work area before the commencement of
repair work.

 Putting in place prominent warning signs

and lights for approaching drivers, some
meters away from the broken-down
vehicle.

 Traffic lane could be close to protect

personnel and the broken-down
vehicle.

 Traffic controller with appropriate

equipment warns approaching drivers of the
traffic danger ahead.
ii Work area lighting and visibility  Worksite area and vehicle must be
adequately lit using auxiliary lighting
systems if required.
 High visibility vest appropriate to day or
night must be worn by personnel at
worksite.
 A combination of warning lights and signs
must be prominently displayed to warn
motorists of the activities going on at the
site.
iii All other rules that are applicable
in the workshop apply here too.

1.1.3 When Working with Lifting Equipment:

Hazards: Failure of lifting equipment causing crushing injuries and/or fatalities. Control
measures to ensure safety are to be taken.

24
Figure 1.3a: Low risk workshop activity: Operating instruction prominently in display.

Figure 1.3b: Low risk workshop activity: Trolley jack and axle stands must be used at all
times.

Table 1.3: When Working with Lifting Equipment

25
 TASK / ACTIVITY RULES/SAFETY MEASURES
i Vehicle hoists  Hoist inspections are to be undertaken to the
manufacturer’s standard.
 Pre-operation inspections are to be done daily.
 Routine inspection and maintenance are to be
done at least every three (3) months.
 Comprehensive annual inspections are to be
conducted.

26
  Results of all inspections, servicing and
maintenance are to be recorded in a log book and
made available to users and maintenance or
inspection personnel.
 All servicing and maintenance are to be carried
out by qualified and competent persons.
 Operating and maintenance instruction plates are
to be prominently displayed on hoists.
 Safe working loads are to be prominently
displayed on equipment.
 The moving parts of the hoist or its loads should
have a minimum clearance of 600 mm to any
fixed structure or other equipment that moves.
 Electrical hoists and wiring are to be tested
according to AS/NZS 3000 Australian
wiring rules.
 The hoist controls are meant to be in good
conditions, properly positioned and clearly
marked for safe operation.
 Dropper bar should be fitted to in-ground
hydraulic ram type hoist to prevent hoist
lowering to less than 760 mm.
 All hoist-safety devices must be operational.
 All hoist operators must be properly trained in
the correct use and inspection of the vehicle
hoist.

ii Hydraulic jacks and trolley Same as vehicle hoist inspection.

jacks use.
iii Vehicle ramps and stands  Vehicle ramps and stands are to be marked with
rated capacities.
 Inspections of the vehicle ramp and stands are to
be undertaken.
 Pre-operation inspections are to be done daily.
 Routine inspection and maintenance are to be
done at least once every 3 months.

 Annual inspections are to be conducted.

The results of all inspections, servicing and
maintenance are to be recorded in a log book
and made available to people using the
equipment.
27
  Vehicles on ramps are to be secured in such a
way to prevent movement.
iv Tag out/lock out system All hoists, trolley jack, stands and ramps that are found to
be unsafe are immediately removed from service.

28
Name: _______________________________________ Date: ___________________________
Year and Course: ______________________________ _Score: __________________________

Formative 4: Workshop Practice

1. Define Automobile repair shop?

2. Define hazard in the shop?

3. List down the different Hazards when working with vehicles in the Roadside?

4. List down the different Hazards When working with vehicles in the workshop

5. List down the different Hazards When Working with Lifting Equipment.

Name: _____________________________________ Date: ___________________________

Year and Course: ____________________________ Score: __________________________

29
 SUMMATIVE EXAM ON AT 201
( SHOP MANAGEMENT)

TEST I: Multiple choice

DIRECTION: Choose the correct answer and write the letter on the space provided for before
the number.

_____1. This are the most efficient source of artificial lights.

a. Filament lamps c. Fluorescent lamps
b. Incandescent lamps d. Mercury vapor lamps
_____2. It refers to a large storage point for supplies?
a. Yard c. Shop
b. Depot d. Warehouse
_____3. What kind of fleet transport that is commonly owned and operated by the
manufacturers.
a. Public for hire fleets c. Passenger transport fleet
b. Private or Proprietary d. Private use transport fleet
_____4. What division is classified to keep the production and handling equipment in
satisfactory often.
a. Records and Supply division c. Transportation division
b. Plan Machinery division d. Building and Facilities
_____5. What type of maintenance shop which services a number of vehicles used for
transporting people and commodities?
a. Fleet maintenance shop c. Heavy equipment maintenance yard
b. Industrial maintenance shop d. Fuel injection calibration shop

TEST II: Enumeration

List at least 5 private companies in the country which maintain their own motor pool.
1.
2.
3.
4.
5.
Give the 3 passenger transport fleet.
6.
7.
8.
What are the 3 kinds of commodity transport?
9.
10.
11.
What are the main objectives of a Proprietary fleets.
12.
13.
14.

30
15.
Give the 6 different types of roof structures of shop buildings.
16.
17.
18.
19.
20.
21.
What are the common types of construction materials?
22.
23.
24.
25.
26.
27.
Give the correct sequence of engine rebuilding.
28. 39.
29. 40.
30. 41.
31. 42.
32. 43.
33. 44.
34. 45.
35. 46.
36. 47.
37. 48.
38. 1 49.
Give the complete word to this abbreviated letters.
50. AERA=

TEST III. Essay ( Use at the back portion in answering)

1. What are the factors to consider in selecting construction materials for the shops?

2. IF you are working in an incline space or uphill road, What precautionary measures you should
do and what preventive measures will you apply?

TEST IV. Drawing (Use additional sheets for the drawing)

1. Prepare a shop layout of any of the following types of shop.

2. Draw a common building designs which are applicable for Equipment maintenance yard.

31