DAEWOO PAKISTAN EXPRESS BUS SERVICE LTDb

W/SHOP BRIEF SUNDER ENGINEERING COMPLEX

DAEWOO PAKISTAN EXPRESS BUS SERVICE LTD

INTRODUCTION

Sunder Engineering Complex was acquired by DAEWOO Pakistan Ltd in July 2010 from VOLVO Pakistan Ltd which used it as their important w/shop unit. Since then it has been serving as the head office of all site w/shops of Daewoo Pakistan. In May 2014, it started working as a separate administrative entity.All types of buses maintenance including complete mechanical and body work is being carried out here.

ORGANIZATIONAL CHART

MANPOWER STATUS

MANPOWER STATUS

MANPOWER STATUS

MAINTENANCE DEPARTMENT

Mechanical Section Body and Paint Section Quality Assurance Section

MECHANICAL SECTION

Periodic Maintenance Engine Shop Transmission & Differential Repair Work Electric Shop AC Shop A/V Shop Machine Shop Radiator Shop Winding Shop

PERIODIC MAINTENANCE

Rather than reactive maintenance - "Fail and Fix" - we have more focus on perfective maintenance "Predict and Prevent" maintenance approach. It normally includes:

Docking Service Periodic Service

DOCKING SERVICE

Docking service is the type of preventive maintenance, in which all the interior & exterior parts (excluding body repair) of the busses are checked / serviced under the observation of w/shop in-charge/ supervisor.

Interval: 100,000 Km No. of Days Required: 4 No. of Mechanics Inducted: 4

DOCKING SHOP

MAJOR PARTS SERVICE/ REPAIR

Major and costly items/ parts are repaired/ serviced in mechanic shop and are reused in buses. These parts include:

Air Compressor Clutch Mini Pack Pump Engine Oil ENT Door Jack Fuel Feed Pump Injection Nozzles Pressure Plate Turbo Charger Water Pump

PERIODIC SERVICE

Various items/ parts (filters, oils etc.) are replaced after specific interval/ mileage prescribed by the manufacturer. It comprises of the following :

15,000 Km Service 30,000 Km Service 50,000 Km Service 100,000 Km Service

ENGINE SHOP

Engine overhauling of the buses and LTVs (operated at different sections of Daewoo Operation) is carried out on need base when any of the following problems/ failures are observed:

Engine Blow By Coolant Pressurized Engine Abnormal Sound Engine Seized/ Block Broken

TRANSMISSION & DIFFERENTIAL REPAIR WORK

Apart from engine, other major assemblies are also repaired in mechanic shop. These include:

Transmission Repair Differential Repair

ELECTRIC SHOP

MAJOR PARTS SERVICE/ REPAIR:Major and costly items/ parts are repaired/ serviced in electric shop and are reused in buses. These parts include:

Alternator Service Starter Motor Repair Auto Timer Speedometer

AC SHOP

MAJOR PARTS SERVICE/ REPAIR:Major and costly items/ parts are repaired/ serviced in AC shop and are reused in buses. These parts include:

AC Compressor Condenser Motors Blower Motors Hot & Cold Cabinet AC Unit/ Plant Service

A/V SHOP

MAJOR PARTS SERVICE/ REPAIR:Major and costly items/ parts are repaired/ serviced in A/V shop and are reused in buses. These parts include:

Selector Switches Inverters DVR LCD Preparation of New Amplifier

BODY & PAINT SECTION

In this section, all the body related maintenance/ repair of the buses is performed. It comprises of the following shops:

Body Shop Paint Shop Upholstery Shop Fabrication Shop

BODY SHOP

Body work of buses is performed in this shop in 2 ways:

Planned Body Renovation Major Body Patch Work Minor Body Patch Work

Unplanned/ Occasional Minor Accident Repair Major Accident Repair

BODY SHOP

BODY RENOVATIONThe process of Body Renovation at body shop includes following 9 steps:

1. Assessing the Need for Body Renovation2. Dispatching /Dismantling3. Structure Making4. Primer Work (Red Oxide)5. Outer Panel Sheets & Bumpers Fitting6. Paint Work7. Fitting Work8. Electric & AC Work9. Cleaning & Final Inspection

MAJOR BODY PATCH WORK

If any of the following operations is performed on the bus, it will be referred to as ‘‘Major Body Patch Work’’:

Dismantling Outside panel sheets (Either one or both) Dismantling all the Luggage Doors Complete Floor Dismantling/ Repairing Complete Paint Work Complete Roof Repairing

MINOR BODY PATCH WORK

If both of the following 2 conditions or 2nd condition is fulfilled, it will be referred to as ‘‘Minor Body Patch Work’’

1) Repairing of bus is completed within 7 days2) Only minor operation (other than the afore-mentioned

5 operations) is performed e.g. Minor dents removing Minor paint work (from where it is chipped off) Interior work like floor mat change (from where it is

necessary) Seat poshish change (from where it is necessary) etc.

ACCIDENT REPAIR

In the enormous fleet and countrywide operation, buses occasionally meet with accidents. Accident repair is also carried out at SDR w/shop. It involves:

Minor Accident Repair Window Glass/ Wind Shield Replacement Bumper Repair/ Replacement Minor Dents Repair/ Paint Work

Major Accident Repair

PAINT SHOP

Paint work is carried out after performing body repair of a bus. Paint work is performed during following operations:

Body Renovation Body Patch Work Accident Repair Miscellaneous Items Paint Work

Dash Board Hot & Cold Cabinet Wheel Rims Passenger Seats & Arms

PAINT SHOP

UPHOLSTERY SHOP

Upholstery work is performed in order to furnish the interior portion of the bus. It involves the sewing and fitting of following items:

Passenger Seats Upholstery Headphone Bags Curtains Floor Mat Pillows (KT Cover and Net) Seat Back Covers

FABRICATION SHOP

Some items/ parts in the bus are fiber-made. These items are fabricated in this shop using the parts-dies, fiber and necessary resins. It includes:

Bumper Making FRT Show Grill Engine Door Console Making AC Roof Set Making

FABRICATION SHOP

QUALITY ASSURANCE SECTION

Quality assurance section is meant for 2 basic jobs:

Quality Repair Work Quality of parts being used in the buses

It performs its jobs in following ways:

Checking of Bus on Arrival & Dispatch from SDR New Parts Quality Assurance Old Parts Quality Checking Road Test of Repaired Vehicle