Neeraj Karmarkar completed a 2-month internship at Mercedes Benz India's paint shop department. During the internship, he learned about the various stages of the painting process, studied the company's control systems, and completed 5 technical projects. This included designing a fixture, simulating oven curves, analyzing air leakage, examining defects, and creating an induction presentation. The internship provided valuable exposure to Mercedes Benz's production operations and processes.

1. 1
Internship Report at Mercedes Benz India
Pvt. Ltd.
By: - Neeraj.S.Karmarkar (PT00938)
Duration: - 17th Nov 2014-10th Jan 2015
Department: - Paint Shop

2. 2
CERTIFICATE
This is to certify that Mr.Neeraj.S.Karmarkar of SKNCOE,Pune-41 has successfully
completed his Industrial training at MB India Pvt. Ltd. From 17th Nov 2014-10th Jan 2015
Dr.A.P.Pandhare
Head of Dept. of Mech Engg.
SKNCOE, Pune-41

3. 3
ACKNOWLEDGEMENTS
First of all, I would like to thank Dr. Mr. A.P.Pandhare the HOD of the department of Mechanical
Engineering(SKNCOE,Pune) for giving me this opportunity of industrial training in Mercedes-Benz
India Limited.
I would like to extend my gratitude towards Mr. Umesh Deshpande, General Manager,Paint Shop for
his continuous support and help. I would like to thank Mr. M.P.Kulkarni, Mr. Prashanth Divakara, Mr.
Ashok Chorghe, Mr. Nityanand Chauhan,Mr. Sambhaji Godase and Mr. Ajay Galagali for guiding me in
various projects. I would also like to thank all the blue collar employees in the Paint Shop who taught
me so much.
In addition to this, I would like to thank Mr. George Thomas from the Production department and , Ms.
Swati More from the HR department.
I would also like to thank my friends, family and all others who were directly or indirectly related to
the successful completion of my training project in Mercedes-Benz India Limited.

4. 4
INDEX
Sr No. Title Page No.
1 Abstract 5
2 Paint Shop Overview 6
3 Study of Control Systems 9
4 Paint Laboratory 10
5 Projects Completed 11
6 Conclusion 13
7 References 14

5. 5
Abstract
A 2 month internship was done at Mercedes Benz Pvt. Ltd at Chakan,Pune.
The main objective of this training was enhancement of technical knowledge and the “know-
how” of all the processes in the company paint shop. The work profile included a 7 day
induction program, documentation & technical projects assigned. This kind of exposure
certainly helped me get in touch with a lot of different aspects fromdifferent departments.
A total of 5 projects and daily assignments were completed successfully during the two-month
internship period.

6. 6
MB India Pvt. Ltd. Paint Shop
The CKD models namely the C,E & S-Class are pre-treated and painted in this
department.
Stages in the Paint Shop:
 Stage 1: BIW Loading: The body is received in the Paint Shop at BIW loading. BIW
stands for “Body in White”.
 Stage 2: PTED: Pre-Treatment and Electro-Deposition: Wherein the cab is dipped in
chemicals and rinsed with water in separate tanks for removal of oil that is already
present on the cab. After this, the cab is made to go through the oven.
 Stage 3: Metal Repair: All minor metal dents in the cars are removed at this station.
 Stage 4: Sealant Application: It has two stations wherein sealant application is done
on the underbody and on the roof. Sealant is applied so that no gaps are formed after
the remaining parts are fitted on the car. The cab is then passed though the oven
where the sealant is hardened.
 Stage 5: Audit Sealer: On this station, the cab is checked thoroughly for proper sealant
application, to check whether any bead is missing as this could prove hazardous
afterwards
 Stage 6: Primer Preparation: Sanding is carried out on the outer surface of the cab
before primer application. Sanding removes foreign particles on surfaces to make
them smooth
 Stage 7: Topcoat Preparation: Sanding is carried out on the outer surface of the cab
before topcoat application. Sanding removes foreign particles on surfaces to make
them smooth
 Stage 8: Topcoat Application: The final coat that is the topcoat is applied (robotic) and
the cab goes through the oven for the last time where the recently applied coat gets
hardened.
 Stage 9: Polishing: Polishing is done on the outer surface of the cab for gloss finish
and to remove pitting. Pitting are small pores on the cab which occur during pre-
treatment.
 Stage 10: Spot-repair: The cab is sent to Spot Repair station if any major defects are
observed.

7. 7
 Stage 11: Waxing: Waxing is done on all the internal parts of the car using special
fixtures and annexures to prevent contact with external factors such as water which
maybe encountered later leading to rusting of internal parts.
After waxing, the cab is taken back to the assembly line where the rest of the assembly
takes place.
All the movement of the cab inside the Paint Shop is maneuvered by using conveyer
belts.
After all the fitments of the car are made in the body shop the cab is brought in the
Paint Shop and after coming out of the Paint Shop, the cab is again brought in the assembly
line for engine fitments and further tests.
Each station has a MSDS sheet (Material Safety Data Sheet) where all types of safety
equipment, measures to be taken in case of emergencies are present.
An air blower is situated at the entrance to remove the dust particles from the body of
the visitor.
Only CKD models are painted at MB India plant.
CKD stands for Completely knocked down where each and every spare part is
imported from Germany and the entire assembly is done in the plant.
Painting of only such models takes place.
There are other two types: SKD and CBU
SKD means Semi-knocked down that is some of the assembly of parts are imported
and the rest of the assembly is done in the plant.
CBU means Completely Built-up unit that is the entire car is imported into the
country.
Painting of SKD and CBU models is not required.
The Paint Shop in MBIL has 3 levels/floors namely “7.5 meter”, “3.5 Meter”, “0 Meter”. The
cab

8. 8
Metal
Repair
BIW (Body
inWhite)
PT-ED Line Sealant
Application
Sealant
Oven
Top Coat
Oven
Primer
Preparation
Audit
Sealer
Top Coat
Application
Top Coat
Preparation
Primer
Oven
Assembly
Line
WaxingPolishing
SpotRepair

9. 9
Study of Control Systems
There are four types of Control Systems:
 Control System 1: It comprises of a team of workers that actually work on the stations
in the Paint Shop. They work on 100% of the vehicles that come on their stations
 Control System 2: This system comprises of a team that overlooks the work of Control
System 1. This is done to ensure that all the necessary operations are carried out by
CS1. They also examine 100% of the cabs on stations
 Control System 3: It comprises of a team that overlooks the job of the Control System 2
team. Random vehicles are selected for examination of faults and thus this team does
not work on all the vehicles
 Control System 4: Their team has a similar task of overlooking the job of the CS3 team.
Random cabs from the final station are picked for inspection. The number of cabs that
they examine is much less as compared to CS2 or CS1.
In case any type of fault is encountered, that fault is entered into record into the job card for
that particular vehicle.
This job card is attached to every vehicle and is useful for vehicle tracking at each station.
The faults that are encountered have been classified into 4 types graded as FK#(Fault Klasse)
FK stands for failure class.
The checking of surface finish is done by using Bykmac instruments.

10. 10
MB Paint Laboratory
The Paint lab is an intermediate medium in between the supplier and the customers. If any
new paint is to be introduced in the market initially testing is done on panels in the Paint
laboratory.
Various instruments like BYK-MAC are used to check parameters like “Shade
Difference”, “Long Wave-Short Wave”, and “Dry Film Thickness” of all cabs.
All the parameters have a certain range of tolerance specified. It is ensured that the measured
parameters are within the specified range. If not; corrective actions are taken.
The Intensity of light at every station is to be maintained. This intensity is tested by a using
Lux-Meter available in the lab.

11. 11
Projects Completed
1. Assignment 1:-
Fixture Design
Purpose of Project: - The main aim of this project was to design a fixture for trunk of cabs.
2. Assignment 2:-
Simulation of Oven Curves.
Purpose of Project: - The main objective of this project was to simulate the main oven curve
with the oven curve in the paint-lab.
3. Assignment 3:-
Air Leakage Analysis.
Purpose of Project: - To reduce the overall consumption of Air.
Solution: - Arresting of all leak points with proper assistance of Maintenance Dept.

12. 12
4. Assignment 4:-
Analysis of missed defects at Control System 2 (CS2) in Polishing Department.
Purpose of Project: - The Main Aim of this project was to offer a Zero Defect Vehicle during
Audit at “Q” Gate.
5. Assignment 5:-
Making a PowerPoint Presentation of Induction of Paint-Shop.
Purpose of Project: - This presentation includes all the details of the Paint-Shop. This will
help any visitor to get an idea about the Paint-Shop at a glance.
Assignments also included daily activities like taking Gas readings, monitoring of KPI charts,
preparing scatter diagrams in the Paint Lab etc.

13. 13
CONCLUSION
The main purpose of the training program was to gain maximum knowledge by working as an
intern in the paint shop division within the Operations department.
The overall experience in the company was absolutely terrific judging from the amount of
knowledge that was gained during the course of two months.
Being in the production department, interaction with staff, interaction with operators,
management skills, various training programs were made aware of in due course of time.
The two months spent in the Paint Shop was a totally different experience as different types of
processes, work equipment, safety items, safety measures, mechanisms, robotic use in
painting, procedures followed at each station, work carried out on each station were made
known.
Having been a part of production department, the exposure received from the training in
Mercedes-Benz India Limited is sure to help me in my future career.

14. 14
REFERENCES
1. www.mercedes-benz.co.in
2. Daimler Work Instruction.