3. 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.
10. 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
11. 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
13. 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
14. 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
15. 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
16. TRANSMISSION & DIFFERENTIAL REPAIR WORK
Apart from engine, other major assemblies are also
repaired in mechanic shop. These include:
Transmission Repair
Differential Repair
17. 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
18. 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
19. 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
20. 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
21. 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
23. BODY RENOVATION
The process of Body Renovation at body shop includes
following 9 steps:
1. Assessing the Need for Body Renovation
2. Dispatching /Dismantling
3. Structure Making
4. Primer Work (Red Oxide)
5. Outer Panel Sheets & Bumpers Fitting
6. Paint Work
7. Fitting Work
8. Electric & AC Work
9. Cleaning & Final Inspection
24. 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
25. 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 days
2) 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.
26. 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
27. 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
29. 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
30. 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
32. 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
