Internship Report on Beml

INTERNSHIP REPORT ON BEML, MYSURU

Submitted by: Aishwarya Pradhani – 4GW13EC002 Asha Patil – 4GW13CS017 Keerthi.R – 4GW13EE021

Geetha Shishu Shikshana Sanga Institute of Engineering and Technology for Women, Mysuru. January 2016

Contents: 1. Introduction 2. Equipment division3. Machine shop 4. Plate shop 5. Fabrication shop 6. Light assembly shop 7. Major assembly shop 8. Progress 9. Quality engineering 10. Tool engineering 11. Manufacturing engineering services 12. Stores 13. Shipping 14. Service 15. Planning 16. R&D department 17. Purchase/Out sourcing 18. Plant Maintenance 19. Engine division20. Machine shop 21. Assembly shop 22. Final testing 23. Float engines 24. Design & Development 25. Marketing26. Spare parts 27. Conclusion

Introduction

BEML Limited (formerly Bharat Earth Movers Limited) was established in May 1964 as a Public Sector Undertaking for manufacture of Rail Coaches & Spare Parts and Mining Equipment at its Bangalore Complex. The Company has partially disinvested and presently Government of India owns 54 percent of total equity and rest 46 percent is held by Public, Financial Institutions, Foreign Institutional Investors, Banks and Employees. The company has 9 manufacturing units spread over the following locations: 1.Kolar Gold Fields (KGF) Complex (around 100 Km from Bangalore) Earth Moving Division, Rail Coach Unit II, Heavy Fabrication Unit and Hydraulic & Powerline Division. 2. Mysore Complex (around 130 Km from Bangalore) Truck Division and Engine Division. 3. Bangalore Complex - Rail & Metro Division, Palakkad Complex and Vignyan Industries, a subsidiary located at Tarikere (around 300 km from Bangalore) Steel Castings. BEML's nationwide network of sales offices enables buyers with ready access to its wide range of products. Also, the full-fledged service centers and parts depots offer total equipment care, maintenance contracts and rehabilitation services. The Company has drawn up VISION – 2013 with an ambitious growth rate of 12% CAGR for crossing Rs.5,000 Cr turnovers by 2013-14 coinciding with BEML’s Golden Jubilee year. With this emerging prospects, BEML has plans to cross Rs.5,000 Cr in the next 2 years and is poised to achieve Rs.10,000 Cr mark by 2016-17 and the company is gearing up with necessary infrastructure for achieving the same.

Equipment division

1. Machine shop Truck Division at Mysuru, located around 130 Kms from Bangalore, was established in 1986 with a total area of 600 acres. Asia’s biggest Dump Truck Factory in India is located at Truck Division, Mysuru. The products manufactured at Truck Division are:  Mining & Construction  Dump Trucks (Mechanical Drive)  Dump Trucks (Electrical Drive)  Water Sprinkler  Motor Grader  Defence  Tatra 6x6 (Euro II)  Air Craft Weapon Loader  Others  Air Craft Towing Tractor  Air Craft Towing Tractor with Ground Power Unit Various dump trucks are as follows1. BH205E-AC 2. BH150E 3. BH100 4. BH60 5. BH40 6. BH35-2

1. BH205E-AC REAR DUMP TRUCK

 Salient Features :  Performance: High power diesel Cummins / MTU engine and world     

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renowed General Electric for electric drive provide smooth consistent gradeability and acceleration performance. Productivity: High power to weight ratio gives ample reserve power for increased engine life. More target area, higher volumetric capacity and a low loading height ensures high productivity. Reliability: Diesel-electric power modules with few wearing parts offer more durability and high availability. Serviceability: Low maintainability and repairability index makes easy serviceability. Maneuverability: Power steering with wide steering angle, results in short turning radius. Comfort: Ideally located spacious deluxe cabin, easy to read and easy to reach instrument panel and operation switches, large tinted glass windows with excellent visibility for increased operator's comfort. Safety: Features include emergency power steering, electrical dynamic retarding with continuously rated blown grids and all hydraulic caliper disc brakes meet relevant safety standard.

WATER SPRINKLERS 1. BWS28-2 2. BWS70

1. BWS28-2 WATER SPRINKLER  Salient features :  Flywheel power (net) : 280 kW (375 hp) @ 2100 rpm  Capacity: 28,000 litres.  Top performance, enhanced productivity, increased reliability, serviceability, exceptional maneuverability.  Superior Operating Comfort Improvement.

2. BW7O WATER SPRINKLER  SALIENT FEATURES:  Flywheel power (net) : 659 kW (883 hp) @ 2050 rpm  Capacity : 70,000 Liter  Top Performance  Enhanced Productivity  Increased Reliability  Excellent Serviceability  Exceptional Maneuverability  Superior Operating Comfort  Improved Safe

2. Plate Shop All machines in plate shop are CNC controlled. Here main server is maintained where all CAED drawings are stored and then fed to particular machines. Local area network is created between the server and the fellow machines. This connection is wireless. CAED drawings are in 1:1 format and quality check (QC) is performed before actual work is started. The generated programs will be in either ISO or ESSI format and are given for four types of machines. Once work is initiated it is automatically carried on. There are 8 frame cutting, 2 sheering, 5 forming and 2 straightening machines.

 Sheet Metal    

A well-established Sheet metal shop has a band of special machines and dedicated machines: Laser cutting machine. NC shearing machine. Punch press: 40 - 1000 T Press Brake: 40 - 500T

 Material Preparation    

Optical tracer flame cutting machines CNC Flame cutting machine. Shot blasting machine for (Rolled section & Plates). Shearing M/C to 30 mm capacity with inbuilt Beveling for weld joints.

 Manufacturing Facilities The complex has large sophisticated machines such as CNC Turning Center, CNC Boring machines, Vertical Turret lathes and Honing machines in addition to General purpose machines.

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3. Fabrication Shop  Under Frame  Foil Roll welding machine for welding of corrugated sheets used for    

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Floor. Corrugated rolling machine. Plasma Cutting machine Submerged Arc welding sets. Check & straightening machine for components.

Major Assembly & Erection Shop  Robot Spot Welding Machine.  Roller bending machine for roof skins.  Foil Roll-Welding M/C for Roof, Side wall & End wall  Roof leak test facility

Pre-treatment & Painting Shop  Conveyorised painting booth.  Shot Blasting facilities for Rolled Sections and plates.  Receipt of raw materials

 Welding Fabrication and Associated Facilities  Electrical resistance Foil Roll butt machines.  Electrical resistance spot welding machine.  Flash butt welding equipment.  Pulse tig-welding machine.  Auto and semi auto submerged Arc welding.  CO2 welding sets of capacity of 400 AMPS.  Thermal stress relieving furnaces.  Radiographic and Ultrasonic tests on welded structures.

4. Light Assembly Shop  Dumper Spares: Backed ourselves with sound amenities and talented personnel, we have emerged as one of the leading firms offering Dumper Spares. These dumper spares are manufactured using top quality material & latest technology as per the se norms of industry. Furthermore, these dumper spares are well tested on various quality parameters by vendor’s experts so as to dispatch its flawlessness. Our dumper spares are available in different specifications as per the requirements of customers.

Features:  Easy installation  Less maintenance  Durable standard

 Grader: We have a spares for BEML motor graders. The product range includes spares of Engine, Transmission, Filters, Ground engaging tools like Cutting edges, End corners etc in Imported/Indian make to cater the variegated demands of our precious clients, and we are highly engrossed in providing a wide range of All Type Ball Bearings. Offered range is largely acknowledged amongst patrons for their robust designs, high strength and excellent sturdiness. These products are developed employing highest quality material in guidelines with the global market standards. These are available as per the client's demands. Moreover, these ball bearings are available at market leading rates.

Features:

 Low maintenance  Suitable for high speeds.  Rust resistant

5. Major Assembly Shop

 60ton and above dumpers, graders and water sprinklers are assembled in this shop.  For purpose of load distribution sometimes 60ton dumpers are also assembled.  Vehicles assembled are BH100, BH60M, WS70, BG605, BG405 and BG825.  There are 3 bays in this shop which are specifically reserved for dumpers, graders and water sprinklers each.  Engine, transmission and fuel tank sub assembly are set up in this shop.  Every equipment under goes 20hrs of test drive.

6.        

Progress

This department is responsible for production control. First demand is projected by marketing people based on this production planning is done. Some materials are manufactured in home environment or procured. For both purchasing is required. PR i.e. Product requisition is by production planning department. Major, light assembly, major assembly, plate, fabrication shop etc. needs raw materials which are listed and stored in stores. Keeping track of material movement between shops and giving materials to individual shops is responsibility of progress department. Job cards are printed and given to subsequent jobs. This card will have information such as, time required to complete the job, completed jobs etc. This department will deposit back issued items to the stores and also keep track of availabilities in stores.

7. Quality Engineering

BEML Limited views Quality improvement as a business strategy and hence remains proactive in the areas of product and service quality. At BEML, a Corporate Quality Policy emphasizing Total Quality Management ensures that quality system adopted results in products, services and processes that meet stringent standards and requisite performance criteria. A separate Quality Department spearheads the thrust towards Total Quality Management. All the manufacturing units of the company have been certified for ISO 9001-2008 Quality Management System (QMS). The KGF Complex, Bangalore Complex and Mysore Complex are certified for ISO 14001-2004 Environmental Management System (EMS). Also, the Bangalore Complex is certified for BS OHSAS 18001-2007 OHSAS Integrated Management system and Engine Division, Mysore complex is certified for AS9100B Aerospace certification. The manufacturing divisions are augmented with test facilities available at its R&D / Technology Division. Laboratories at R&D, KGF and Mysore Complex are accredited to National Accreditation Board for Laboratories (NABL) covering Calibration of Flow, Pressure, Torque and Mechanical Measuring Instruments. The facilities include custom made test tracks to evaluate the performance of equipment. Well established vendor base is a key strength of BEML. Vendor assessment and development is a key component of the company's strategy for achieving Total Quality. 'Quality Function Deployment' is actively pursued in the organization. Crossfunctional teams routinely visit customer sites to capture 'Voice of Customer'. Such actions have resulted in incorporating a number of product improvements to fine tune product features on both in-house developed as well as collaborated products to suit specific customer requirements and operating conditions. BEML actively promotes small group activities to encourage and enhance 'Quality Culture' at all levels. The small group activity teams regularly participate in regional / national / international level competition and have achieved

recognition as meritorious performers. It is our proud privilege to mention that our QC teams have raised the BEML flag high in the international arena by winning 'Gold Medal' in the ICQCC-2008 and 'Silver Medal' in the ICQCC-2009 competition. Quality Circle Team 'WHEEL' from EM Division, KGF Complex have been conferred with the Life Time Award as the 'LONGEST & ACTIVE QUALITY CIRCLE' by M/s. QCFI during 2010.

8. Tool Engineering  This department comes under engineering services.  Tool engineering has its under  Tool design  Manufacturing of tools  Planning  By using component drawing and process sheets, finds out work centre and then particular tool is given to concerned shop.  If required meeting is done with operators of machines for procurement of tools.  Also by this meeting they take operators views and generate the final drawing.  Tools like spanner, cutting tools etc. follow consumption based activity and consider 3years of consumption and plan.  This department uses SAP technology to maintain tool history.  They contact purchase department for re ordering or ordering of tools and to put in the stores.  Main motto of this department is to increase productivity with decrease in cost.

9. Manufacturing Engineering Services

 Mainly performs capacity planning, complex and employees planning.  There are 4 types of men employees, trainees, sub-contractors, trained casual labours who all need to be maintained.  Different incentive scheme are being provided for all these types of men.  They take decisions to procure or manufacture required raw material.  Focuses on optimum utilization of resources.  This department performs time study that is time required to complete the particular activity and also performance management system check.  Here SAP technique is used as intranet.  MIS management information system: Any data to be known by management or anybody is provided.  Money matter is put through this department for corporate.

10.

Stores

Metal Storage systems have always been the pioneer in thinking about the well being of their clients first. Thus, we rank the best in making your life organized and fulfilled and give you easy expertise in the field of storage systems. We believe that it is only with organized racking system that the work environment can be suitable. We have been the pioneers, market leaders and in top among the rung for making good storage products. Our infrastructure set up is of that good quality that you are only going to get world-class design, product management and manufacturing from us. We also offer strong sales support for the better service of all of your needs. The good point of the team that it gives individual attention and detailing to each of its client. Thus, once any requirements from client have come, our team will reach the client place understand actual requirement & restructure the plan as per the client requirement & convenience. We make sure in the end the client is very happy and satisfied with whatever they get. So be it any kind of service that you would require-right form selective pallet racking to angle shelving, we are very good in giving any and every kind of storage requirement. Thus, being an ISO certified company, you can be pretty sure that we produce only something that is intelligently made. We are also very efficient in our post sales period. Thus, after sales, we give complete storage solution according to client product. We do thoroughly understand what the client product is, thus, we thoroughly design storage solution to save our time and even space. We make sure that whatever we do it is to the convenience of the client and is done in a pocket friendly way. Being the leading Industrial Storage Rack manufacturers and Heavy-Duty Rack Manufacturers in entire south India, we have made it possible to supply out highly value added products available to each and every prestigious client. Being user-friendly racks, the products and spares which are stored in the rack has become easy to audit as it is segregated perfectly and sequentially.

11. Shipping

The first step is to select the appropriate packaging for the item that is to be shipped. Once that is done a trucking company arrives at the factory, loads the order into a container, which is bolted shut and fitted with a security seal. The container will not be opened until it reaches its destination. Customs official, armed with careful evaluation of each container’s documentation, select those containers for specific inspection. Once cleared by customs, workers unload the container and the items are now dispatched and assembled in the destination place.

12.

Service  BEML's nation-wide after-sales service network includes    

12 Regional Offices 20 District Offices 5 Service Centres 2 Activity Centres at Itanagar and Katni

Each office in the vast network, is headed by a senior level executive for product support at pit-head / on-site, for Erection & Commissioning, Maintenance, Trouble-shooting, Condition Based Monitoring (CBM), Training, Total Support for Mid-life Overhauling & Major Rehabilitation of Equipment to enhance the equipment availability & productivity. The Product support packages include Annual Maintenance Contracts (AMC), Annual Service Contracts (ASC), Maintenance and Repair Contracts (MARC) and Guaranteed Availability & Spare Consumption Contract BEML has established full-fledged 'Service Training Centres' at KGF, 90 Kms from Bengaluru, Global Service HQ - Nagpur and Mysore Complex for offering variety of programs, scheduled round-the-year.

13. Planning  Planning is important to accomplish work successfully.  It covers 8 to 9 wings.  Production Control/Progress- the nerve centre  Based on roll-out schedules loading material to the shop-floors.  Moving the finished components between shops as per routing.  Informing about the storage items to the purchase.  Material and job accounting through system.  Process/ Method planning- the “do like this” process  Determining processes for all the parts and installation.  Determining quality plan for the parts.  Identifying and projecting important tool requirements.  Estimating the requirement of consumables.  Industrial engineering & MIS-the “improvement” process  Based on master production and roll-out schedule determines the load.  Analysing shop capacities and projecting capacity gap for taking decision for additional bought-out and man-power deployment.  Establishing time for all the processes, as per norms.  Monitoring utilization of men and machines and informing to the management.  Monitoring improvement projects.  Tool planning- the “enabling” process  Provisioning of tools projected by the process planner.  Maintenance of existing tools.  Estimation and procurement planning for consumable tools.  Facilities planning- the “asset creating” process  Provisioning of necessary machinery, welfare equipment, building and pc.  Looking for up gradation or modernization of existing facilities

 Subcontracting/Outsourcing- the “let me help you” process  Assisting production shops by taking out parts for operations.  Arranging and executing work contracts.  Facilitate cost reduction throughout sourcing.

14. R&D Department  There are two major areas R&D and Product design.  This is initial step of designing and building component.  Software for designing 2D drawing auto caed is used and for 3D proE is used.  R&D concerns with  Designing new product.  Improving existing product.  Improving quality and reliability.  Cost reduction.  The output of this department is caed drawing which in turn is input for planning department.  ECN (Engineering Change Notice) will have any changes or updates to be done on product. Based on the MPR raised by the concerned project groups and approved by the Competent Authority, the Purchase group in R&D at Divisions can issue enquiries to the parties selected/identified by them only for procurement of inputs for new, R&D projects and indigenization, within the amount sanctioned by CMD/Board. However, standard items already being procured / produced by division will continue to be procured by the divisional purchase department. R&D can only go for direct purchase of new and critical items on single tender basis to expedite R&D projects.

15. Purchase/Out Sourcing  In order to build a product numbers of items are required.  These items can be either manufactured in home environment or purchased from the vendors.  Items which cannot be manufactured or if done its economically costs high have to be purchased.  MRP (Material Resource Planning) is calculated based on Bill of Material.  System with SAP technique will recreate requirements and further planning will generate PR.  After this step the actual work of purchase department starts.  Supplier Relationship Management Software (SRM) enquiry is done and bid invitation is given.  Preparatory and limited tender are called off.  All quotes by different vendors are compared and Purchase Order (PO) is sent back to approved organisation.  This PO contains list of items, delivery schedule etc.  GR is made once ordered goods are received in the gate as per delivery schedule.  As soon as GR is generated the stores is updated with arrived items.  Next quality engineering shop checks for correctness of quality and quantity.  Later distributes for required shops.  Purchase shop should follow up about materials that are needed, rejected and one which has to be re-delivered.  This department co-ordinates with planning (for PR), security (for intake of items) , finance (bill issue) , quality (checking of items).

16. Plant Maintenance  Takes care of complete maintenance of various plants such as civil, electrical, mechanical, transport etc.  Each and every shop in complex is also maintained.  In addition landscaping, housekeeping is also done.

 Maintenance is overviewed through SAP technique.  Suppliers will only help the operators to maintain and train about the supplied machinery.  Canteen is also maintained.  Brief note on maintenance responsibilities of sub sections of plant maintenance  ELECTRICAL  Common electrical service  Power system maintenance  Machine tools, welding sets, flame cutting machines and robots  Crane’s, telephone lines, AC’S  MECHANICAL  Machine tools  Air compressors  Canteen equipment such as boilers  TRANSPORTATION  Material loading  Transportation  CIVIL & LANDSCAPING  Civil construction & maintenance  Housekeeping the landscape  Water supply & sanitary  Liaoning with KIADB, BWSSB etc.  PLANNING  Supply parts for entire plant maintenance department  Liaoning with all department for timely receipt of materials  Material Information System  SAFETY  Factory safety  Liaoning with inspectors of the factory

Engine Division

17. Machine Shop  Diesel engines from 84hp to 740hp are manufactured.  There are 4 lines in this shop, each one for camshaft, conrod, cylinder head and cylinder block.  Some of the machines are manually controlled and some are CNC.  Flexible Management System is being setup in this shop  Setup should be flexible to change over palates of different series.  Huge number of tools can be loaded on machine so that it can support al series.  Rail carrier machine: for the movement of tools and components between machines/ to take tool in and out, this reduces movement time. The robot which serves this purpose is peggi.  Automatic selection of program of different series id done so that it reduces the chances of feeding wrong program.  CNC machines enable a check on blunt tool and replace it.  There are three heavy duty machinery  FMS  MAG-HMC  Line Boring Machine  CAMSHAFT LINE  Camshaft opens and closes the inlet and exhaust valves to cylinder block.  High carbon and forging boron alloy steel is raw input for preparation of camshaft.  Some of the machinery list  CNC milling machine.  Gun drilling machine.  Weight balancing.  Machine crack detector.  Fine boring machine.  Straightening machine.  Induction hardening machine.  CYLINDER BLOCK LINE  There are 4 series of cylinder 170, 140, 125,105.  These numbers indicates the bore size of cylinders.

 Cylinder block is the main body of engine which houses cylinder liner, crankshaft, and camshaft.  CYLINDER HEAD LINE  Cylinder head of diesel engine is expected to perform multiple functions.  It is critical casting which houses inlet port, outlet port, water passages.  After sub assembly it houses fuel injector, valves, valve guides, valve seats etc.  There are two types of cylinder: Split type &Mono type  MCCRMOCU casting is raw input for preparation of cylinder head.  This cylinder head is moulded on cylinder blocks.  Operations performed are milling, boring, drilling, hole milling, tapping, reaming and finally sealing of cylinder blocks.

18. Assembly Shop There are 5 stages in assembling of a engine.

 STAGE 1  Cylinder block loading  Crankshaft mounting  Piston, conrod assembly  Piston Cooling Nozzles mounting  Oil pump, suction tubes     

 STAGE 2 Gears, camshaft, front cover Damper crank pulley Cam follower cover Water pump, wire harness Oil collar, Fuel Injection Pump sub assembly  STAGE 3  Fly wheel housing  Starter fly wheel mounting  Oil pan, dipstick  Oil adopter mounting  Fuel Injection Pump & peeping  Centrifugal filter and bracket  Cylinder head assembly mounting  STAGE 4  Cross head mounting  Rocker arm housing & water pipes  Thermo housing mounting  Rocker arm sub assembly and fuel nozzle  Exhaust & intake manifold  HP lines, water bypass tube  STAGE 5  Turbo charger mounting  Cross over mounting

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Air cleaner and connector Fuel, oil filter and hoses Tension pulley and ALT mounting Fan case and belt mounting

19. Final Testing There are several steps followed in testing process  Oil charging  Test bed  Oil temperature test  Water temperature test  Oil pressure test  Water pressure test  Five minutes of engine run which detects any abnormality  Tappet setting is done  Run In: one hour running of engine where complete checking is done  By setting engine to more power and maximum torque performance testing is done  Leak test  Engine air leak test  Water leak test  Oil leak test  Diesel leak test  Painting is done.  Final assembly is done.  R&D: EPTS (Engine Performance Test Standard) will have basic standard values of a perfect engine, which has to be compared with newly built engine to check its values.  For 5minutes run, tappet setting, run in, performance test and leak test EPT standards are considered.  Once engine passes all these stages of testing it is dispatched.

20.

Float Engines

 Engines are manufactured and supplied to customers in engine division.

 Also maintenance and servicing are most important steps to be followed once engine is sold to customer.  This maintenance and servicing is done by float engine shop.  They will always have a ready assembled engine i.e. i good running condition with them.  Once customer approaches for any problem in the engine and struck in working field, immediately already assembled engine will be sent to customer.  Later the customer’s engine is serviced and sent back.

21. Design & Development            

Study and Evaluation of Technological Innovations. Up gradation of Existing Products. Development of New Products through In-House R&D. Introduction of New Products through Technology Transfer. In-House Development of Critical Hi-Tech Aggregates. Joint Development with Industries & Academic Institutions. Representing BEML in various Technology Forums. Patenting and Intellectual Property Rights (IPR) Activities. Collaborative R&D with DSIR Laboratories. Collaborative Product Development with Funding Agencies like TIFAC. Company Standardization Activities. Technology absorption and Indigenization on Tot

Marketing 22.

Spare Parts

 Mainly marketing division covers three major shops

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 Equipment sales  Service  Spare parts Spare parts division has almost 700 crore of business all over India. Around 3000 spare parts will be kept in stores and is distributed based on customer needs. If parts are under warranty then it is replaced to customer for free of cost or else done on chargeable basis. Also once spare parts are delivered to customers it is informed to particular manufacturing shop of that part requesting to put back the parts in the stores.

Conclusion We conclude that while going through the entire industrial visit, the Cooperation is found to be very well organized, developed and most ideal industry in every walk of its production, administration and management aspects. We extend our heartiest thanks to BEML,

MYSURU for providing an opportunity to visit such an esteemed organization.

Thank you