Académique Documents
Professionnel Documents
Culture Documents
BEML, MYSURU
Submitted by:
Aishwarya Pradhani 4GW13EC002
Asha Patil 4GW13CS017
Keerthi.R 4GW13EE021
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
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. Asias 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
Salient Features :
Performance: High power diesel Cummins / MTU engine and world
WATER SPRINKLERS
1. BWS28-2
2. BWS70
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
Material Preparation
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.
3. Fabrication Shop
Under Frame
Foil Roll welding machine for welding of corrugated sheets used for
Floor.
Corrugated rolling machine.
Plasma Cutting machine
Submerged Arc welding sets.
Check & straightening machine for components.
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
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
7. Quality Engineering
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.
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 containers 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
Engine Division
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.
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
20.
Float Engines
Marketing
22.
Spare Parts
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,
Thank you