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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:
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1. BH205E-AC REAR DUMP TRUCK
Salient Features :
Performance: High power diesel Cummins / MTU engine and world
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.
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Fig.01
WATER SPRINKLERS
1. BWS28-2
2. BWS70
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Top performance, enhanced productivity, increased reliability,
serviceability, exceptional maneuverability.
Superior Operating Comfort Improvement.
fig.02
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.
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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.
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
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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.
fig.03
4. Light Assembly Shop
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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
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fig.04
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
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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.
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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. Cross-
functional 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
8. Tool Engineering
This department comes under engineering services.
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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.
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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
fig.05
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
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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,
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workers unload the container and the items are now dispatched and
assembled in the destination place.
12. Service
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.
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Moving the finished components between shops
as per routing.
Informing about the storage items to the
purchase.
Material and job accounting through system.
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15. Purchase/Out Sourcing
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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
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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.
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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.
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fig.06
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
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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
Air cleaner and connector
Fuel, oil filter and hoses
Tension pulley and ALT mounting
Fan case and belt mounting
Marketing
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,
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MYSURU for providing an opportunity to visit such an esteemed
organization.
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Thank you
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