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.

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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:

 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 follows-

1. BH205E-AC
2. BH150E
3. BH100
4. BH60
5. BH40
6. BH35-2

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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

1. BWS28-2 WATER SPRINKLER

 Salient features :
 Flywheel power (net) : 280 kW (375 hp) @ 2100 rpm
 Capacity: 28,000 litres.

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  Top performance, enhanced productivity, increased reliability,
serviceability, exceptional maneuverability.
 Superior Operating Comfort Improvement.

fig.02

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
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  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.
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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

 Welding Fabrication and Associated Facilities

 Electrical resistance Foil Roll butt machines.

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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

 This department is responsible for production control.

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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

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.
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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.

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.

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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

 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.

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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.

 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.
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  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.

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 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

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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

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
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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

19. Final Testing

There are several steps followed in testing process
 Oil charging
 Test bed
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  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.
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  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

 Equipment sales
 Service
 Spare parts
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  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,

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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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