Introduction About Internship Industry Profile

BEML INTERNSHIP REPORT 2019-2020
INTRODUCTION ABOUT INTERNSHIP
INDUSTRY PROFILE
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.
4. Palakkad Complex - Manufacturer of Defence & Rail products & The green field project
at BEML LIMITED , Kinfra Park, Menon Para Road , Kanjikode East , Palakkad
-678621, Kerala , India.
BEML's nationwide network of sales offices enables buyers with ready access to its wide
range of products. Also, the full-fledged service centres 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.
Department of ECE, VVIET, Mysuru Page 1

Mysore BEML Complex is divided into different divisions
Equipment division :
Machine shop
Plate shop
Fabrication shop
Light assembly shop
Major assembly shop
Progress
Quality engineering
Tool engineering
Manufacturing engineering services
Stores
Shipping
Service
Planning
R&D department
Purchase
Out sourcing
Plant Maintenance
Dredging
Engine division :
Machine shop
Assembly shop
Final testing
Float engines
Purchase
Stores
Quality engineering
Marketing Division:
Spare parts
The overall objectives of the study:
 To study the organization structure.

 To know about its products and service activities.
 To know the different functions of all the departments.
 To know the responsibilities of the top management and how to execute responsibility
in a competitive economy.
 To analyze the organization using SWOT analysis.
 To familiarize with the different departments in the organization and their functions and
activities including documentation.
 To understand how the information is used in organization for decision making at

various levels.
 To understand how the key business processes are carried out in an organization.
 To understand the growth and diversification strategies, portfolio structure of the

organization.
 To study the overall performance of the organization.
EQUIPMENT DIVISION
MACHINE SHOP
Truck Division or Equipment 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.
Here machines like CNC machines, manually handed, radial/horizontal lathe
machines, torrent machines are used for performing different operations for making different
products.
The products manufactured at Truck Division are:
 Mining & Construction :
 Dump Trucks (Mechanical Drive)

 Dump Trucks (Electrical Drive)
 Water Sprinkler
 Motor Graders :
 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 -

 BH205E-AC
 BH150E
 BH100
 BH60
 BH40
 BH35-2
BH205E-AC REAR DUMP TRUCK (Electrical Drive)
Salient Features :
 Performance: High power diesel Cummins / MTU engine and world renowned
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.
BH35-2 REAR DUMP TRUCK (Mechanical Drive) –

Salient features:
Travel speed : 50km/h

Steering Type: Orbital, full time power steering
Frame: box section construction made of high tensile strength steel.
Type: IC-diesel, 4-stroke turbo charged, after cooled,direct injection, watercooled for
Cummins Make and for BEML Make, IC-diesel, 4-stroke, turbo charged,direct
injection,water cooled
No of cylinders: 6line
Fly wheel power: 280kw (375hp) at 2100 rpm
Maximum Torque: 1627N-m(166kg-m) at 1400rpm
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.

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 Safety
MOTOR GRADER :

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.
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.

 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.
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
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.
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.
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. 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.
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.
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.
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.
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.
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.
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
 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.
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.
Purchase and 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).

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.
DREDGING :
Dredging is the operation of removing material from one part of the water
environment and relocating it to another.
In all but a few situations the excavation is undertaken by specialist floating plant, known as
a ‘dredger’. The main objectives of carrying out dredging are usually to recover material that
has some value or use or to create a greater depth of water.
Dredgers are often equipped with dredge monitoring software to help the
dredge operator position the dredger and monitor the current dredge level. The monitoring
software often uses Real Time Kinematic satellite navigation to accurately record where the
machine has been operating and to what depth the machine has dredged to.
ENGINE DIVISION :
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 supportal series.
 Rail carrier machine: for the movement of tools and components between the
machines or to take tool in and out , this inturn reduces the 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

Assembly Shop :
There are 5 stages in assembling of a engine , they are :
 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
 Air cleaner and connector
 Fuel, oil filter and hoses
 Tension pulley and ALT mounting
 Fan case and belt mounting
Final Testing :
There are several steps to be followed in the testing process & they are as follows :
 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
 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
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.
Purchase :
The purchase of the materials in the engine division is same as the processes
or the formal procedures that are carried out in the equipment or the truck division
while purchasing the materials.
The process starts with the purchase request (PR) and it will be continued with either
one of the usual three kinds of tendors and preferably L1 ( L2 is selected in few
cases) is chosen.
And SAP , a German software is utilized for the proceedings.
Stores :
The store in the engine division is similar to the truck division but in addition
there is a HOLDING STORES which is a high racking system to store the materials
at the required locations for the easy accessibility .
Quality Engineering :
The functions and the visions of this department are very similar to the
functions that are taken care by the quality engineering department of the truck
division .
MARKETING DIVISION
Spare Parts :
 Mainly marketing division covers three major shops and they are :
 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 then the particular
manufacturing shop of that part requesting to put back the parts in the stores with the
HIGH RACKS SYSTEM .
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
Electronic safety devices that are mounted on the vehicles to make them more
able to work in the extreme environment conditions
 ABS Brake sensor system –

For extreme gradients – Retardation Mechanism , slowly the brake will be applied to
the vehicle as the AC relay operates & decreases the RPM to help it not to move from
its place even with the heavier payloads on it .
 Auto Dipper –
The light from the opposite vehicle will be sensed and the lights of the vehicle dims
or dips automatically with the help of photocells .
For efficient use of this mechanism , the other vehicles should also have the same
state of provisions .
 Auto Loop system –

Grease and anti - friction system ~ The heat generated within the vehicle will reduce
the greasing action & increases the friction so this system is used to periodically
grease the system automatically and to increase the performance of the vehicle .
 Central Alarming ( Buzzer ) –

Any kind of failure in the vehicle will be detected & a cautioning alarm will ring and
brings the error to the driver’s notice . As the error will be displayed on the display
unit or a particular Led will glow so it will be very easy for the driver to understand
the problem & get through .

 Auto Fire Protection System –
There will be a Electronic control unit ( ECU ) and a Solenoid mainly near the engine
which will be surrounded by hose pipes and twisted wires . When there is fire , these
twisted wires will melt and a signal will be sent by the ECU to the controlling unit in
the cabin . Then a 24V signal will be sent to the solenoid & it will demagnetise and
the anti – fire powder will be sprinkled over the fire catch areas and the engine will be
cut down .
 Anti - Collision system –

In order to avoid the accidents this system has been provided.
It can work efficiently between the distance range of 1m to 5m .
Here Potentiometer is used for Sensing the other objects within that specific distance
range .
 Fog Lights provision
 Inter locking using weight sensor

Driver bord the vehicle but forgets to lock the cabin but this sensor moniter the driver
seat and atomatically locks the cabin
 Controlling Unit using Relays in the Driver Cabin –

Many Electronically controlled displays and switches are provided in the cabin for
the ease of the driver work .
 Proximity sensor alarming ( Magnetic ) –

Hall effect position sensors are non-contact devices that convert energy from a
magnetic field into an electrical signal .They use the Hall effect , a voltage caused by
current flow in the presence of a magnetic field i.e, when a metal blocks the path of
this sensor ,the required sensing & alarming action will happen to aid the desired
tasks .
 Magnetic Pickup ( Level Sensor – A 9V AC Relay ) –

The vehicle body or the bucket while unloading ,once reaches its extreme end ,this
sensor cautions the driver to stop the unloading since it has reached it maximum .
 Front And Rear cameras –

Since the vehicles are heavy vehicles ,these cameras will help the driver to operate
safely .
 Display Units ( with the aid of Microprocessors ) in the Cabin-

Provision of camera displays and even the displays to show the errors or the failures
in the vehicle.
 Led Indicators in the Cabin
 Pressure sensor
 Heat sensor
 Digital Barometer
During testing of the engine the engine as to work in all atmospheric condition as a result
the atmospheric pressure is checked using barometer and altered based on the pre defined
chart.
 ETS[energies to stop]
This sensor is are commonly connected to desele supply and oil temperature sensor and
water temperature sensor. There is a defined set rpm, when rpm is greater or the oil or
water temperature rises above the threshold ETS get activated and it partially cuts off the
fuel for every 100m to make the vehicle to stop instead of stopping the vehicle at once
and causing the damage to the engine due to over heating so it can be rectified.
 Tachometer
Normally engines are serviced one the pre defined kilometers are completed but in
BEML service is given to its engines based on number of hours the engine has worked
.Initial free service is done once 60,000 hours by BEML. The time is calculated using
tachometer.
 Speed Sensor
 Fuel indication sensor
 Emergency Steering System –

Coupled with Electric motor & pump to pump the hydraulic oil to the steering in the
case of emergencies , it can work upto 90 seconds .
 Payload Monitoring System –

Measurement of payload is done using the 4 pressure sensors mounted on different
places of the vehicle’s body. When the load goes behound the limit current varies
with the load and a caution led will glow if it exceeds the limit. PLMS - It can
record Up to 3000 Events i.e, Record of the vehicle performance history .
MAIN RECEIVING STATION ( MRS ) :

 A MAIN RECEIVING STATION is a part of an electrical generation

, transmission, and distribution system. Stations transform voltage from high to low
or the reverse or perform any of the several other important functions.
 Between the generating station and consumer, electric power may flow through
several substations at different voltage levels. A substation includes transformers to
change the voltage levels between high transmission voltages and lower distribution
voltages, or at the interconnection of two different transmission voltages.
 As central generation stations became larger, smaller generating plants were

converted to distribution stations,
receiving their energy supply from a larger plant instead of using their own generators. The
first substations were connected to only one power station, where the generators were
housed, and were subsidiaries of that power station.
Elements of a substation :
A: Primary power lines' side

B: Secondary power lines' side
1. Primary power lines
2. Ground wire
3. Overhead lines

4. Transformer for measurement of electric voltage
5. Disconnect switch
6. Circuit breaker
7. Current transformer
8. Lightning arrester
9. Main transformer
10. Control building
11. Security fence
12. Secondary power line
 At the BEML organization , the Main Receiving Station receives the 3 phase 66 KV
from the Mains - SRS power station and it is stepped down twice using the 66
KV/11 KV and 11 KV/440 V transformers respectively at the station .
 The consumption of the power in the organization is around 3.5 lakh units.
 Here through tapping , the 3 phase 440 V is used for the machinery working at the
different assembly substations and the single phase 230 V is used for lightning
purposes .
 The transformers have SF6 as the isolator to avoid the arcs , Vaccum circuit breaker ,
OLPC , Silica gel as the Breather , main tank , conservator , oil and temperature
gauge , cooling Radiators , Relays , Bus bars ,failure alarming systems ,…etc
 In order to reduce the Lag angle , the capacitors are utilized such that the possible
power conservation can be carried out .
CONCLUSION :

THANK YOU

Introduction About Internship Industry Profile

Uploaded by

Copyright:

Available Formats

Introduction About Internship Industry Profile

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Introduction About Internship Industry Profile

Uploaded by

Copyright:

Available Formats

What are the main products and services of BEML?

What are the main products and services of BEML?

What are the different divisions within BEML and their functions?

What are the different divisions within BEML and their functions?

BEML INTERNSHIP REPORT 2019-2020

INTRODUCTION ABOUT INTERNSHIP

The company has 9 manufacturing units spread over the following

Department of ECE, VVIET, Mysuru Page 1

The overall objectives of the study:

 To study the organization structure.

Department of ECE, VVIET, Mysuru Page 2

 To know the different functions of all the departments.

 To analyze the organization using SWOT analysis.

 To understand how the information is used in organization for decision making at

 To understand the growth and diversification strategies, portfolio structure of the

 To study the overall performance of the organization.

Department of ECE, VVIET, Mysuru Page 3

The products manufactured at Truck Division are:

 Mining & Construction :

 Dump Trucks (Mechanical Drive)

 Air Craft Towing Tractor

Various dump trucks are as follows -

BH205E-AC REAR DUMP TRUCK (Electrical Drive)

BH35-2 REAR DUMP TRUCK (Mechanical Drive) –

Travel speed : 50km/h

BWS28-2 WATER SPRINKLER :

Flywheel power (net): 280 kW (375 hp) @ 2100 rpm

Department of ECE, VVIET, Mysuru Page 6

BW7O WATER SPRINKLER :

Flywheel power (net) : 659 kW (883 hp) @ 2050 rpm

Department of ECE, VVIET, Mysuru Page 7

There are 8 frame cutting, 2 sheering, 5 forming and 2 straightening machines.

Laser cutting machine.

Punch press: 40 - 1000 T

Press Brake: 40 - 500T

Optical tracer flame cutting machines

Department of ECE, VVIET, Mysuru Page 8

Major Assembly & Erection Shop

Pre-treatment & Painting Shop

Welding Fabrication and Associated Facilities

 Electrical resistance Foil Roll butt machines.

Department of ECE, VVIET, Mysuru Page 9

Light Assembly Shop :

Major Assembly Shop :

 This department is responsible for production control.

BEML Limited views Quality improvement as a business strategy and hence

Department of ECE, VVIET, Mysuru Page 12

Department of ECE, VVIET, Mysuru Page 13

Manufacturing Engineering Services :

 Mainly performs capacity planning, complex and employees planning.

Department of ECE, VVIET, Mysuru Page 14

Department of ECE, VVIET, Mysuru Page 16

 Process/ Method planning- the “do like this” process

 Tool planning- the “enabling” process

Department of ECE, VVIET, Mysuru Page 17

Department of ECE, VVIET, Mysuru Page 18

Purchase and Out Sourcing :

 In order to build a product numbers of items are required.

Department of ECE, VVIET, Mysuru Page 19