bharat electronics limited training report

7/21/2019 bharat electronics limited training report

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INDUSTRIAL TRAINING

PROJECT REPORTAT

Submitted by:-

Gagan maggo

Upt no. : 6123\14


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Introduction

Bharat Electronics Ltd. (BEL)was established in 1954 to meet the Defence needs

of the Government of India. Three units of BEL, located in Bangalore, Hyderabad

& Ghaziabad, were included on the list of Indian entities that were subjected to

US sanctions announced after the May 1998 nuclear tests. Added to the US

sanctions, these units are also faced with passive sanctions from some European

countries.

Presently, it is the country's premier electronics organization, having nine

manufacturing units located at Bangalore, Madras, Hyderabad, Machilipatnam,

Pune, Taloja, Panchkula, Ghaziabad and Kotdwara. Its corporate office is at

Bangalore. BEL is engaged in the design, development and manufacture of

sophisticated, state-of-the art electronic equipments for the use of Indian

Defence Services, and Para military organizations. BE is India's only manufacturer

of radars, sensors, sonars and the complete range of antennae for defense

surveillance requirements in various configurations meant for ground, air and

naval use. For high-tech support to defense, BE makes sophisticated simulators

and trainers, gun fire control and stabilization systems, and optical and opto-

electronic passive night vision devices. Communication equipment for the army

includes HF, VHF and UHF man packs; mobile and static transreceivers and

transmitters of various capacities; radio relays; digital troposcatter systems; as

well as secure voice & data equipment and digital switching systems. For naval

communication, BE manufactures ship-borne transmitters & receivers, display

and console systems and ESM & ECM electronic warfare systems for various


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platforms. Communications' for the air force includes satcom systems and shelter

based tactical secure air support communication packages.

Other users are All India Radio, Doordarshan, Department ofTelecommunications, Police, and Meteorological Department etc. It has a very

wide product range and makes over 350 different products, comprising

communications equipment, radars for military and civil use, optical and opto-

electronic equipment, sound and vision broadcasting equipment and electronic

components. Bharat Electronics has manufacturing units with special focus on

products such as Defence Communication, Radars, Optical & Opto Electronics,Telecommunications, Sound and Vision Broadcasting, and Electronic Components.

BEL is a technology driven multi-product, multi-unit professional electronics

Government of India Enterprise under the Ministry of Defence. Accredited to ISO

9001/9002 quality standards, BEL's turnover during 1998-99 was over $280

million. Out of the 2000 engineers working in nine manufacturing units, more

than 800 are R&D Engineers. BEL manufactures a wide range of products in areas

like Defence Communications, Radars, Telecommunications, SATCOM, Sound and

Vision Broadcasting, Opto & medical Electronics and Electronic Components.

Services offered by BEL include Contract Manufacturing, Telecom Consultancy

and Semiconductor Device packaging.


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Manufacturing units


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Vision, mission values &

objectives

Corporate motto

"Quality, Technology and Innovation."

VISION

To be a world-class enterprise in professional electronics.

MISSION

To be a customer focused, globally competitive company in defence electronics

and in other chosen areas of professional electronics, through quality, technology

and innovation.

VALUES

- Putting customers first.

- Working with transparency, honesty & integrity.

- Trusting and respecting individuals.

- Fostering team work.


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- Striving to achieve high employee satisfaction.

- Encouraging flexibility & innovation.

- Endeavoring to fulfill social responsibilities.

- Proud of being a part of the organization

OBJECTIVES

- To be a customer focused company providing state-of-the-art products &

solutions at competitive prices, meeting the demands of quality, delivery &

service.

- To generate internal resources for profitable growth.

- To attain technological leadership in defence electronics through in-house R&D,

partnership with defence/research laboratories & academic institutions.

- To give thrust to exports.

- To create a facilitating environment for people to realize their full potential

through continuous learning & team work.

- To give value for money to customers & create wealth for shareholders.

- To constantly benchmark companys performance with best-in-class

internationally.

- To raise marketing abilities to global standards.

- To strive for self-reliance through indigenization


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RREESSEEAARRCCHH&&DDEEVVEELLOOPPMMEENNTT

Research & Development started in 1963 at BEL and has been contributing

steadily to the growth of BELs business and self-reliance in the field of Defence

Electronics and other chosen areas of professional electronics.

BELs R&D Policy is to enhance the companys pre-eminence in Defence

Electronics and other chosen fields and products through Research &

Development. Major R&D objectives of BEL is development of new products and

enabling technology modules to meet customer requirements ensuring that the

developed products are commercially viable, state-of-the-art, competitive and of

highest quality of design.

Resources and Investments

All the 9 manufacturing Units of BEL have their own Unit Development &

Engineering (D&E) divisions. The role of Unit D&E divisions is to develop new

products and obtain customer acceptance, generate new business, provide

product lifecycle support and upgrades, develop processes and components as

necessary.

There are several core Central D&E groups at Bangalore, whose role is to support

Unit D&E divisions with the supply of specialized technology modules. BEL also

has two Central Research Laboratories (CRLs) located at Bangalore and


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Ghaziabad, whose primary role is to work on critical areas of technology, develop

enabling technology modules for use by Unit D&E divisions and provide advance

training to D&E engineers on emerging technologies.

Presently there are about 1,150 engineers and 450 support staff in the R&D

Divisions of BEL, concentrating on various projects. D&E divisions of BEL pursue

various categories of projects: in-house development projects, joint development

or ToT projects with DRDO / other national design agencies and ToT or joint

development projects with foreign vendors. Usually, 45 to 50% of the turnover is

from BEL designed products, 10 to 15% of turnover is from products designed byDRDO and other National Design Agencies and the remaining 35 to 45% of

turnover is from foreign collaborations.

The annual R&D expenditure is around 4 to 5% of BELs sales turnover. BEL

regularly recruits young engineers based on the identification of required

competencies for the R&D divisions. There are schemes for on-the-job training

after placement and facilities for continuous learning for these engineers. There

are recognition and reward schemes for excellence among R&D engineers. There

are project selection criteria in conformity with the Perspective Plan and the

companys commercial and technological objectives, viz, technology, market and

investment. There are established project monitoring mechanisms for the on-

going R&D projects by various levels of officers in the organization and

institutional reviews of projects by customers also.

BEL R&D units are recognised by the Department of Scientific & Industrial

Research (DSIR) under the Ministry of Science and Technology, Government of


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India. BELs Software Technology Centre at Bangalore has the recognition of

Capability Maturity Model (CMM) Level 4 Rating from Software Engineering

Institute (SEI).

Areas of R&D Activity

R&D engineers are engaged in the development of new products, enabling

technology modules, processes & components in the following major areas:-

- Tactical Communication, Switching & Encryption

- Electronic Warfare Systems

- Tank Electronics & Electro Optics

- Command Control Systems

- Radars

- Sonars & Naval Systems

- Broadcast, Satcom & Telecom


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DEPARTMENTS AT B.E.L.

PANCHKULA

1.D&E DEVELOPMENT & ENGINEERING

It is to design the project, make the modifications to prepare design and

related documents.

CNR , HUD , Cell Phone Jammer

Product Design & Engineering Drawing Office , Standards and Technical

Information Center

VPD-MK-IV

High Data Tactical Radio

Base Station Security Radio

2. MKTG MARKETING

SalesIt is to prepare ESO equipment source order.

TL (Technical Literature) It is the booklet with the project having

instructions.

PR (Public Relation)It is the relation with the customers.


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3.MS/HRD HUMAN RESOURCES DEVELOPMENT

HRD-Human Resources Development

EDP (Electronic Data Processing)It is the network system for copy. It is

also for the enquiry of item.

Management Services

4. MFG MANUFACTURING

Works Assembly There are different types of work assembly i.e. PCB

assembly, Module Assembly, Final Assembly. Works FabricationIt is the department for mechanical work.

AMF (Advanced Manufacturing Facilities)Advanced machines are used

in the manufacturing of the projects and it is an automatic system to

mount the item on the PCB.

PE (Production Engineering)It is for installation of new machinery.

PPC (Production Planning & Control)In this work is planned.

SC (Sub Contract)

5. MM MATERIAL MANAGEMENT

PUR (Purchase)This department purchases the materials.

ISM-Integrated Stores Management , IGS-Inward Goods Store , HS-

Holding Store , MC-Material Control

FGS-Finished Goods Store


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6. PA PRODUCT ASSURANCE

SC & TM-Self Certification & Test Methods

C.Test (Ciphor Testing ) - Its used for secret coding.

PS (Product Support)Its done after sale services.

QC-Quality Control

Inspection-Works Fabrication

Inspection-Works Assembly

INSPECTION-Sub Contract

7. P&S PLANT & SERVICES

Civil

Mechanical

Electrical

Air Conditioning

8. HR

HUMAN RESOURCES

Security

Personnel

Establishments

Medical

Crche

Canteen

Welfare


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9. F&A FINANCE & ACCOUNTS

FinanceDept. for the sanction of money.

PayrollIt is the salary of employees.

Budget

Accounts

AuditSurvey of the systems.

10. QM QUALITY MANAGEMENT

International Organization For Standardization Six Sigma Quality Control Circle

TES-Test Equipment Support

IGQA-Inward Goods Quality Assurance


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PRODUCTS:-

1. STARS-V (SECURE TACTICAL ARMY RADIO SYSTEM)

STARS-V (Secure Tactical Army Radio System - VHF) is a family of fixed frequency

and frequency hopping radio sets available in 5W and 25W power output

configurations. The radios provide communication in voice clear, voice secure and

data modes. They can be controlled from a remote location up to 2 km. All front

panel controls (except ON/OFF) are extended using 2 wire cables to a Remote

Control Unit (RCU) at the remote location. Intercom operation between radio set

and RCU is also provided. The radio set can be configured for fully automatic

rebroadcast operation. It is also possible to setup rebroadcast over two wires for

voice clear mode only. External data interface is provided on the front panel to

facilitate data communication with suitable modem the radios are fully modular

in construction. They are designed to perform in conformance to MIL 461 class of

EMI/EMC specifications. STARS-V radios find use in Man pack as well as vehicular

applications for providing voice and data communications in VHF frequency range

of 30-88 MHz

FEATURES

VHF frequency range of 30 - 88 MHz

2320 channels with 25 KHz spacing

1W/2W/5W/25W power outputs in different models


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250 hops per sec for FH radios

In built GPS

32 preset crypto keys + 1 manual key

BITE up to module level

Built-in data modem

Complaint to MIL 461 EMI specifications

2.CNR (COMPOSITE NET RADIO)

VHF Transrecievers (CNR) is a software controlled frequency hopping radio

(Transmitter and Receiver) in the VHF frequency band of 3088 MHz the design

of the radio is based on Digital Signal Processor (DSP) technology making use of

Direct Digital Frequency Synthesis (DDFX). The radio works in Anti-jam frequencyhopping and fixed frequency modes with built-in high grade digital secrecy. The

radio supports both Voice and Data communication in clear as well as secure

mode.

FEATURES

Radio is based on DSP technology

Frequency range of 30-88 MHz with 25 KHz channel spacing

Supports 2320 channels with 10 preset channels and 10 hop sets

Scan and BITE facility

Automatic re-broadcast facility

Direct serial data interface (RS-232C)

Modular construction


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3.SECTEL (SECURE TELEPHONE)

Secure Telephone is a compact, full duplex digital Subscriber End Secrecy Device

(SESD) providing highest grade of secrecy on normal telephone lines. It replaces

subscribers normal telephone instruments. It can operate over any standard

voice channel of telephone networks like DOT hired miltrunk single link circuits

and STD channels. It operates from 230 V AC mains using AC-DC adapter. Key

management is supported by Fillgun. Speech is digitized using Linear Predictive

Coding (LPC) technique and digitally encrypted by a highly complex crypto

algorithm which ensures highest grade of secrecy. The encrypted speech is

transmitted over the telephone line using a Full Duplex QAS 25modem. At thereceiver end, the encrypted data stream is demodulated / decrypted and the

original speech is synthesized. The user can switch between clear and secure

mode during the same call.

FEATURES

High-grade speech secrecy

Full duplex transmission in Secure and Clear mode

Data rate 2.4 kbps full duplex Memory dialing of 10 stored numbers

Multi-function keypad for different functions

Simple connectivity over standard two wire telephone lines

2 x 16 character LCD display to show the status


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4.SECURE UHF HANDHELD RADIO (LUP 291):

LUP 291 is a UHF handheld radio with inbuilt high grade digital secrecy. The radio

set is stateofthe art design, compact and light weight. Interface is provided

for Headgear and Crypto key loading. The operator interface is user friendly with

minimum number of controls. The radio set is provided with helical and magnetic

mount antennas. The radio set has in-built mic and speaker. VOX headgear

is also available as optional accessory for hands free operation

FEATURES

Continuous Tone coded squelch(CTCSS)

RF Power Output : 5W /1 W (selectable) Various programmable features like Scan, CTCSS frequency selection,

Power Save, Password etc.

Inbuilt Powerful Diagnosis feature (BITE)

TX Inhibit (Sulk ) , Clone , Erase and Whisper facilities

7.2 V Primary & Secondary batteries

Antennas : Helical and magnetic mount

Complaint to MIL 461 EMI specs

Optional accessories: Battery charger, Headgear,

Handset, Fillgun/ Programmer etc.

Frequency range 403 - 470 MHZ Channel Spacing 12.5 /25 kHz Builtin high grade Crypto

32 Preset crypto keys + 1 manual key Selective call facility

16 Preset frequencies


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5.DBC (DUAL BATTERY CHARGER):-

DBC stands for dual battery charger. It is used to charge the battery which is used

in VPS set. DBC is designed in such a way that it can charge two batteries at a

time. It can work with AC as well as DC input also. Its working range is 0C to

40C.. It is also shockproof.

FEATURES

Can charge two batteries at a time

Temp range- 0C -40C

Can work with AC as well as DC input

Display for voltage indication

LEDs used to indicate charging, discharging and overcharging Fuse used to prevent it from very high input voltage

Controller card Is used


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6.VLF/HF Receiver (HS 495)

This is a powerful receiver for voice reception and data communication. It

operates in the frequency range of 10 KHz to 30 MHz with a resolution of 1 Hz. It

is designed for civil, administrative and military applications. The receiver can be

locally controlled by means of the control and display elements on its front panel.

FEATURES

Compact DSP based receiver for radio communication and search operation

Provides demodulation for AM,CW,LSB,USB,ISB,FM,FSK, AFSK & FAX

Frequency range 10 kHz to 30 MHz in 1Hz steps.

Easy to operate from front panel or via terminal computer

Fast and low-noise synthesizer

1000 programmable channels

13 bandwidths from 150 Hz to 8 kHz

Switchable RF preamplifier

High rejection of strong interfering signals


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Scan mode for programmable frequency ranges and any desired channel

sequences

BITE for module testing

High availability due to long MTBF (>14000 hrs) and short MTTR

Low power consumption

Meets environmental conditions as per MIL-STD-810D and EMC as per MIL-

STD-461C

Light Weight


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Environmental Management in BEL In

Pursuit of Sustainable Development

Set in clean and green surroundings, all the nine Units of BEL effectively maintain

environmental friendly work processes. The pristine beauty of the environment in

our plants are home to many species of birds which are at the top end of the eco

chain fostering bio diversity in flora and fauna supporting the insects and other

life forms. This harmony has been built on the foundation of strong

environmental management practices which are deep rooted and based on

International Standards such as ISO14001(2004), pollution prevention measures,

energy and water conservation, use of eco friendly materials and processes,

reduction, reuse and recycling of waste, reduction of hazardous waste and

sustenance of Zero discharge. The Company has now measured its carbon

footprint and is planning to move towards Carbon Neutral status by use of green

renewable energy for its operations. Several capacity building programs have

been conducted to increase awareness among the workforce to environmental

issues and promote an environment free of pollution. The Company strives to

serve as an example in its environment endeavors by the following initiatives:

Cleaner Technology

The key driver for a pollution free environment stems from cleaner technology

adapted for product and process design. Large volumes of BEL Standards support

its core design strength. A key factor for continual improvement is introduction of

cleaner technology in manufacturing processes that has reduced the generation

of pollutants to a large extent. BEL has recognized that a more effective

contribution to clean environment begins at design stage itself. BEL Corporate

Standards Division has published several guidelines connected to environment

friendly materials, components and manufacturing process to be used across the

Company. Corporate standards have already commenced standardization and


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introduction of many RoHS (Restriction of Certain Hazardous Substance) items

complaint to European and other International directives. Continuing its efforts in

the previous years, in the year gone by, twenty five new RoHS compliant

components have been introduced covering areas like like Inductors, LEDs,

Connectors, Relays, Microcircuits and Microwave Components. Based on the

above guidelines, many of the RoHS compliant processes have been introduced in

PCB manufacturing and metal finishing process. Low VOC metal finishing

operation (Poly urethane) and anti IR coating system are adopted in the process

to contain pollution. Eco - friendly Chorine - free copier paper for photocopying

and laser printing has been standardized for lower environmental impact. BEL has

completely eliminated all ozone depleting chemicals with eco friendly substances.

Introduction of Low Halogen/ Halogen Free, Fire and Radiation Resistant cables

resulted in lesser emission. Use of new generation EMI/ EMC/ EMP compatible

materials and Components, such as, Aluminium Hexagonal Honeycomb Cellular

Materials and Solid Silicone Materials Embedded with Monel Wires helped in

minimizing radiation hazard.

Hazardous Waste Management

Hazardous wastes generated are handled in a scientific way. Exclusive, well-

protected, enclosed areas are created for safe- keeping the hazardous waste.

Intermediate stores exist in each production Division wherein identified

Hazardous Wastes are quantified and stored till shifting to central hazardous

waste stores. These items are brought and stored in the central hazardous waste

stores and disposed of as per the norms of State Pollution Control Board. BEL has

tied up with the State Pollution Control Board Treatment, Storage & Disposal

Facility operators for disposal of landfillable solid hazardous waste. This system

in practice effectively prevents pollution caused by hazardous wastes. By

introduction of appropriate chemicals that generate less hazardous sludge in

detoxification of wastewater and by adoption of cleaner technology, hazardous

waste generation has been reduced at the process level itself. Besides

introduction of Cyanide-free Zinc and Copper plating processes, use of sodium


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hydrides, sodium hypochlorite and sodium Meta bisulphate in place of lime,

bleaching powder and ferrous sulphate, help in reduction of large volume of

hazardous sludge. Hazardous wastes generated are disposed of scientifically as

per the direction of the State Pollution Control Board. There is a drastic reduction

in sludge-generation as a result of several process improvements carried out.

Control of Emission to Air Air emissions from process are controlled through

appropriate air pollution control equipment. By virtue of the nature of chemical

used and the processes adapted in the manufacture of our products, the impact

from the pollutants are insignificant, the results of which are also substantiated

with high quality of ambient air measured at different locations within the Plants.

Control of Water Pollution

Waste water generated from production centres are treated to meet reusable

standards and recycled for production purpose again. Likewise domestic effluent

generated in the factory and colony is treated and recycled for horticulture

purpose.

Sustainable development InitiativesThe Company has taken the sustainable development projects in the area of air

conditioning, air compressor, LED lighting and carbon footprint. The Company has

established a systematic approach for conservation of natural resources. Major

focus revolves around saving power, water and greenery and several initiatives

have been taken in this regard. Generation of wind energy (Green Energy)

through 5.5 MW capacity wind mills reduces release of Green House Gases into

the atmosphere. During the year 2012-13, about 9.98 million KWhrs of electricalenergy was wheeled from wind power plants installed at Davanagere and Hassan

of Karnataka state for captive consumption, which contributes to 37.5 % of

energy consumed by Bangalore Unit. The Company has placed an order for

addition of 10.5 MW to be put into operation during 2013-14. After establishing

this plant, BEL Bangalore Unit will become carbon neutral.


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During the year 2012-13 the Company spent Rs 187 lakhs on Sustainable

Development projects, which include the following:

Conservation of potable water by using recycled sewage water from

Bangalore Water Supply and Sewage Board for horticulture resulting inreduction of consumption of 200 ML (Million litres) of fresh potable water

every year thus reducing the demand of potable water requirement. This

also improves the ground water level and greenery around the Company

Campus.

Upgradation of Air Compressor plant by replacing water cooled

reciprocating compressor with state-of art energy efficient air cooled

compressor resulting in reduction of energy consumption at the central Air

Compressor plant and the Energy saved is made available for other usages. Carbon Footprint Study: CIIGodrej GBC team carried out Carbon

Footprint Study at BEL, Bangalore, in February & May 2012. This study was

carried out in accordance with the Corporate GHG Accounting and

Reporting Standard(GHG Protocol)/ISO 14064 standard which categorizes

emissions into three scopes that comprises of direct and indirect emissions.

Bangalore Unit GHG emission intensity was calculated based on GHG

Emissions per Rs. Crore Turnover is about 4.8 MT of CO2/ Rs. Crore

Turnover in 2010-11 and which has reduced to 3.5 MT of CO2/ Rs. Crore

Turnover during 2011-12.

Setting up of Rain water harvesting system at Ghaziabad. Rainwater

harvesting is the accumulation and deposition of rainwater for reuse before

it reaches the aquifer. The harvested water can be used for drinking

purpose and water for gardening as well, etc.

Two projects viz., Upgradation of Air Compressor plant and Establishing

Carbon Foot Print were evaluated by external agency namely Petroleum

Conservation Research Association, Bangalore & CII-Sohrabji Godrej Green

Business Centre, Mumbai respectively and results are found to be

satisfactory.

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