TRAINING CUM PROJECT REPORT

At

Bharat Electronics Limited

PANCHKULA( A Govt. of India Enterprises)

FROM 28.06.10 TO 08.08.10

IN PARTIAL FULFILLMENT OF DEGREE OF BACHELOR OF TECHNOLOGY

(B.TECH.)

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Submitted by: - Apoorav

Ahluwalia

PREFACE

With the ongoing revolution in electronic and communication where

Innovations are taking at the blink of eye, it is impossible to keep the pace

with the emerging trends. Excellence is an attitude that that whole of

human race is born with. It is the environment that makes sure that

whether the result of this attitude is visible or otherwise. A Well planned,

properly executed and evaluated industrial training helps a lot in

inculcating a professional attitude. It provides a linkage between the

student and industry to develop an awareness of industrial approach to

problem solving, based on a broad understanding of process and mode of

operation of organization.

During this period, the student gets the real experience for working in the

actual Industry environment. Most of the theoretical knowledge that has

been gained during the course of their studies is put to test here. Apart

from this the student gets an opportunity to learn the latest technology,

which is immensely helps in them in building their career.

I had the opportunity to have a real experience on many ventures, which

increased my sphere of knowledge to great extent. I got a chance to learn

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many new technologies and was also interfaced to many instruments. And

all this credit goes to organization Bharat Electronics Ltd.

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It is a great pleasure and matter of immense satisfaction for me to represent the dissertation of my Training Report.

We are highly indebted to BEL Panchkula, the leading electronics company of our nation, for letting us undertake our training with them. It was really a very valuable period for us as we got our first exposure to the industry. We would like to express our gratitude towards Shri R. K. Mishra, Sr. DGM, (HR&A), who allowed us to join BEL as a trainee, who helped us in every possible way and was a source of inspiration for all the trainees since his energy and attitude towards learning was unmatched. He really got us creative juices flowing and it was because of him that we could complete our training successfully.

We specially thank Mrs. Rekha Aggarwal, DM (HRD) for providing me with such learning atmosphere in BEL and support us whenever we needed help at every point of our training. I also express my profound gratitude to all the staff members of HRD specially Mr. Rajesh Prashar, Mr. Tej Pal, Sr. Off. Supdt, HRD, Mr. Joginder Singh & Smt. Rajbiri.

We are also grateful to the entire staff of IS/MS, especially, Mrs. Meenakshi Sehgal, who gave us technical and managerial insights into the company’s operation. We also express our special thanks to Mrs. Sweety Kapoor and Shobha Mittal who extended full cooperation and helped us to carry our project successfully.

Last but not at least I also convey my thanks to my Principal. I would also like to thank my Parents & all my friends who made this training a rich experience and success.

Apoorav Ahluwalia

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THE PANCHKULA UNIT (PROFIT FROM DAY ONE)

In August 1983, NIDC, a Public Sector Firm, was appointed as he consultant for the project on a fee of Rs. 30 lakhs. A preliminary estimate of Rs. 21 crores and a likely construction period of fifteen months were indicated to the Board on 26.11.83.

The Panchkula unit started functioning in 1984 from special cells formed in Bangalore and Ghaziabad. The products identified for the unit were: tactical communication sets, both man pack and hand held. The selected personnel started familiarizing themselves with these products in the cells in Bangalore while the cell in Ghaziabad was involved with work relating to land acquisition, government approvals and building construction.

Brig. M.H. Pai was earmarked to head this unit.

After the completion of the layout and the designs by the consultant, tenders were invited in June, 1984 in respect of both civil works and services. Contracts were awarded in September and the work was started immediately thereafter. The job of constructing 136 employee quarters was given to HUDA, a State sector company.

A detailed project report for the project (DPR) was prepared over the next few months and was presented to the Board on 29.11.1985. The cost of the project was placed at Rs. 24.84 crores comprising Rs. 14.72 crores on civil works and Rs. 10.12 crores on plant and machinery. The expenditure was to be spread over a period of seven years so as to keep pace with the growth in the activity levels. The government approved the DPR in 1986.

The project was to be funded to the extent of Rs. 9.56 crores from internal reserves of the company and the remaining Rs. 15.28 crores were to come from the government, Rs. 8.28 crores by way of equity capital and Rs. 7 crores as long-term loan.

The major project lines envisaged for this unit were VHF and UHF Tranreceivers and Encryption equipment for the defence forces. The project was expected to yield an internal rate of return (IRR) of 19%, taking only the first six years of production.

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The construction of the Panchkula Unit actually took more than two years and the main buildings were ready for occupation only in 1987.

During the construction stage, a building meant to house the fabrication facility caught fire and progress was stalled for some time. This proved to be a blessing in disguise as the mechanical parts perforce had to be sourced from outside. The success of sub-contracting provided an opportunity to review the need for establishing a full-fledged fabrication facility.

Since it was located in a developed area, minimum housing only was built. Transport facility was also not provided. The canteen was run by a contractor. Executives and non-executives shared the same canteen. Manpower was kept low.

The unit was formally inaugurated by the then Defence Minister, Shri K. C. Pant, on 18 July 1987.

However, production in temporary sheds had already commenced in 1984. A turnover of Rs. 40 million was achieved in 1985-86 and Rs. 110 million in 1986-87.

In spite of frequent change of unit heads due to resignation and retirement, the unit maintained robust progress thanks to the dedicated efforts of second level officers hand-picked from Bangalore and Ghaziabad. Lt. Col. Ambady, Sri M.s. Jagannathan, Sri K. Vaidyalingam headed the unit in quick succession after Brig. Pai retired. Sri M.V. Srinivasan, GM, then headed it for 3 years.

A remarkable feature of this project is the fact that it sighted profit in the very first year of regular production.

And, incidentally, there was practically no cost over-run in this project. The actual expenditure was Rs. 24.95 crores, only a wee bit over the sanctioned figure of Rs.24.84 crores.

OVERVIEW OF BHARAT ELECTRONICS LIMITED

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The information regarding BEL is categorized under the following headings:

BHARAT ELECTRONICS LIMITED AT A GLANCE

MISSION & OBJECTIVES OF BEL

HISTORY/MILESTONES OF BEL

MANUFACTURING UNITS OF BEL

INDIAN MARKET OF BEL

CUSTOMERS OF COMPANY

PRODUCTS OF BEL

ORGANISATION OF BEL PANCHKULA

BHARAT ELECTRONICS LIMITED AT A GLANCE

Bharat Electronics Limited (BEL) is a Government of India undertaking set up under the Ministry of Defence. BEL was established in 1954 in Bangalore, primarily to meet strategic defence electronics needs of the country. With nine manufacturing units located in Bangalore, Ghaziabad, Panchkula, Kotdwara, Pune, Taloja, Hyderabad, Chennai & Machilipatnam, Bharat Electronics commands a strong presence in practically every vital area of professional electronics in the country.

Bharat Electronics has been awarded the coveted ISO 9000 certification, the benchmark of international quality.

BEL’s philosophy is epitomized on its motto “Quality, Technology, Innovation”.

With in-house R&D and sate-of-art manufacturing facilities, BEL manufactures a wide range encompasses Semiconductor Devices, Professional Vacuum Tubes, Crystal Devices, Solar Cells & Systems.

Almost all components manufactured by Bharat Electronics conform to international specifications. The component part numbers are equivalent to and application compatible with international part numbers.

MISSION & OBJECTIVES OF BEL

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MISSION To be the market leader in Defence Electronics & in other chosen fields & products.

OBJECTIVES

To become a customer-driven company supplying quality products at competitive prices at the expected time & providing excellent support.

To achieve growth in the operations commensurate with the growth of professional electronics industry in the country.

To generate internal resources for financing the investments required for modernization, expansion & growth for ensuring a fair return to the investor.

In order to meet the Nation’s strategic needs, to strive for self reliance by indigenization of materials & components.

To retain the technological leadership of the company in defense & other chosen fields of electronics through in-house Research & Development as well as through collaboration/co-operation with Defence/National Research Laboratories, International companies, Universities & Academic institutions.

To progressively increase overseas sales of its products & services. To create an organizational culture this encourages members of the organization to realize their full potential through continuous learning on the job & through other HRD initiatives.

HISTORY OF BEL

HISTORY

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SINCE 1954 With over four decades of manufacturing experience Bharat Electronics Limited has pioneered the professional electronics movement in India. With continuous up gradation of technology, commitment to quality & constant innovation, BEL has grown into a multi product, multi unit, and multi technology company.

BEL has set up impressive infrastructure & manufacturing facilities in their nine ISO certified production units around the country.

BEL has also established two joint ventures – with General Electric Medical Systems, USA for X-ray tubes & Multitone, UK for paging systems & has a subsidiary company BEL Optronic Devices Limited for the manufacture of Image Intensifier tubes.

MANUFACTURING UNITS OF BEL

In 1954 with a factory of Jallahali, Bharat Electronics grew into nine units, spread all over India. The locations & products of the units are given below:-

1. BANGALORE :

This is also called BG Complex. Jallahali unit which is the mother unit is now a part of the BG Complex. This is the

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biggest unit with approx. 10,000 employees working here. Among the products here, the important ones are:

Communication equipment Air & Doordarshan equipment like mobile van for live

telecast etc. Radar-mobile, one dimensional, 3-dimensional & multi

dimensional Radars are manufactured here.

Different range of semi-conductor devices like ICs,

resistors & black & white color TV picture tube glasses.

ISRO’s requirements are met at space electronics department at Bangalore. Satellite launch vehicle was also manufactured here.

2. GHAZIABAD :

This is the second unit which was set up in 1974, & approx. 2500 employees working here. Radars & some communication equipment are The products manufactured here are:

Radars Some communication equipments like antennas SATCOM (defence) Microwave components

3. PUNE:

To diversify further one more branch was added 1979 & this was in Pune. In this branch around 700-800 employees are working. The product profile includes:

Image convertor, image intensifier, X-ray tubes Batteries Electro-optics

4. MACHLIPATNAM:

There was one Andhra scientific company, which was a sick unit. This was taken over by BEL & is called ASCO unit in 1983. The products include:

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Optical & opto-electronic equipment like binoculars,

microscopes Medical Electronics

5. NAVI MUMBAI:

This is an industrial place near Mumbai. This unit makes:

Glass shells for black & white TV picture tubes Shelters for Electronic Equipment Train Actuated Warning System Electronic Equipment Assembly

6. PANCHKULA:

Panchkula & Kotdwara were proposed simultaneously by the Government in 1985. It was proposed to set up one unit each in Haryana & Uttar-Pradesh. But the place in U.P. for setting up a BEL unit could not be decided while that at Haryana was decided & hence this unit started earlier. This unit manufactures only tactical communication equipment like VHF, UHF transceivers etc.

7. KOTDWARA:

This is a unit in Garhwal district of Uttar-Pradesh. This unit manufactures radio relay, multiplex equipments & exchanges etc.

8. CHENNAI:

The eight unit of BEL was established in Chennai. This unit manufactures:

Tank related electronic equipments Optical fire control systems

9. HYDERABAD:

This is another unit of BEL which manufactures electronics warfare equipments.

CORPORATE VISION, MISSION, VALUES & OBJECTIVES

PRODUCTS OF BEL

The products of BEL mainly focused on defense purposes but later on BEL also started manufacturing some commercially useful items also. The major products

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include communication devices which provide secure mode of communication. Also the major products include RADARS, X-RAY TUBES, and TRANSRECIEVERS etc. BEL has been involved in providing state-of-the-art communication equipment to the Indian Army, be it hand held mobile radios and terminals, ground based systems, airborne and even ship borne equipments and systems.

The communication equipments developed here cover HF, VHF, UHF, and V/UHF frequency bands. The most important project of BEL under the communication equipments is STARS-V which provides secure mode of data transfer. In STARS-V, the data to be transferred is first encrypted using a microprocessor which could be read only by a similar device with same coding. Now the latest technology of frequency hopping is being implemented which is a very useful tool in making a secure data transfer system. BEL manufactures a lot of product which is very difficult to list but some of the major products were as follows:

Integrated circuits and micro circuits X-ray tubes and magnetrons B/W picture tubes HF & broadcast equipment Radars STARS-V SECTEL CNR HUD ACME MK II SPACE GUIDING EQUIPMENTS AIRBORNE GPS RECEIVER (UA-429) PRIME LUP SRAX TIDEX SECURE FAX SECURE TELEPHONE SPURT MESSAGE ALPHANUMERIC RADIO TERMINAL (AS-7306)

QUALITY POLICY

We are committed to consistently deliver enhancement value to our customers, through continual improvement of our products and processes.

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AWARDS & RECOGNITIONS

ISO 9001-2000 & ISO 14001-2004

Self Certification from Indian Army For VHF Radio Sets (5w / 25w)

CII-Exim Bank Excellence Award for Strong Commitment To Excel

(Derived from EFQM and similar to Malcom Aldridge Award)

(2004,2005)

DSIR (Dept. of Scientific & Industrial Research) Award for

Development & Engg.

NABL Accreditation for Calibration Lab.

QCC Awards:

Ist Prize in CII Northern Region QCC - 2004 Excellent Presentation Award in QCFI - 2004 Distinguished Presentation Award in QCFI -2005

First Prize for implementation of Hindi in the Northern Region by

MHA

Procedure followed in the decision making process

BEL has a well-defined system of decision making with adequate channels of supervision and accountability. Proposals requiring decisions of any nature are initiated at appropriate Executive level at the Units/Offices and at the Corporate level. Proposals generally pass through a minimum of 3 levels before they are approved. All proposals having financial implications are routed through respective Finance Departments/Divisions. Powers sub-delegated to various approving authorities are clearly spelled out in BEL’s “Sub-Delegation of Powers”document. Where required, Departmental/Divisional/Unit committees are formed to facilitate decision making. Major policy decisions and decisions going beyond the sub-delegation of powers upto CMD level are put up to the Board for approval. A detailed Organizational Chart of BEL, clearly spelling out the areas ofresponsibilities at various levels, is appended herewith.

INDIAN MARKET OF BELBharat Electronics’ Limited is a major supplier of products and turnkey systems to the Indian Defense Services. Over the years, BEL has being offered to civilian products as well. Large turnkey telecommunication solutions are also being offered to civilian market. A brief list of the Customers in the Defense and civilian market segments and the products and services offered to them are given below:

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Products and services CustomersDefence Communication Indian Defence services Para-

military forcesRadar & Sonar Indian Defense Services, Civil

Aviation, Metrological Department, Space Department.

Telecommunication Department of Telecommunication, Paramilitary forces, Power sector, Oil Industry, Railways

Broadcasting Equipments and Studio Systems

All India Radio, Doordarshan, (National Radio &TV Broadcasters)

Electronic Voting Electronic Communication of India.Solar Products & Systems Individuals, Private and, Govt.

organizations.Turnkey Systems, E- Governance Networks

Police, State Govt., Public sector undertaking.

Components All India Radio And Doordarshan the National Radio & TV Broadcasters, Instrumentation Industry Switching Industry, Entertaining Industry, Telephone Industry.

CUSTOMERS OF COMPANY

The customer profile for products of Bharat electronics is also must varied as can be seen from the list given below:

ARMY NAVY AIR FORCE PARA MILTRY

FORCES SPACE

DEPARTMENTS ALL INDIA RADIO DOORDARSHAN MINISTER OF

EDUCATION NCERT

NUCLEAR POWER CORPORATION

DEPARTMENT OF TELECOMMUNICATION

CIVIL AVIATION METROLOGICAL

DEPARTMENT IRRIGATION AND

ELECTRICITY DEPARTMENT

OIL INDUSTRY MEDICAL AND

HEALTH CARE TELEPHANE

INDUSTRY HEAVY WATER

PROJECT

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ORGANISATION OF BEL-PANCHKULA BEL Panchkula has different divisions which are further divided into departments- 1. D&E –(Development and Engineering): This is a division which is further divided into departments. They are

D&E (DEVELOPMENT & ENGINEERING) – It is to design the project, make the modifications to prepare design and related documents.

D&E CRYPTO – It is for designing of secure communication.

TIC (Technical Information Centre) – TIC is a library for designing purpose.

DRA OFFICE - It is the Drawing office.

STDS (STANDARDS) –These are the standards for Drafting, Design manure, Quality standards.

2. MFG (MANUFACTURING):

WA (WORK ASSEMBLY) – There are different types of work assembly i.e PCB assembly, Module assembly, Final assembly.

WF (WORK FABRICATION) – It is the department for the mechanical work.

AMF (ADVANCED MANUFACTURING FACILITIES) – Advanced machines are used in the manufacturing of the projects as SMT (Surface Mounted Technology), it is an automatic system to mount the item on the PCB.

PE (PRODUCTION ENGINEERING) – It is for the installation of the new machinery.

PPC (PRODUCTION, PLANNING and CONTROL) – In this the work is planned.

SC (SUB CONTRACT)

3. MM (MATERIAL MANAGEMENT):

It is the management of the materials.

PUR (PURCHASE DEPARTMENT) - This department purchases the materials.

ISM (INTEGRATED STORE MANAGEMENT)

HS (HOLDING STORE) – It has different bins that holds items after inspection.

IGS (INCOMING GOODS STORE)

MC (MATERIAL CONTROL)

4. MKTG / PA (MARKETING / PRODUCT ASSURANCE):.

MKTG (Marketing Division)

Sales – It is to prepare ESO equipment source order.

FGS (FINISH GOODS STORE) – After finishing the project it is sent to FGS for final packing.

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

PR (PUBLIC RELATION) –It is the relation with the customers.

TESTING – Products are tested by different tests

C TEST (CIPHER TEST) - It is the test for the secrecy.

PS (PRODUCT SUPPORT) – It is done after sale services.

SELF CERT (SELF CERTIFICATION) – It is the department which visits the place where work is going on.

5. QA (QUALITY ASSURANCE):

It deals with the quality of the material.

INSP(WA) {INSPECTION IN WORK ASSEMBLY)

INSP(WF) {INSPECTION IN WORK FABRICATION)

R&E (RELIABILITY & EVALUATION) - The materials are checked before giving it to customers.

6. P&S (PLANT AND SERVICES):

It is the department for providing the services to company. Services are water supply, electrical supply, transport, horticulture.

HRD (HUMAN RESOURCES DEPARTMENT) – it is the training center.

SECURITY – security facility is available.

7. HR & A (HUMAN RESOURCES & ADMINISTRATION):

PERSON. (PERSONNEL) – In this department the recruitment of employees is done.

ESTD. (ESTABLISHMENT) – It is to use manpower in different areas.

MEDICAL – Medical facilities are also available.

CRECHE

CANTEEN

WELFARE

8. F&A (FINANCE & ACCOUNT):

FINANCE - Department for the sanction of money.

PAYROLL – It is the salary of the employees.

BUDGET – It is made for one year.

ACCOUNTS – It is the record of the money.

AUDIT – Survey of the systems.

9. IS / MS (INFORMATION SYSTEMS):

MRP - All Production Related work related to assy, stores, purchase etc.

PAYROLL - Related to Salary.

FINANCE - Concerned with ledgers, sub-sidary ledgers,General ledger etc.

9. QM (QUALITY MANAGEMENT):

ISO (INTERNATIONAL STANDARDS ORGANISATION) – It is to sell our products in the international market.

6 SIGMA – It is the statistical Technique for maintaining

Quality.

TES (TEST EQUIPMENT AND SUPPORT) – Calibration or measuring of instruments.

IGI (INCOMING GOODS INSPECTION)

QCC (QUALITY CONTROL CIRCLE) – In this department there is a group of employees who discuss the problems, find out its solution and present it to manager.

BHARAT ELECTRONICS PANCHKULA AT A GLANCE

PLANT

Project Cost Rs. 248 million

Annual Project Capacity Rs. 400 million

Land for Factory 23 Hectare

Max Demand Electrical Power 4000 KVA

TOWNSHIP

Land 12 Hectare

No. of Flats 222

PROJECT COST BREAKUP

Civil and Utilities Rs. 75.50 million

Electrical work Climatic Rs. 46.50 million

Control facility

Plant & Machinery Rs. 107 million

Township Rs. 25 million

MANPOWER

Executives 107

Non-Executive 565

LECTURES

In this first stage that is during the first week of the training, the most efficient faculty members delivered lectures on various topics concerned with the productivity area of the company. The topics that were covered in the lecture are:

INTRODUCTION TO BEL

RADIO COMMUNICATION

PCB DESIGNING AND MANUFACTURING

TESTING AND TESTING INSTRUMENTS

ADVANCED MANUFACTURING FACILITY

FREQUENCY HOPPING RADIO

ORGANIZATIONAL SET UP AND PROJECTS OF BEL, PANCHKULA.

INTRODUCTION TO BEL

Bharat Electronics Limited(BEL) is a public sector undertaking under the Ministry of Defense. It is a professional electronic company in India incorporated in 1954.BEL was born to meet the growing needs of Indian Defense Services for electronic systems. Employing the best engineering talent available in the country, BEL has progressed manufacturing state-of-the-art products in the field of defense electronics like communications including encryption, radars and strategic components.BEL has diversified to meet the needs of civilian customers as well and has provided products and network solutions on turnkey basis to customers in India and abroad.

The Heads: Nowadays BEL is headed by the Chairman and Managing Director Mr. A K Datt. The General Manager of BEL, Panchkula is Shri Suresh N.

Milestones: BEL has nurtured itself to be known as one of the best public sector units in the nation.

Mission: To be the market leader in defence electronics and in other chosen fields and products.

Motto: The motto of BEL is Quality, Innovation ,Technology.

INTRODUCTION TO IS / MSIS / MS is electronic data processing department, here, all work is done on the computers. In this department, around 15 people are working here.I would like to express my gratitude towards Mrs Meenakshi Sehgal(Manager). This department is allotted to computer students who come here for the training. We, the trainee of EDP department, have made a project on LEAVE RECORD’ under the instructions of Mrs. Shobha Mittal .

The work is categorized in three sections:

ProductionFinancePayroll

FINACIAL ACCOUTING SUB SYSTEMS

Introduction: One of the activities of the finance and accounts department is the maintain ace of financial transactions and carry out the detailed information for various analysis. All transactions entered into the company have to be recorded as either debits or credits under different account heads. Five primary documents are used to record these transactions. At the end of a period, which could be a month, the entries in these documents are transcribed into the ledger of accounts. The net debit or credit entry in each account is computed and used to compile the Trial Balance, General ledger etc.

Objectives: (1) To generate the General Ledger for all account heads.(2) To prepare consolidated cash flow analysis.(3) To prepare the Trial Balance.(4) To prepare the subsidiary ledgers for the different account heads.(5) To generate cash and bankbook.(6) To prepare profit and loss via group schedules.(7) To prepare the balance sheet.

PAYROLL SYSTEM

Electronic Attendance Recording (Smart Card System): An Identity Card is issued to each employee with ID No on it. The attendance of each employee communicated by the readers installed at gate to the mainframe computer. Software of attendance recording is in Visual Basic. Salary is processed from 23rd of last month to 22nd of current month. Various Functions of Payroll Processing are: -

(1) Leaves: - Movement Orders, Leaves, Leave adjustments, Refund are the part of payroll processing. First of all above mentions leaves entered by EDP. Then these leaves are processed for validation and then error free leaves are updated in the leave file. Different type of leave are given as below: -

AL Annual LeaveAA Advance

Annual LeaveCL Casual LeaveSH Sick Leave

With Half PaySF Sick Leave

With Full PayOH Optional

Leave

LWP Leave Without Pay

AWL Absent Without Leave

SP Special Leave

COCompensatory OffPT Paternity

LeaveMT Maternity

Leave

(2) According to the attendance employees regularize their attendance. They can see their attendance on online module. Regularisations are then entered in F&A deptt.

(3) Every deptt. Enter shift of employees according to their shift. a. GS 09.00 17.00 For General

Employeesb. AS 06.00 14.00 For Security Staffc. BS 14.00 20.00 For Security Staffd. CS 20.00 06.00 For Security Staffe. A 06.30 14.30 For General

Employeesf. B 14.30 20.30 For General

Employeesg. C 20.30 06.30 For General

Employeesh. BB 14.00 20.00 Only for Apprentices

(2) F&A deptt send feeding file to EDP with different transactions like PG/PH, Loans, Savings, Leave Encashment, OT Single/double, Optional PF, Information about quarters, fixed earnings and deductions, bank A/C no,s etc. These all feeding are entered by EDP deptt for salary processing.

(3) Must-Roll is processed depending on the punches leaves of employees. And if punch is not available and leave also not applied then it marks AWL (??). This program also calculates attended hours, overtime (OT) hours, short hours, overtime days, night shift days (NSA), Lunch and subsidy days (L&T) etc.

(4) AL, CL leave program updates the leave file against AWL (??).

(5) According to the hours attended salary is processed.