Tuesday, November 26, 2013

Bharat Electronics Limited - Product Profile


Army Communication Products
Home/Products/Defence/Army Communication Systems

VHF Base Station (LVM 294)
VHF Repeater Station (LVS 297)
Secure UHF Radio (LUP 291)
Base Station
UHF Base Station (LUM 295)
UHF Repeater Station (LUS 296)
Man Pack/Vehicular
V/UHF Transreceiver (LUP 322)
V/UHF AM/FM Transreceiver – INCOM Compatible (LUP 329)
Secure VHF Handheld Radio (LVP 285)
Encryption Products
Secure Telephone for PSTN Network (Cryptel)
Subscriber End Encryption Device (SEED)
Bulk Encryption Unit – Secure Multi Interface Link Encryptor (SMILE)
Burst Error Control System for Teleprinter (BEST)
Spurt Message Alphanumeric Radio Terminal (SMART)
Handheld Field Ciphering / Deciphering Equipment (CORAL)
IP Encryptors
Duplex Crypto Device (BEACON MK III)
Secure Data Adaptor (SDA)
2 MBPS Link Encryptor
Link Encryptor for Versatile Environment (LIVE)
MFTDMA Encryptor
CDMA Handset Encryptor
Satcom Encryptor
STM 1 Bulk Encryption Unit
STM 16 Bulk Encryption Unit
Radio Relays
UHF Radio Relay
Military Switching & Network
Semi Ruggedised Automatic Exchange (SRAX Mk II)
Unit Level Switch Board (ULSB Mk III)
Network Control & Management System (NCMS)
Automatic Electronic Switch (AES Mk II – E972)
Data Communication
Stand Alone Communication Unit (SACU – 3100)
Hand Held Radio Terminal (HART)
Shelterised Multilayer Military Communication Network
Digital Mobile Radio Relay (DMRR)
Mobile Communication Terminal (MCT)
Strategic Communication System
Multilayer Voice & Data Network
Satellite Based Secure Communication Platform
Products Under Development
Software Defined Radio

Friday, November 22, 2013

Kirloskar Brothers Limited - Productivity - Cost Reduction Drive

Our productivity is one-tenth in comparison to China. China has high quality workforce and has achieved excellent productivity level by sweating of assets and effective utilization of available resources.


BMGI India - Lean Systems Consultancy

Breakthrough Management Group International (BMGI), a global consulting firm with a strong focus on delivering results, partners with organizations in various stages of their business life cycle to transform their business performance. BMGI is recognized as the world leader in harnessing the power of cutting edge techniques in the area of Innovation, Strategy, ProblemSolving and BusinessTransformation for achieving tangible business results. BMGI enables businesses drive growth and improve profitability. Headquartered in the US, BMGI has offices in 13 countries around the globe.

BMGI has delivered cumulative benefits to its clients worth several billion dollars with an ROI of 5:1 to 20:1.

In India, BMGI is located in Mumbai.

71B, Mittal Court Nariman Point, Mumbai, Pin-400021, India

For More Information, Contact:

Business Division

Vishnupriya Sharma
Phone : +91 22 4002 0045
Email : press@bmgindia.com
Corporate Office

Divesh Sawhney
Phone : +91 22 4002 0045
Email : press@bmgindia.com


Monday, November 18, 2013

India - Productivity Improvement Projects - Examples - 2012

Pune Productivity Council

Sr Case study No. Company Case Study Title

1 5 Tata Motors Limited, (Nano machine shop car plant-Pune.) Productivity improvement case study on machine availability improvement.
2 7 Tata Motors Limited, Nano machine shop car plant-Pune. Productivity improvement case study in nano machine shop car plant – Pune.
3 9 Tata Motors Limited, Nano Engine Assembly Car Plant-Pune. Need of production per shift to increase from 75 units to 100 units.
4 10 Minda Industries ltd (Switch Division) Pune. Productivity Improvement through losses elimination of left hand bar    switch assembly line and soldering line.
5 15 Mahindra & Mahindra Ltd. Nagpur. Productivity Improvement by 15% to meet the production requirement of 400 control valves in 2 shifts.
6 16 Mahindra & Mahindra Nashik. (Scorpio). To meet higher market demand at cheaper cost.
7 22 Bharat Electronics Limited Modification of alignment method of holder fixing through X-Ray Radiation to Optical Method for DRA1 X-Ray tube
8 30 Mahindra & Mahindra Ltd., Kandivali Plant. To improve utilization of resource i.e Man, Machine & Material.
9 32 Tata Blue Scope Steel Limited, Pune. Automation of stacker & conveyor on Trimdek Roll Forming Machine.
10 33 Tata Blue Scope Steel Limited, Pune. Optimum utilization of diesel generator power.
11 42 MGI COUTIER Exotech Industries Pvt. Ltd. Process Improvent in MFG Of Air Brake
12 31 Grindwell Norton – Saint Gobain Abrasives Ltd. Reduction in Rework & Customer Complaint for Small Wheel Sulphur Treatment product.
13 John Deere Capacity enhancement
14 John Deere Poka-yoke (Transmission)
Category -  Engg & Auto-   Associate
15 48 John Deere Energy conservation
16 49 John Deere Productivity improvement
17 50 John Deere Poka-yoke / Mistake proofing at Engine Assembly.

Sr Case study No. Company Case Study Title

1 47 Classic Auto Tubes Ltd. / Apollo Tyres Ltd. Reduce Scrap Cost due to Fly Loss
2 19 Mahindra Hinoday Industries Ltd. To meet 100% demand increase in induction cook top coils.
3 21 Maxtech Sintered Product Pvt Ltd. Receiving time reduction by VSM for product family Hego Boss.
4 4 Hindalco Industries Limited, Taloja. Improvement in Canron cold rolling mill speeds.
5 12 Hindalco Industries Ltd. Rolling emulsion bypass line modification.
6 1 Rashtriya Chemicals and Fertilizers Limited, Thal. Productivity improvement by steam saving. (Urea Plant)
7 2 Rashtriya Chemicals and Fertilizers Limited, Thal. Provision of Two Pressure Cooling water system by Cooling water Header Bifurcation
8 3 Rashtriya Chemicals and Fertilizers Limited, Thal. Productivity improvement by revamping Synthesis Gas Compressor Drive Turbine.
9 35 Tube Products of India Limited. Recovering the loss increasing increase in per shift output of 50 ton draw bench.
10 36 Tube Products of India Limited. Man power reduction by reducing material handling on new SINICO machine.

Sr Case study No. Company Case Study Title

1 8 Tata Motors Limited, Maval foundry. Energy conservation in melting shop.
2 11 Ashok Iron Works Pvt Ltd. Productivity improvement by reducing internal rejection.
3 20 Mahindra Hinoday Industries Ltd. To focus on preventive actions to eliminate equipment failures / breakdowns in order to ensure availability & reliability of equipments & to minimize cost of maintenance (TPM).
4 27 Mahindra Hinoday Industries Limited, Pune. Zero Breakdown Approach For Machine Availability up by TPM way.
5 28 Mahindra Hinoday Industries Limited, Pune. Improvement on G200TCI Flywheel Magnet (MHIL part no PD 1319) for crack & strength defect.
6 23 Excel Industries Limited, Roha. Productivity improvement case study by doing modification in ETP Slurry handling centrifugal Pumps & ETP Aerators for bioreactors.
7 37 Tube Products of India Limited. To eliminate manual tag cutting operation at SOOCO cutting machine to achieve 100% OTD in front fork.
8 38 Tube Products of India Limited. To eliminate wastage of abrasive cutting wheels by converting used abrasive cutting wheels into grinding wheels.
9 39 Epcos India Limited. Reduction in setting time and scrap during slitting of wave cut free margin profiles.
10 40 Epcos India Limited. Elimination of Excess consumption of Spray Wire.
11 41 Epcos India Limited. Reduction in setting time and scrap during slitting of wave cut free margin profiles.
12 45 SKF India Limited To improved productivity on bearing components machining.
13 6 BSA Facilities Limited Pune. Elimination of customer complaints in main wiring harness.
14 26 Seinumero Nirman Pvt. Ltd. POKA-YOKE (Mistake Proofing) of Tapped Holes missing on Magna-flanges.

Sr Case study No. Company Title

1 13 L.G Electronics, Pune. Error free operation in compressor model and circuit diagram fixing.
2 14 Essel Propack Ltd. Reduce changeover time lami tubes from 342 minutes to 60 minutes.
3 17 TATA TOYO Radiator Ltd. Productivity improvement of X3 Nano ECS assembly from 207 units / day to 347 units / day.
4 18 TATA TOYO Radiator Ltd. JD Radiator assembly quality improvement.
5 24 Godrej & Boyce Manufacturing Co. Ltd. Reduce vacuum forming process rejections by using Six-sigma methodology.
6 25 Mahindra & Mahindra Ltd (Automotive sector, Nasik). Capacity Enhancement & Manpower Optimization.
7 29 Tata Motors Limited, CVBU - Pune. KAIZEN Methodology for Breakthrough Improvements.
8 34 05 TATA Motors Limited, Pune. Uptime improvement in NANO engine testing car plant. Productivity improvement case study on machine availability improvement.
9 44 Kirloskar Brothers Development of UP & TB Pump  Improved Assembly process to increase productivity from 2 to 6 Pumps / man/shift.
10 46 Kirloskar Brothers Reduction in throughput time of large SCT thru bore Pumps from 14 Hrs to 8 hrs. By DFMA & Process Improvement.
11 43 Kirloskar Brothers Productivity improvement by reduction in manufacturing process time of SCT Pumps from 23 hrs per pump to 6 Hrs per pump. Discharge head quality improvement.
12 John Deere Equipment Pvt. Ltd. Vehicle shop capacity enhancement through lean.

Bharat Electronics Limited - Cost Reduction - Efficiency Improvement

Bharat Electronics Limited (BEL) is a state-owned electronics company with about nine factories.

It is owned by the Indian Government & primarily manufactures advanced electronic products for the Defence. BEL is one of the eight PSUs under Ministry of Defence, Government Of India. It has earned the government's Navratna status.

BEL designs, develops and manufactures products in the fields of:

Electronic Voting Machines
BEL Weapon Locating Radar
BEL Battle Field Surveillance Radar
Indian Doppler Radar
Samyukta Electronic Warfare System
Central Acquisition Radar (3D-CAR)
Reporter Radar
Sound and Vision Broadcasting
Information Technology
Akash (missile)
Composite Communication System (CCS)
Fire-control system
Electronic Warfare Systems
Samyukta Electronic Warfare System
Tank electronics
Combined day sight for Arjun MBT
Defence Communications
Data Link II communications system for the Indian Navy’s P-8I
Combat Management system for Indian Navy
Solar systems
Naval systems
A low-cost tablet pc being used in Socio-Economic Caste Census 2011
Biometrics Capturing for Nation Population Register.
Encrypters for Ministry of Home Affairs
IFF(Identify Friend or Foe) secondary Radar


Units of Bharat Electronics Limited are in the following cities and towns

Bangalore (Corporate Head Office)
Chennai, Tamilnadu
Panchkula (Haryana)
Kotdwara, (UttaraKhand)
Ghaziabad, (Uttar Pradesh)
Navi Mumbai

Cost Reduction Project by a Summer Intern

1) Servo Controller Tester

Developing a low cost, efficient and reliable system for testing “Servo Motor Controllers (SMC)” developed by BEL. The project simulated the antenna’s rotation based on the SMC’s power and control output.
the project  focused on the Doppler Weather Radar's (DWR) Servo Motor Controller (SMC).
The system setup description
It has a custom CPU core developed on a Virtex-4 FPGA, acting as the main processing element of the SMC.
This FPGA receives control signals from a radar controller via a LAN setup.
The antenna setup consists of a 4 ton S-Band antenna, 2 Servo motors to rotate the antenna in both elevation and azimuth positions, a rotary encoder to relay back the current position of the antenna to the SMC.
Once the rotation positions are received from the Radar Controller, the FPGA then controls an Azimuth amplifier and a Elevation amplifier which in turn drives an Isolation amplifier with a 3 Phase, 70KV AC output.
The power output of the isolation amplifier is then fed to the servo motor of the antenna which makes it rotate proportionately.
The SMC reads the current position of the encoder via a clock and data line. Clock lines and data lines are of RS485 to enable long distance noiseless transmission.
Now, to test a Servo Controller, BEL had to install the antenna setup which is a 4 ton S-Band antenna, build the "Redome" and then perform the testing. This costs BEL nearly INR 2,500,000 ($50,000) and nearly 3 months of labor to install the setup.

Project aimed at reducing the complexity involved in testing the SMC by developing a simulator of the antenna. This development involved interfacing with the SMC's ASIC core and the output power to the Servo Motor.

The design had an Analog Front End (AFE) and the MSP430 micro controller. The AFE interfaced the MSP to the Isolation Amplifier Output which usually drives the Servo Motor, and also to a reference clock (again differential) and a differential data transmission unit, all of which are in RS-485 standards and had to be reduced to the 3.3V logic of the MSP controller.

It is currently being used by BEL to test their Servo Motor Controllers.

2) A Universal antenna simulator with on-board programming support for ASIC adaptability

It is an extension of my project “Servo Controller Tester”.
BEL develops 2 versions of Doppler Weather Radars (DWR)’s, the C-Band and the S-Band radars. The SMC for each is different and so is the interface b/w the SMC and antenna.
This project allows the testing equipment to be reprogrammed with minor modification in the clock and counter sequence of the MSP430 controller for testing any version of the SMC. Since the interface unit to the antenna remains unchanged, there is no need for any modifications in the Analog Front End of the new  system.
It “adapts” to the ASIC used in the SMC.

The cost of testing using new system Rs. 1600 instead of the cost of old system Rs. 25,00,000.


Cost reduction efforts were due to design change, indigenization, and alternative sources of procurement.

During the period 2007-08 to 2009-10 the company achieved cost reduction of 398.23 cr. which was only  2.72 percent of total value of production.

Out of that Rs. 155.80 cr was due to negotiations with vendors.

Government of India Audit Report April 2011

26 October 2013
Rani Vergis, GM (finance)/BEL-Bangalore
Rani Vergis joined BEL-Ghaziabad in September 1985 after completing B.Com (Hons) from Delhi University and Chartered Accountancy. In a span of 24 years, she worked in all areas of finance at BEL-Ghaziabad. She served as Finance Head of Ghaziabad Unit and Military Radars and Military Communications SBUs of BEL-Bangalore before being transferred to BEL’s Corporate Office. She won the BEL Executive Excellence Award in the year 2002-03. She has also served as Secretary and later as Chairman of the BEL Provident Fund Trust (Northern Units) and has been a member of the Productivity Steering Committee of BEL-Bangalore and Corporate Steering Committee for cost reduction in BEL.

BEL Project report