INDUSTRIAL TRAINING

PROJECT REPORT
AT





Submitted by:-
Gagan maggo
Upt no. : 6123\14


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
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 of
Telecommunications, 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.


Manufacturing units




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.
- 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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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
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 by
DRDO 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
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








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
Sales It 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.




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 Fabrication It 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



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


9. F&A FINANCE & ACCOUNTS
Finance Dept. for the sanction of money.
Payroll It is the salary of employees.
Budget
Accounts
Audit Survey 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









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
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 30 88 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 frequency
hopping 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
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 the
receiver 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
4. SECURE UHF HANDHELD RADIO (LUP 291):

LUP 291 is a UHF handheld radio with inbuilt high grade digital secrecy. The radio
set is state of the 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
Built in high grade Crypto
32 Preset crypto keys + 1 manual key
Selective call facility
16 Preset frequencies

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










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
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















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
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
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 Initiatives
The 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 electrical
energy 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.
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 in
reduction 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: CII Godrej 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.