INTRODUCTION

Bharat Electronics Limited (BEL) is a professional electronics company of India

with a note worthy history of pioneering achievements.

BEL was established in 1954, and is basically a defense organization. BEL has grown
to a multi-product, multi-unit, technology driven company. With over five decades of
experience, BEL has pioneered the professional electronics movement in India. BEL
has the knowledge for designing & developing electronics warfare systems in area of
Signal Intelligence, Electronic Support Measure.

BEL has setup an impressive infrastructure and manufacturing facility in their NINE
ISO certified production units around the country.

BEL has established two joint ventures with General Electric Medical System, USA
and Multitone, UK.

BEL has won a number of national and international awards for productivity, quality,
safety, standardization etc.

BEL is involved in providing state of art communication equipment to the INDIAN

ARMY be it hand held radios & terminals, ground based systems, airborne & even
ship borne equipments & systems. Products & systems offered by BEL cover HF, VHF,
UHF & V/UHF frequency bands.

BEL manufactures wide variety of control command & communication systems as

well as RADARS, SONARS, various tranreceivers, for example STARS-V 25, TX/RX
LUP 322 etc.

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 OVERVIEW

The information regarding BEL is categorized under the following headings:

 BHARAT ELECTRONICS LIMITED AT A GLANCE

 MISSION & OBJECTIVES

 HISTORY/MILESTONES

 MANUFACTURING UNITS

 REGIONAL OFFICES

 JOINT VENTURES

 INDIAN MARKET

 CLIENTS

 PRODUCTS

 PROJECTS

 ORGANISATION OF BEL PANCHKULA

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 BHARAT ELECTRONICS AT A GLANCE

Bharat Electronics Limited (BEL) established in 1954 with its corporate office at
Bangalore, has nine units in the country. It is engaged in the design development
and manufacture of sophisticated State-of-the-art electronics
equipments/components for the use of defence services, Para military organisations
and other governmental users like All India Radio, Doordarshan, Department of
Telecommunications, Police Wireless, Meteorological Department, etc. The BEL is
also the premier indigenous source for professional electronic equipment.

State-of-the-art manufacturing testing and quality assurance facility has been set u p
in all units of BEL. On line computerisation for materials management state-of-the-
art test facilities, facilities for carrying out environment and reliability checks electro-
magnetic interference/Electro Magnetic Compatibility Testing facility, Antenna
Testing facility, back-up support from Standardisation Technical information and
Documentation, Computer Aided Design and Manufacture have made BEL a modern
professional Electronic Company. All manufacturing divisions/units of BEL have been
accredited with ISO 9002/ISO 9001.

Bharat Electronics Limited (BEL) designs, develops and manufactures state-of- the-
art products in the field of Radars, Defence Communications, Telecommunications,
Sound and Vision Broadcasting, Opto-electronics, Solar systems, IT products and
Electronic components. BEL has the expertise in engineering Radar, Telecom and
Satcom networks, providing network solutions to meet customer needs. These
systems are supplied and commissioned on turnkey basis.

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

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 MISSION & OBJECTIVES

MISSION

To be a customer focussed, globally competitive company in defence electronics and

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

OBJECTIVES

 To be a customer focussed 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 strive for self-reliance through indigenization.

 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 realise their full potential

through continuous learning & team work.

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

 To constantly benchmark company’s performance with best-in-class

internationally.

 To raise marketing abilities to global standards.

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 HISTORY/MILESTONES

HISTORY

SINCE 1954

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

BEL has set up impressive infrastructure and 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 and Multitone, UK for paging systems and has a subsidiary
company BEL Optronic Devices Limited for the manufacture of Image Intensifier
tubes.

MILESTONES

BEL has nurtured itself to be known as one of the best public sector units in the
nation. A peep into Bharat Eectronics's Archives section, gives an idea of the
progress at BEL.

2003 BEL celebrates its Golden Jubilee Year

2002 BEL acquires Category -I Mini Ratna status
Foundation Stone laid for BEL's new corporate Office Building
2002
in Bangalore
2001 BEL bags National R & D Award in electronics Industry sector
Bangalore Unit of BEL implements Rain Water Harvesting on
2000
an industrial basis
1999 Bharat Electronics Quality Institute

1998 - Hyderabad unit gets ISO 9002

1998 Kotdwara unit gets ISO 9001

1996 Joint venture with Multitone and GEMS
1994 ISO-9001 Accreditation
1993 ISO-9002 Accreditation

1992 - Central Research Laboratory, Ghaziabad

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1991 SATCOM
1990 EMI/EMC Test Facilities & Computer Software
Telecom - Switching & Transmission System and Mass Mfg.
1989
Facility
1988 Central Research Laboratory, Bangalore
1987 Naval Equipment Division
Kotdwara, Taloja & Hyderabad Units. Klystrons & Traveling
1986
Wave Tubes.
Madras & Panchkula Units, Broadcast & TV, Digital
1985
Communication Equipment Divisions, Vacuum Interrupters
1983 (ASCO) Machilipatnam Integrated with BEL
1982 Space Electronics Division

1979 - Pune Unit

1974 Ghaziabad Unit

1972 B/W TV Picture Tubes
1971 Integrated Circuits & Hybrid Microcircuits
1970 X-Ray Tubes & Magnetrons
1968 HF & Broadcast Equipment, Silicon Semiconductors
1967 Transmitting Tubes
1966 Radars
1962 Germanium Semiconductors
1961 receiving Valves
Equipment Production started at Bangalore (present LPE
1956
Division)
1954 Incorporation of BEL

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 MANUFACTURING UNITS

In 1954 with a factory of Jallahali, Bharat Electronics grew into nine units, spread all
over the 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
this complex. This is the biggest unit with approx. 10000 employees working here.
Among the products manufactured here, the important ones are:
 Military Communications
 Naval Systems
 Radars
 Telecom & Broadcasting Systems
 Electronic Components

2. GHAZIABAD:

This is the second unit which was setup in 1974, &approx. 2500 employees are
working here. The products manufactured here are:
 Radars
 Antennae
 SATCOM(Defence)
 Microwave Components

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 3. PUNE:

To diversify further one more branch was added in 1979 & this was in pune. In this
branch around 700-800 employees are working here.
The product profile includes:
 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 product includes:
 Optical Products
 Medical Electronics

5. TALOJA:

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

 Shelters for Electornic Equipment
 Train Actuated Warning System
 Electornic Equipment Assembly

6. PANCHKULA:

Panchkula & Kotdwara were proposed simultaneously by the Government in 1985. It

was proposed to setup one unit each in Haryana & Uttar Pradesh. But the place in
U.P. for setting up a unit could not be decided while at Haryana it was decided &
hence this unit started earlier. This unit manufactures only Tactical Communication
Equipment.

7. KOTDWARA:

This is a unit in Garhwal district of U.P. this manufactures radio relay, multiplex
equipments & exchanges etc.

8. CHENNAI:

The eighth unit of BEL was established in Chennai. This unit manufactures:
 Tank Electronics
 Optical Fire Control Systems

9. HYDERABAD:

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

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 REGIONAL OFFICES

LOCATION IMPORTANT ACTIVITIES

1. NEW DELHI
 Co-ordination with Government
Bharat Electronics Limited
representatives & Defence
8th Floor, 36, Janpath
customers
New Delhi-110001

2. KOLKATA
 Co-ordination with customers in
Bharat Electronics Limited
the Eastern region.
40, Ashutosh Mukerjee Road
 Service centre
Kolkata-700020

3. MUMBAI
Bharat Electronics Limited
 Co-ordination with customers in
World Trade Centre, 9th Floor
the Western region
Unit 1, Centre 1, Cuffe Parade
 Customers clearance
Colaba,
Mumbai-400005

4. CHENNAI
Bharat Electronics Limited
 Co-ordination with the customers
SIET Building
in Tamil Nadu & Kerala
312, Anna Salai
Chennai-600018

5. HYDERABAD
Bharat Electronics Limited  Co-ordination with customers in
5-9-241,Abids Road Andhara Pradesh
Hyderabad-500001

6. VISHAKHAPATNAM
Bharat Electronics Limited
 Co-ordination with the Indian
c/o WED (V), 9-IRSD Area
Navy.
Kancharapatnam Post
Vishakhapatnam-530008

BEL also has Over Seas Offices in SINGAPORE & NEW YORK

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 JOINT VENTURES

BEL-GE Medical Systems

GEBEL is a joint venture between Bharat Electronics and General Electric Medical
Systems. The facility based at Whitefield, Bangalore, India, manufactures X-ray
tubes, for RAD & F and CT systems, as well as components such as High Voltage
Tanks and Detector modules for CT system. The products are exported worldwide
and meet the safety and regulatory standards specified by FDA, CE, MHW, AERB and
the facility have been accredited with ISO 9001 certification. GEBEL also markets the
conventional X-ray tubes made at Pune Unit of BEL.

The turnover of GEBEL during 2002-2003 was over Rs. 350 Crores including an
export of over Rs. 310 Crores.

The company was recognized for its outstanding export performance during 2000-
01; 2001-02 by the Export Council. Besides, the facility has been recognized by GE
as a Global Star site meeting the Environment, Health & Safety standards.

Apart from manufacturing, a dedicated engineering team is working on the

development of new tube technologies to meet global needs.

BEL-MULTITONE

BEL and Multitone, UK, offers state- of- the- art Mobile Communication Products for
the workplace. Multitone invented paging in 1956 when it developed the world's first
system to serve the "life or death" environment of St.Thomas Hospital, London. With
the strength of Bharat Electronics in the Radio Communications field and the
technology of Multitone in the field of Radio Paging, the joint venture company is in a
position to offer tailor made solutions to the Mobile Communication needs at
workplaces in various market segments.

The joint venture offers one of the most comprehensive on-site product ranges -
from small, easy to use pagers to practical, durable private Mobile Radios and the
latest technology, digital cordless communication systems. Brief details of the
products are:

 Access 700 one-way speech paging system which supports 100 pagers.
 Access 1000/3000 Radio Paging system which supports 1500/5000 users.
 Computer Radio Integration units.
Digital Cordless Communication Systems.

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 INDIAN MARKET

Bharat Electronics Limited is a major supplier of products and turnkey systems to the
Indian Defence Services. Over the years, BEL has diversified into manufacturing
many civilian products as well. Large turnkey telecommunication solutions are also
being offered to civilian market. A brief list of the Customers in the defence and
civilian market segments and the products and services offered to them is given
below:

Products and Services Customers

Defence Communication Indian Defence Services, Para-military forces

Indian Defence Services, Civil Aviation,

Radars & Sonars
Meteorological Department, Space Department.

Department of Telecommunication, Para-military

Telecommunication
forces, Power sector, Oil Industry, Railways.

Broadcasting Equipments and All India Radio, Doordarshan, (National Radio & TV
Studio Systems Broadcasters).

Electronic Voting Machine Election Commission of India.

Solar Products & Systems Individuals, Private and Government organizations.

Turnkey Systems, E-Governance Police, State governments, Public sector

Networks undertakings.

All India Radio and Doordarshan the National Radio

& TV Broadcasters, Instrumentation Industry,
Components
Switching Industry, Entertainment Industry,
Telephone Industry.

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 CLIENTS

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

 ARMY

 NAVY

 AIR FORCE

 PARA MILITARY FORCES

 SPACE DEPARTMENT

 ALL INDIA RADIO

 DOORDARSHAN

 MINISTRY OF EDUCATION

 DEPARTMENT OF TELECOMMUNICATION

 CIVIL AVIATION

 METROLOGICAL DEPARTMENT

 IRRIGATION AND ELECTRICAL DEPARTMENT

 OIL INDUSTRY

 MEDICAL AND HEALTHCARE

 TELEPHONE INDUSTRY

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 PRODUCTS

The products of BEL are mainly focused on defence purposes but later on BEL also
started manufacturing some commercially useful items also. The major products
include communication devices which provide secure mode of communication. Also
the major products include RADARS, X-RAY tubes, and TRANSRECEIVERS etc. BEL
has been involved in providing state of art communication equipment to the Indian
Army, be it hand held mobile radios and terminals, ground based systems, air borne
and even ship borne equipments.

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 the frequency hopping is being
implemented which is a very useful tool in making a secure data transfer system.

BEL manufactures a lot of products which are very difficult to list but some of the
major products are given below:

o Integrated circuits and micro circuits

o X-ray tubes and magnetos
o B/W picture tubes
o HF & broadcast equipment
o Radars
o STARS-V
o SECTEL
o CNR
o HUD
o ACME MK II
o Space guiding equipments
o Airborne GPS receiver
o PRIME
o LUP
o SRAX
o TIDEX
o SECURE FAX
o SECURE TELEPHONE
o SPURT MESSAGE ALPHANUMERIC RADIO TERMINAL (AS-7306)

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 PROJECTS

1. VHF/UHF TRANSRECEIVER (LUP 322)

The Radio Set LUP 322 is a fully solid-state, light weight, high performance
V/UHF transreceiver designed for ground –to-ground and ground-to-air
communications. It thoroughly complies with existing VHF, UHF and V/UHF
transreceiver standards. The transreceiver covers the VHF band of 100 to 156 MHz
and UHF band of 225 to 400 MHz in 25 KHz channel spacing. It provides 2 way AM
simplex communication. The transmitter output power is 5 Watts (CW) with provision
for reduced output levels. 16 channels can be field programmed into memory bank A
and 16 other channels into memory bank B. The radio set operates from 24 volts
NiCd battery. The radio may also be connected to an external 24V-dc source such as
a vehicle battery. An AC power supply is available as an option for fixed site
operation using either 110V or 220V ac supplies.

100-156 MHz & 225-400 MHz

25 KHz channel spacing
9240 synthesized channels
32 channel instant recall continuous memory
LED display of frequency
Built in test facilities
High reliability
Low lifetime cost
Remote control
Automatic rebroadcast
ATE compatible
Mounts easily in most vehicles

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2. STARS-V (SECURE TACTICAL ARMY RADIO SYSTEM 5W/25W)

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 upto 2 km. All front panel
controls (except ON/OFF) are extended using 2 wire cable 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 manpack as well as vehicular applications for providing
voice and data communications in VHF frequency range of 30-88 MHz.

VHF frequency range of 30 - 88 MHz

2320 channels with 25 KHz spacing
1W/2W/5W/25W power outputs in different m odels
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
Manpack / Vehicular roles

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 3. CNR (COMPOSITE NET RADIO)

VHF transreceiver (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.

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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 4. 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
subscriber’s 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 QASK modem. 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.

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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 ORGANISATION

BEL Panchkula has different divisions which are further divided into departments:-

1. D & E (Development and Engineering)

 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.

 DRG OFFICE – It is the Drawing office.

2. 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

the instructions.

 PR (Public Relation) – It deals with public relations.

3. 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)

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 4. MS/HRD (Human Resources Department)

 HRD – It is the training centre.

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

also for the enquiry of an item.

5. MM (Material Management)

It is the management of the materials.

 ISM (Integrated Store Management).

 PUR (Purchase department) – This department purchases the materials.

 HS (Holding Store) – It has different bins that hold items after inspection.

 IGS (Incoming Good Store).

 MC (Material Contract)

6. PA (Product Assurance)

 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.

7. P & S (Plant and Services)

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

8. P & A (Personnel & Administration)

 Security – this department look after the security of the company

premises and the residential townships.

 PERSON. (Personnel) – In this department the recruitment of employees is

done.

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

 MEDICAL – Medical facilities are also available.

 CRECHE

 CANTEEN

 WELFARE

9. F & A (Finance and Account)

 FINANCE – Department for the sanction of money.

 PAYROLL – It deals with the salaries of the employees.

 BUDGET – It is made for one year.

 ACCOUNTS – It is the record of the money.

 AUDIT – Survey of the systems.

10. QM (Quality Management)

 ISO (International Standards Organization) – It is to sell our products in

the international market.

 6∑ - 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 group of

employees who discuss the problems, find out its solution and present it
to manager.

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 IMPORTANT FEATURES

PLANT FEATURES

Project Cost Rs. 248 Million

Annual Project Capacity Rs. 400 Million

Land for Factory 23 Hectares

Max. Demand Elec. Power 4000 KVA

TOWNSHIP
Land 12 Hectares

No. of Flats 222

PROJECT COST BREAK UP

Civil & Utilities Rs.75.50 Million

Electrical marks Climatic & Dust Control

Rs. 107 Million
Facility

Township Rs. 20 Million

MANPOWER

Executives 107

Non-Executives 565

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 PRODUCT GROUP

Production, Planning And Control

This sub-department forms the most important section among the others present,
because it forms the ‘Back bone’. Right form the beginning till the end of the
production of a particular set the responsibility lies in the hands of this section, it
mainly performs three functions namely:

 Scheduling
 Launching
 Control

The market section takes the order forms the customer and gives the equipment
stock order to PPC. The management- servicing department prepare the work order
and given it to PPC. Now PPC makes the list of each component involved in product.
This called Scheduling.

Next function that comes in launched PPC prepares shop order and engineering
documents such as drawings. This function is called Launching.

Now comes material control. Here PPC keeps track of production i.e. the purchase
requisition is given to purchase department and the sub-contact department. The
purchase material comes to IGS (Inward goods section) where it is tested in IGI. The
accepted pieces are then stored in holding stores.

ASSEMBLY SECTION

As the name suggest, in this department all the components are mounted on PCBs.
This PCBs are than set properly in the complete set. It is divided into three sections.

 PCB Assembly section

 Coil winding section
 Final assembly section

The sets reach the final assembly section only after they pass all the tests, done in
the inspection department.

AUTOMATED ASSEMBLY INSPECTION

When the components have been mounted on the PCBs then the prepared PCBs are
brought to AAI (Automated assembly inspection). In AAI electrical test is done on
each individual component. This is very important department because it ensures
that quality of BEL standards is maintained.

An automated machine knows as in circuit tester does the checking. The make of the
machine is GEN RAD-2372 CIRCUIT BOARD TEST SYSTEM. PCB has to be tested;
first of all the drawing of the circuit is taken. Every path, connected branches of two
components is given a number manually. This number has to be fed in the program
that is entered through a keyboard to the in the circuit tester. When all the
numbering has been done, a program is fed into the machine. There is a monitor
present for viewing the entire being done. The machine bites its own number known

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as Hybrid numbers. These numbers give information about the nail where the wiring
connection has toile done during the checking of PCB is placed, such that one end of
the needle holds the junction point (where the components is soldered to the PCB),
while the other end of the needle a wire is connected. The other end of the wire is
connected a particular nail whose number matches with the hybrid number given by
the machine itself.

At a time only one PCB is tested. When a PCB is placed over the needle with the help
of a vacuum it is tightened to the casting. It should be noted that a very important
advantage of using this machine is that tasting of an individual component is done in
such a way that it is guarded from the surrounding components. By the term
guarding it means that the testing takes place as if only the particular component
was present. This advantage is really essential because the presence of other
components do affect the testing.

The in-circuit tester checks the value of an individual component. It checks whether
particular component has been done without error. It is a master of few seconds in
which the in-circuit Tester checks a PCB containing hundred of components.

If not for the Presence of the machine, it would have been impossible to check the
PCBs manually. It really pays for its cost, which is approximately Rs. 60 Lakhs.

TESTING & INSPECTION

AAI mentioned above is by itself a part of inspection section, but due to its
importance mentioned, it is a separate section in PG-I. Inspection is done at every
stage of PCB namely at:

 Module stage
 Sub-assembly
 Final stage

It is also done after environmental testing and before sending for testing. The most
important parameters that are to be followed during the inspection are as follow:

1. The values of the various components.

2. The visible characteristics of the various active devices.
3. Various interconnections.
4. Whether the BEL standards are being maintained or not.

Testing is very important stage in production of any stage module. Hence various
specifications, which a product has to be given to the customers, are checked. The
quality of the product is highly maintained in this department because the
instruments are used in the fields and any failure to the systems in the field may
result in large damage. For this, highly supplicated instruments are used in the
testing that is calibrated regularly in the TES (Test equipment support). If the PCB is
faulty, then fault is specified in troubleshooting.
In PG-1 manufacturing of VPS & DBC is the main job. Testing of VPS is done in two
main stages namely:

1. PCB level testing

2. Main testing

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PCB level testing takes place in various steps. Firstly these PCBs are kept in chamber
o o
with temperature of -30 C to +50 C. This is done to check the stability of the
characteristics of the PCB as well as its components. This process is done for
approximately 80 hours. This is called Ageing process.

The PCB that passes out of the ageing process are then brought in the block to put
them through Test Jigs. These test jigs provide the perfect environment in the terms
of signals that the actual set shall face in the field.

In testing the product is subjected to adverse conditions to check the reliability of

the product under the condition in which the defense forces will use it.

The PCB is sent to assembly section back and they come out clear from the test jigs.
Now in the assembly section all the components are packed finally. These packed
sets are now sent for main testing.

The main testing includes many sternums test that the sets face. The first is the
BUMP & VIBRATION TEST. This is done to check the resistance of the set against
mechanical bumps and vibrations.

Next is the Thermal Shock Test. To check the availability of the set to sudden change
in the temperature, Thermal shocks are given. The sets are subjected to temperature
range of 40 oC to 70oC.

Leakage test is done to check the set for any leakage. In this Radio is immersed in
water. The air is filled inside set through a nozzle at pressure of 3 PSI. If air bubbles
appear on the set then it is sent for repairing.

There is a spatial section in the testing by the name CHIPER. Here the encryption
part of the PCB is enabling and checked and the entry in this section is strictly
restricted for anyone, apart from authorized personnel.

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 QUALITY POLICY

We are committed to consistently deliver enhanced value to our customers, through

continual improvement of our products and processes.

OBJECTIVES

1. Effective and Efficient design and development process, considering the

present and future needs of customers.

2. Enhanced customer satisfaction by on-time delivery of defect free products

and effective life cycle support.

3. Continual up gradation and utilization of infrastructure and human resources.

4. Mutually beneficial alliances with suppliers.

5. Continual improvement of processes through innovation, technology and

knowledge management.

TORQUE

(Total Organizational Quality Enhancement) is the mantra being followed in BEL

today. It is being imbibed into BELs culture through three phases:

 Knowledge
 Application
 Normalization

QUALITY MANAGEMENT

Development of Quality Assurance System In The Early Stages.

I. Right from inception in 1954, the Management of Bharat Electronics has

understood the varying levels of Quality and Reliability required by our
customers and has been striving to give them complete satisfaction in these
areas. Bharat Electronics has developed Quality Systems and Procedures over
the years.

II. Right from inception in 1954, the Management of Bharat Electronics has
understood the varying levels of Quality and Reliability required by our
customers and has been striving to give them complete satisfaction in these
areas. Bharat Electronics has developed Quality Systems and Procedures over
the years.

III. From the initial days of the company, we had a unique opportunity to interact
with large electronic manufacturers like Siemens, Germany; Plessey, U;
Contraves, Switzerland; Signal Apparaten, Netherlands; Bendix & RCA, USA;
Nippon Electric, Japan; Thompson CSF, France; etc. Based on these

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 interactions and our own studies were developed having good Quality
Assurance Systems.

IV. Quality is the responsibility of the owner of the process. Quality functions of
the design, manufacture, etc., are well integrated with the Central Quality
Assurance Division which provides overall support for QA activities in the
company. Starting as an inspection oriented Quality system during the fifties
and sixties, we are the pioneers in adopting the MIL-Q-9858 Quality
Management System during the early seventies. The distinguishing features
of this QA System are:

a) Bifurcation of Quality functions into staff and line functions

b) Responsibility for satisfactory conduct of line functions is assigned to

respective manufacturing divisions and responsibility for satisfactory
conduct of staff functions is assigned to QA division. The central QA division
was therefore, equipped with all the required infrastructure facilities to
perform the intended QA functions.

During the period 1976 to 1987, a number of initiatives were taken to improve the
Quality Management System.

They include:

a) Release of documented QA manual

b) Promotion of participative culture in the organization
c) Launching of QC Circles & Suggestion Scheme
d) Introduction of Quality Management System
e) Product Quality Improvement covering:

i. Identification of implicit and explicit needs of the customer for each product
ii. Design control aimed at optimum design and development
iii. Standardization aiming at careful selection of materials, components,
processes and vendors
iv. Quality assessment using intensive testing and evaluation at each stage
(inward goods, prototypes, production models and final products).
v. Building robustness in design using parameter design and tolerance design
techniques
vi. Provision of useful documentation for operation, maintenance, installation and
useful hints for proper usage of equipment
vii. Customer support aimed at warranty support, provision of spares with
commitments up to 10 years or more
viii. Training of customer representatives in understanding the layout and
operation of equipment, etc.

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INTRODUCTION TO TQM (TORQUE)

Bharat Electronics has adopted the Total Quality Management (TQM) philosophy
under the acronym "TORQUE" which stands for Total Organizational Quality
Enhancement. This is a disciplined approach to manage Quality by involvement and
commitment of all levels in the organization. TORQUE is a problem solving and
process-improving methodology. TORQUE is used as one of the factors to evaluate
the performance of the divisions.

TORQUE PARAMETERS

1. Quality cost (percentage to production value)

2. (a) Number of processes under Statistical Process Control(SPC ) (b) Yield
increase percentage
3. Cycle time reduction for purchase requisition to purchase order (average lead
time in number of days)
4. Cycle time reduction for sub-contract requisition to sub-contract order (average
lead time in number of days)
5. Percentage full-kit launching to total
6. Down time for key machines (% down time to available time)
7. Worst case response time to customer c omplaints for service (in number of
days)
8. Delay in supplies - rupee months (with reference to monthly action plan)
9. Quality Control Circle (QCC)
o % Coverage
o Number of case study presentations
o Number of dormant circles for activation

Major TORQUE Initiatives

The major initiatives taken for implementation of TQM (TORQUE) during the period
from 1987 till date are as follows:

 Formation of Steering Committee and Training on TORQUE; release of TORQUE

Manual
 Introduction of Quality Cost calculation methodolog y and improvement of the
same
 Revision of QA Manual based on ISO 9000 standards
 Formulation of Quality Policy and further revision of the same during 1996
 Revision of Company's Mission and Objectives
 Certification of 2 divisions to ISO 9001 and 27 divisions to ISO 9002 Quality
System standards
 Customer Satisfaction Service

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  Audits of Quality Systems, Processes and Products
 Reliability prediction for all products
 Computerization of Quality Management System (MRP II)

Thrust Areas of TORQUE

a) Improvement in Quality Management Systems

b) Consolidation and improvement of Quality Control Circles
c) Introduction of Statistical Process Control (SPC)
d) Reduction of cycle time in all areas and thus reduction delivery time of products
e) Improvement in Quality of design
f) Collection and analysis of Quality costs and reducing cost of poor Quality
g) Institutionalizing continuous improvements with the involvement of employees
in all areas
h) Improvements in safety of operations, Quality of work life and customer
satisfaction

Journey through Torque:

Our journey towards TQM (TORQUE) covers the following aspects:

1. Human Resource Development And Utilization:

Education, Training, self-development and career development opportunities
form the essential elements of HRD, aimed at utilization of full potential of
human resources.

2. Employees' Participation In Improvement Process:

Quality Control Circles (QCCs) are playing a significant role for contributing in
improvement in various areas. There are 462 circles covering 35% of
employees and more than 1300 problems have been identified & solved so far.
Many of our QCCs have won awards at various forums and two circles have
participated in International Conventions bringing laurels to the organization.
Suggestion Scheme is playing complementary role to QCC in the improvement
process. From April '95 to Dec '95, total number of suggestions given is 355
involving 517 suggestors.

3. Safety And Health Of Employees:

Safety and health of employees are considered important factors contributing to
productivity. A full fledged Safety Department takes care of this aspect, with
various activities having focus on creating awareness among the employees.

Quality of work life of employees, conducive work environment and concern for
society play a significant role for organization efficiency. Statutory committees
formed within the organization, welfare measures adopted by the management

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 and effective steps taken to maintain a healthy and clean environment are
aimed at achieving this objective.

4. Company's Standardization:
Standardization & Quality are two inseparable parts of TQM process and they
play a complementary role. The corporate standards department, with four
decades of its activity, has evolved 4000 standards providing effective support
for design, manufacturing and vendor development.

5. Quality Function Deployment(QFD):

To ensure that the requirements of the customers are understood and the same
are translated into product design, the following steps are taken:

 R & D holds regular meetings with the customers to understand their

requirements before actual design work is started
 Design review meetings are held to make mid-course corrections
 Products undergo evaluation at each & every stage to check that they meet
quality and reliability requirements of the customers
 Extensive user trials are carried out before finalization of design
 Design modification takes place based on feedback provided by customers

6. Listening Of The Voice Of The Customer

 Feedback meetings with all major customers are held twice in a year to
resolve problems
 Every product shipped from the factory goes with a set of feedback cards in
which customers can report any defects observed in the product for
corrective action
 Senior officers from R & D, quality and Sales visit customers periodically to
understand the customer problem and the information is passed on to the
concerned agencies
 Accessibility is provided to customer to have any information needed by him
 Customer Satisfaction survey is made once in three years by a Senior
Executive of the Company

7. Bench Marking
The data pertaining to Quality of products and Services is collected from our
collaborators like NEC, Japan; HAS, Holland; Thompson CSF, France; Motorola,
USA; etc., and from other leading manufacturers like Hewlett Packard, USA and
India; Anritsu, Japan; etc. Data with regard to value engineering, concurrent
designs, Design of experiments, Quality Function Deployment and marketing
strategies are compiled from time to time. The data is first analyzed at the
company's director's level and distributed to senior managers for taking
appropriate action with regard to implementation. Information is also collected

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 with respect to business strategies, value added per employee, inventory, etc.
for comparison and improvement. In the strategic electronics area, the Quality
level of our products compares favorably with the Quality levels of
corresponding products of our collaborators and other companies
manufacturing similar products elsewhere in the world. One of the crowning
achievements is the s uccessful execution of a prestigious export order for
RADAR sub-systems to an European country by Bharat Electronics, Bangalore.

8. Monitoring Quality During Manufacturing

The major thrust is on prevention of defects rather than detection and
correction. This is ensured by:

 Having line Quality functions in manufacturing divisions by the respective

QA departments
 Central QA division overseas implementation of Quality Management
System and Procedures by production divisions
 Use of standard & approved components and materials
 Identification of 'special processes" and application of SPC techniques
 Periodic calibration of all instruments used in manufacturing areas and
preventive maintenance of machines
 Formation of fact based "problem solving terms" in production areas

9. Other Initiatives For Further Improvement Include:

Modernization of assembly, testing, plating and painting shops to ensure better
infrastructure facilities
 Formation of Productivity Steering Committee for monitoring productivity
 Establishing "task force" for better inventory control
 Strict monitoring of vendors / sub-contractors by vendor evaluation and
rating system

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