COURSE NO – ME 332 COURSE TITLE – PRODUCTION PROCESS MECHANICAL DEPARTMENT PREPARED BY F/O RUBAIAT ISLAM LINDA GAZI ASRIB BIN SALAM FATEMATUZ ZOHORA - 200518013 - 200518029 - 200518040 2 • ACKNOWLEDGEMENT First of all we would like to thank our honorable instructors of MIST for giving us the opportunity to complete our Industrial Training in a place like Bangladesh Machine Tools Factory. Abu Taher. During the Industrial Training period. We would also like to thank all the technicians in different shops for helping us to understand the operating system of different machines during preparation of the jobs given by different Deputy General Managers of different shops. We are grateful to respected Deputy Managing Director of BMTF Col Md. all Deputy General Managers of different shops have helped us a lot by spending their valuable times with us by giving advices regarding our training and operations of different machines used in BMTF and by giving us opportunity to work with different machines. Mominul Hoque. honorable Managing Director of Bangladesh Machine Tools Factory for allowing us to have a rare opportunity to visit and to do work in hand in this factory. We would like to thank Lt Col Md. At last but not the least we would like to thank Brig Gen Md. 3 . Shahid Sarwar. General Manager planning and training. We are very much grateful to them for their help. who helped us a lot by giving different ideas to complete the training. for giving us the opportunity to visit and to do work in different shops practically. afwc. psc. psc. which will help us to gather practical experience of working in industry. CONTENTS S/N 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 TOPICS Introduction Different departments Planning and training department Accounts department Marketing department Purchasing department Production facilities Central tooling department Machine shop Forge shop Foundry shop Assembly shop Pattern shop Forging heat treatment shop Load body surface preparation shop Past products of BMTF Products under army management Present state of BMTF Achievement Economic efficiency Comparison Limitations Recommendations Assignments Conclusion PAGE NO 5 6 6 6 7 7 8 9 10 10 11 12 15 15 16 17 19 22 22 22 22 23 23 24 26 4 . c. within the jurisdiction of the Ministry of Defence. Open area for proposed workers colony – 31.66 acres. which needed to be managed properly.66 acres. e. This factory was conceived in 1963 and work started in 1966. Officers residential area . the factory could not achieve its objectives and suffered financial losses throughout.• INRTODUCTION Bangladesh Machine Tools Factory (BMTF Ltd) is one of the biggest factories of its kind in the country. The reasons for apparent failure of the factory were many.05 acres. BMTF was handed over to Bangladesh Army on 04 Jul 2000 for its management and operation. Open area for Industrial complex – 69. The total area of BMTF is 247. Staff colony area – 24.21. But without any doubt BMTF with its enormous potentiality remained as a great asset of our country. Finally.33 acres.68 acres. It was closed down in 1994 only after 14 yrs of operation. Area for railway siding & approach road – 31. b. it started operation in 1979.14 acres. As a new arena for the Army the task of operation of this huge factory was challenging and needed full attention. (for future expansion ) f. 5 . Factory area-69. According to the government gazette notification it would operate as a public limited company under the management of the Army. Unfortunately. With this in view.63 acres d. It includes: a. To plan for the new job order received by designing or drawing the product. To determine the present rate of material and labor. d. • Accounts department Accounts branch is a very sensitive section for any factory which maintain all financial account. d. b. heat treatment. machines etc. assembling. The total management has four departments.• DIFFERENT DEPARTMENTS BMTF was established as a mother-industry in the field of engineering in Bangladesh. To take full advantage of these facilities it needs a very efficient management. Planning and training department ( P&T ) Accounts department Marketing department Purchasing department • Planning and training department ( P&T ): The basic function of this section is to plan for each job order. g. To train up the workers. renovation and modification of different types of vehicles were available in BMTF. This section is also known as “ Production planning and control department (PPC)”. To schedule the tasks to available resources. These are : a. spare parts and other intermediate products. f. profit. to train up workers and to offer scopes to train to improve skill and efficiency. machining. c. it is the largest industry in the country. To select appropriate raw material. To estimate the total material and labor cost. loss and other financial data. forging. such as : a. Several tasks are performed by this department. c. b. Facilities of casting. it is well equipped with sophisticated and high precision machine and equipment to produce machines. to control the production process. To receive job order from outside customers. Accounts 6 . e. cost of production. number of workers. c. Calculate the total cost of production and determine selling price of a product. b. The budget of coming fiscal year is prepared. purchasing of preparatory item directly from suppliers b. Raw materials are purchased against the order received by the factory. • Purchasing department Material purchasing for production is the main function of this department. d. d. This procurement is of two type : a. e. Accounts department performs several tasks in BMTF. Arrange inspection of finished goods.branch follow a standard rules and regulations to explain income statement and relative financial ratio to explain profitable and viability of the factory. Add overhead cost. Renew the total overhead cost annually and compare it with sales to determine the overhead rate. f. c. Internal audit h. Annual management report and audit report are prepared. when goods are required emergency II. b. profit and other expenses with the prime cost estimated by the P&T department. Such as : a. Selling and marketing of product. • Marketing department To have smooth function of BMTF and make it a profitable organization marketing department perform several tasks. At the end of any fiscal year two audits are performed – g. Activities on receipt of job through tender. Foreign : Materials are purchased through bidding tender 7 . Participation in tender by buying and preparing of tender documents both technically and commercially. such as a. through tender. procurement from the local suppliers is performed in two ways: I. Government or commercial audit. transformer room. honing. Casting: Casting light and heavy ferrous and non-ferrous metals. gear making etc. Pattern: Pattern making both wooden and metallic. 4. power house. Heat Treatment: Heat treatment for both forged and machined components. 5. g. b. Assembly: Vehicle (including body manufacturing). h. These machines & equipments are basically of universal type which can be utilized for production of light to medium range mechanical products. BMTF has compressor house. 2. Central tooling department (CTD) Machine shop Forge shop Foundry shop Assembly shop There are ancillary facilities for these major ones. These are :1. Forging: Yearly production capability is 1500 M T. broaching. f. Machinery and equipment assembly facilities. There are five major facilities in BMTF. milling. 3. c. 8 . plant and equipment available in BMTF. main and temporary stores and maintenance department. Surface Treatment: Surface treatment including Galvanizing. The production facilities that exist in the factory are: a. These are :1. d.• PRODUCTION FACILITIES There are about 674 machineries. e. Pattern shop Load body surface preparation shop Galvanizing shop Forge heat treatment shop In spite of these. Machining: Machining like turning. 3. 2. 4. shaping grinding. jig boring. Manufacturing: Manufacturing of machines and spare parts for wide range of machines and equipment. Vertical milling machine I. To make jigs and fixtures. For making keyway IV. It can operate automatically and can perform many operations. To make screws and threads e. Column drill machine i. For squaring job V. Vertical jig boring machine i. The lathe and milling section 2. Such as : a. Horizontal jig boring machine i. For drilling VI. Sharpening section Under the lathe and milling section there are few machines. Gaze measuring device ii. It can be operated both manually and automatically. g. For boring b. It has a special use for A sharpening section is included in the CTD which contains machines and manpower for sharpening tools and grinders which are sharpened and resharpened to be used in different machineries in BMTF. For screw cutting ii. For boring c. It can produce product for automobile engine parts and auto tempo gear boxes. d. For threading iii. For slotting III. broach sharpening machine to sharpen tools of milling and 9 . It has universal tool and cutter grinder. Special lathe i. To produce mainly spiral and helical gears II.• Central tooling department (CTD) It has two sections – 1. These jigs and fixtures are then used in other shops. Copy lathe machine i. Celtic lathe i. To examine a gaze such as vernier and micrometer f. d. The specialized machines are enable to produce all kinds of gears. annealing. It performs the tasks of machining finished products of casting. g.plainer machine. All most all kind of machining is possible here. e. • Machine shop BMTF can be proud of its rich machine shop. In this shop there are some machines which are the only one piece in whole through the country. tempering. Numerous forged products are available here. Major facilities are as follows : a. h. carburizing etc processes. c. f. die casting etc. f. e. i. drills. stamping. Copy milling machine Automatic hydro-copying machine Drop forging hammer Pneumatic hammer Mechanical press Screw press Straightening press 10 . that maintain the best quality. It also has circular saw sharpening machine to sharpen wood cutter automatically. Oerlikon chucker lathe Double column planning machine Center less grinding machine Universal copying lathe Vertical broaching machine Vertical lathe machine Voumard internal grinding machine Gleason spiral bevel gear generator Gear shaping machine Maag gear grinder Inside this shop there is a heat treatment shop where different jobs are being heat treated through quenching. b. j. The forging capacity of this shop is 1500M ton per year. • Forge shop The forging facilities include modern die making for mass production. b. g. c. this machine shop is equipped with all general and special machines. taps and turning tools. free forging and heat treatment including normalizing. d. hardening and tempering. The total capacity that can be generated is about half million machine hours per year. Some major machines are : a. k. o. It has three foundries each with different capacity for producing different products with different size and shapes. Here following processes are available : a. Molding : Sand molding is used for making molds using sand mixer. Horizontal forging machine Hardening and tempering double furnace Loading machine Continuous heat treatment installation Vertical hardening and tempering furnace Washing machine apron type Gödel hammer Gathering machine Crack detecting machine Hardness testing machine The major forged products are : a. cranes) are used. Ferrous casting : For casting ferrous products. n. d. c. Core making : For making hollow shapes core and collages are used in molds which are also made here and given certain strength by core drier. manpower.h. q. 11 . Electric line hardware which are satisfactorily being used by rural electrification and Power Development Board (PDB) b. l. automatic molding machine and manpower for manual molding. crucibles for low volume production. Non-ferrous casting : this uses tilting furnace and dies from forge shop are supplied. material handling system (overhead cranes. i. Cores are made by using sand mixer and core drier. b. cupola furnace for mass production. m. j. Railway components • Foundry shop The mechanized foundries o BMTF are the largest in Bangladesh having a combined output of about 5000 tons per year. Hollow product making by using cores. Perforated steel plank d. Open ended spanners c. e. p. They are: a. Assembly shop There are mainly two lines in assembly shop. Piping b. Transfer b. Those are: 1. Gas governor 5. Die casting : BMTF uses high pressure die casting and it is capable of producing one million die cast parts per year. Propeller shaft c. This facility offers us the 630 ton builders die casting machine with its excellence in making quality products. auto and motorcycle spares. Fuel tank d. Load body surface preparation 2. Axle attachment b. Harness attachment c. Engine sub assembly b. Suspension 4. Pipe line a. Pitman attachment 6. Radiator attachment d. bicycle parts etc. Cleaning of the finished good by sand blasting machine. Disc wheel attachment d. Bracket attachment d. Leaf spring attachment c. Axle line a. Transfer installation action line a. Air tank attachment e. Transmission sub assembly c.f. Tire attachment e. Typical die cast products are electric fan parts. Isuzu line b. Air cleaner 12 . Toyota line Under the Isuzu line there are certain sequences for doing assembly. Engine and transmission line a. Paint booth 3. • g. Distribution 8. Engine sub assembly 5. Clutch and brake c. Trimming a. Installation of all items of deck and cabin c. Material handling and distribution a. c. e. Box opening b. Piping c. Engine b. Cabin a. Glass attachment 6. Dash board attachment b. Leaf spring attachment c. Chassis section a. Checking of CKD components c. Final section a. installation Dash board Instrument cluster Steering column Seat Trimming Under the Toyota line there are also some sequence for working. Painting section a. b. Surface preparation for painting b. Metal a. Inspection a.7. b. Final painting 4. Air bleed attachment 7. Wash primer c. Setting of deck and cabin b. are: 1. Horn and lighting d. Axle attachment b. Painting 13 . Wheel attachment d. d. c. d. Spot welding 2. Those section Gas welding Brazing Soldering Finishing 3. 14 . Auto electric section a. 3) Modification of 3 ton truck into a mobile workshop for use of defense personnel in battlefield. Main position i. Convoy position i. 4) Modification of 3 ton truck into a store bin body for use of defense personnel in battlefield to carry all fast moving spare parts of military transport.9. It was not done earlier. army management find out this product diversification and implemented it in the field. Front Convoy position 1) Convoy indicator 2) Convoy head/driving light ii. Back Convoy position 1) Convoy indicator 2) Convoy parking 3) Convoy brake With these all job some other jobs are also done in this shop. 2) Assembling of 1 ton pickup from CKD to CBU. such as: 1) Assembling of 3 ton truck from Completely Knock Down (CKD) to Completely Build up Unit (CBU). Back main position 1) Side indicator 2) Stop/parking light 3) Brake light 4) Reverse/back gear light 5) Rear fog light 6) 12-pin socket 7) number plate light b. Front main position 1) Head light a) High beam b) Low beam 2) Side indicator 3) Stop/parking light 4) Fog light 5) Door/room light 6) Gear light ii. As a case of product diversification. Several heat treatment facilities are here including following machine: 1. • Forging heat treatment shop The heat treatment of the surfaces of the products which are forged in forge shop are performed in this shop. then first a wooden or metallic pattern is made. Then following the specifications and using machines. When any drawing of some types of cast products are provided. patterns are made. Short blasting machine 15 . Tapers and graphite coating is also provide with those better ejection of molds. Thread rolling machine 2. Metallic pattern Wooden patterns are easy to machine and wood can be brought at relatively lower cost. The equipments for pattern making are: 1. Metallic patterns are used in case of high volume of production means mass production. BMTF has a huge and large storage of almost all type of pattern of different products made in Bangladesh. etc. Wooden pattern 2. Sanding machine. While producing the pattern.5) Modification of 1 ton truck into ambulance to carry patient • Pattern shop The foundries are served with “In-house” pattern making facilities. 1. Two types of patterns are made in this shop. Circular saw machine 2. Then the patterns are supplied to the foundry according to the demand. Its raw material is supplied by the store and material handling shop. Generally for low volume production these patterns are used. Universal milling machine 3. required allowances and tolerances are provided. Hardness testing machine 4. Generally six times coatings of the painting is required to get the final look. car. navy blue.3. Load body surface preparation shop • BMTF has a complete facility for preparation of surface of load body i. Quenching furnace. Tempering furnace 3. green according to the demand is painted on it.e. Hardening furnace 2. black. Then etching is done by water on it for neutralizing the acid and then again rust remover is applied. Then any surface color such as. truck body and other large body. At first acid bath of dilute sulfuric acid is given to load body o removing rust. Crack detecting machine Here are three types of furnaces: 1. The flowchart of surface preparation is given here: 20′ x 12′ x 8′ Acid bath ( Dilute H2SO4 ) Removing rust Water bath ( neutralizing ) Surface cleaning Apply rust remover Oven ( 125°-130°C) 30-45min Red oxide painting Surfacer Al-Karim FLOW CHART OF LOAD BODY SURFACE PREPARATION 16 . After heating red oxide is painted over it because other painting colors are better set on it and red oxide is rust resistive. generally gray. Then it is heated in an oven so that red oxide coating can be set in the body properly. • PRODUCTS OF BMTF • Past Products of BMTF During the operative period of BMTF (under BSEC Management). Power tillers 2. Agricultural Sector: i. 3 Wheeler Auto Tempo Shujon including some spares 17 . Transport Sector: i. the factory used to produce a variety of products mainly: 1. Irrigation pumps ii. Machine Tools: i. Lifter bracket iv. Textile: i. grinding machines etc. slides ii. Jute Mill Spares: i. Cutting blade iii. Lathes ii.3. Paper and Fertilizer mill spares 7. screws. Reeling machines ii. Crank through 6. 5. Faller bars. Spares for chemical Industries 18 . Spinning frame 4. Drill iii. Anti creep V-anchor vi. Dog spike v. Coupling draw bar 10.8. Swing hanger ix. Elastic spike vii. Crossing body iii. Screw coupling viii. There was no working capital and skilled manpower either. The team of officers with their 19 . Few of the machineries and production facilities were not operational and needed huge maintenance and repair works. Points and crossing ii. Trap switch iv. the army management decided to go for production as soon as possible. Railway Hardware i. Electric Line hardware • Production under Army Management After taking over. Spares for Electric fan Industries 9. hard work and sincerity could establish the line of assembly for ISUZU trucks as well as its body manufacturing. few open bids were participated and won. In these process. Later on the management started venturing for public sector jobs. all these production lines were absolutely new experience for BMTF but theses were all successful. With the prudent decision of assigning assembly and manufacturing of USUZU chassis. Now BMTF is fully capable to produce quality line hardware products and become an important supplier of REB and PDB. Subsequently. 1 ton Pick up and ¼ Ton jeep was included in the list. The line production started with slight fault at the beginning. Gradually. It is to be mentioned that. a number of old employees were reemployed. 3 Ton Isuzu Truck Fuel Bowser ¼ Ton Toyota Jeep 1 Ton Toyota Pick-up Fuel Trailer Ambulance Mobile Workshop Van 20 . With lots of hard work and creativity they could start production of REB & PDB line hardware. BMTF started take off. 5000 Ltr Construction & Fabrication of Fuel Trailer.000 600 Bulk 150 645 40000 100 Bulk Organization/ Firm REB & PDB Police Dhaka WASA Fertilizer Company Gas Fields CAAB Nitol Group BADC Election Commission TATA Security Printing Press 21 Qty 1306 1163 308 05 16 17 80 60 35+15 Remarks . Civil Sectors Ser 1 2 3 4 5 6 7 8 9 10 11 12 Product Line Hardware Items for REB & PDB Assembly & Body Building of Prisoner Van Manhole Cover for Dhaka WASA Spare Parts for Fertilizer Company PSP for Bangladesh Gas Fields Passenger Luggage Trolley for CAAB Pump Volute Case Brake Drum for Nitol Group Centrifugal Pump for BADC Ballot Box for Election Commission Modification of TATA GATI Vehicle Spares for Security Printing Press Qty Bulk 32 2300 Bulk 5. Bangladesh Army Ser 1 2 3 4 5 6 7 8 9 Product Assy of 3 Ton ISUZU Truck Incl mfg of Rear Load Body Assy of 1 Ton Toyota Pickup Assembly of 1/4 Ton Toyota Jeep Construction & Fabrication of Fuel Bowser. 2000 Ltr Manufacturing of Water Trailer 250 Gallons Modification of Pickup Ambulance Composite Mobile Workshop Van & Store Bin Lorry b. 5000 Ltr Construction & Fabrication of Water Bowser.A statistics of works done (till 04 Nov 2007) by present BMTF is given below: a. b.646 2. installations by c. Ser 1 2 3 4 5 6 Description 3 Ton Isuzu Truck Fabrication of 250 Gal water Trailer Supply of Tyres (APC BTR-80) Installation of Air Conditioning System in Military Vehicles Earmarked for UN Mission Steel Furniture Power Tiller Qty 71 100 600 48 7. • ECONOMIC EFFICIENCY Currently the army management team maintaining a reasonable inventory stock basing on present requirement to reduce financial overhead. The achievements are: a. within one year of operation the factory was turned into a profitable one. Supporting number of industries/ manufacturing complex spare parts. Manufacturing defense stores which are being supplied to the defense forces and UN Peace Keeping Missions. Creating job opportunity for about 400 persons. 22 .000 Remarks • ACHIEVEMENT After taken over.13 14 15 Rappelling Tower for PGR Pole Fittings Item for TSS Spares for Textile Mills 1 Bulk Bulk PGR TSS Textile Mills • Present State of BMTF Work in Hand. d. Saving foreign currency by local production of import substitute items. Poor market survey to find out demand for any product. idea and setting of corporate goals to maximize wealth of shareholders. • COMPARISON Management is responsible to formulate business strategy. Poor promotional management. • RECOMMENDATIONS BMTF was handed over to army on 04 July 2000 from BSEC. Lack of technical experts. Lack of experience of the officers in business management. Innovativeness 23 . v. For this advance planning. where the management responsibilities lie with Bangladesh army. i. Lack of financial experts. xi. Though. After studying of BMTF the following recommendations should be taken into account for benefit of the factory. iii. ix. ii. But now being under the control of army management BMTF has become a profitable industry. Less initiative to develop new product. i. army is not a business organization. eight Managing Directors were posted out. Having no proper business strategy. staffs and workers relation were unhealthy. iv. Poor administrative back-up. Now it has been operated under MOD. It has been observed that in 13 years from the year of 1991. basing on basis where BMTF has become lowest in the tender. vi. It is very much disadvantageous to any factory. even that the present management of BMTF pulling well. now BMTF can deliver goods to the user end in schedule time avoiding unnecessary loss which created unpleasant environment in the past. It’s management has a number of limitations and weakness. vii. monitoring and understanding. x. Lack of marketing experts. • LIMITATIONS BMTF is a state owned enterprise. which make this organization in a disadvantageous position.Raw materials are purchased well in advance. Managements. Lack of knowledge in professional matter. Employees wariness due to lack of job security. viii. xii. During the time of previous management there was a lack of coordination. Job in Machine Shop 2.ii. iii. xi. ix. vii. Job in Forge Shop 24 . v. x. ASSIGNMENTS 1. vi. • Job monitoring Joint-venture agreement Future marketing orientation Set up marketing strategy Train up local manpower to different machines and working process Improvement of administrative back-up Some budget may fix for advertisement purpose Need prompt decision Participation in various business fair Establishment of marketing office in Dhaka Has no distribution agent in different areas or divisions. iv. viii. xii. Job in Pattern and Foundry Shop Wooden Pattern Pressing The Molding Sand Molding Melting The Metal (Mild Steel) Hot Metal Mold 25 .3. BMTF is no more burdens to the nation. and existing rules and procedures should be taken into consideration while evaluating BMTF. remained closed for another six years and lost most of its potentials. Limitation of BMTF in terms of its technical ability. which was closed down after 14 years of operation due to continuous losses. A factory. Expectations are very high but limitations are there. It was not design to earn profit rather it was established to support other local industries by supplying spare parts and services. At the same time it should not also be treated as an army organization. Though the progress and development is noticeable. yet opinion of the experts may be sought for appropriate utilisation of BMTF.Cooling and Etching with Water Finished Product After Machining • CONCLUSION BMTF is a state owned Business organization. cooperation from all concern will remain a key factor for enhancing its business potentiality. knowledge on commerce and finance of the army officers serving here. BMTF should be understood to its right perspective. This factory contributes into national economy by producing skill manpower. It should not be compared with other private factories where they enjoy more freedom of action. which does not give much flexibility in terms of commercial activities. 26 . saving of foreign currency and earning government revenue through VAT and IT and depreciation value. developed technology. Nevertheless. rather it is an asset and highly potential business organization to contribute to national economy under army management. 27 .