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

 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. We would like to thank Lt Col Md. Abu Taher, General Manager planning and training, who helped us a lot by giving different ideas to complete the training. During the Industrial Training period, 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. We are very much grateful to them for their help. 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. Shahid Sarwar, psc, for giving us the opportunity to visit and to do work in different shops practically, which will help us to gather practical experience of working in industry. At last but not the least we would like to thank Brig Gen Md. Mominul Hoque, afwc, psc, 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.

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

 INRTODUCTION
Bangladesh Machine Tools Factory (BMTF Ltd) is one of the biggest factories of its kind in the country. This factory was conceived in 1963 and work started in 1966. Finally, it started operation in 1979. Unfortunately, the factory could not achieve its objectives and suffered financial losses throughout. It was closed down in 1994 only after 14 yrs of operation. The reasons for apparent failure of the factory were many. But without any doubt BMTF with its enormous potentiality remained as a great asset of our country, which needed to be managed properly. With this in view, BMTF was handed over to Bangladesh Army on 04 Jul 2000 for its management and operation. According to the government gazette notification it would operate as a public limited company under the management of the Army, within the jurisdiction of the Ministry of Defence. As a new arena for the Army the task of operation of this huge factory was challenging and needed full attention. The total area of BMTF is 247.66 acres. It includes: a. Area for railway siding & approach road 31.05 acres. b. Factory area-69.33 acres. c. Officers residential area - 21.63 acres d. Staff colony area 24.14 acres. e. Open area for Industrial complex 69.68 acres. (for future expansion ) f. Open area for proposed workers colony 31.66 acres.

 DIFFERENT DEPARTMENTS
BMTF was established as a mother-industry in the field of engineering in Bangladesh. it is the largest industry in the country. it is well equipped with sophisticated and high precision machine and equipment to produce machines, spare parts and other intermediate products. Facilities of casting, forging, machining, heat treatment, assembling, renovation and modification of different types of vehicles were available in BMTF. To take full advantage of these facilities it needs a very efficient management. The total management has four departments. These are : a. b. c. d. 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, to control the production process, to train up workers and to offer scopes to train to improve skill and efficiency. This section is also known as Production planning and control department (PPC). Several tasks are performed by this department, such as : a. To receive job order from outside customers. b. To plan for the new job order received by designing or drawing the product. c. To select appropriate raw material, number of workers, machines etc. d. To determine the present rate of material and labor, cost of production. e. To estimate the total material and labor cost. f. To schedule the tasks to available resources. g. To train up the workers.

Accounts department

Accounts branch is a very sensitive section for any factory which maintain all financial account, profit, loss and other financial data. Accounts 6

branch follow a standard rules and regulations to explain income statement and relative financial ratio to explain profitable and viability of the factory. Accounts department performs several tasks in BMTF, such as a. Annual management report and audit report are prepared. b. The budget of coming fiscal year is prepared. c. Calculate the total cost of production and determine selling price of a product. d. Add overhead cost, profit and other expenses with the prime cost estimated by the P&T department. e. Renew the total overhead cost annually and compare it with sales to determine the overhead rate. f. At the end of any fiscal year two audits are performed g. Internal audit h. Government or commercial audit.

Marketing department

To have smooth function of BMTF and make it a profitable organization marketing department perform several tasks. Such as : a. b. c. d. Activities on receipt of job through tender. Arrange inspection of finished goods. Selling and marketing of product. Participation in tender by buying and preparing of tender documents both technically and commercially.

Purchasing department

Material purchasing for production is the main function of this department. Raw materials are purchased against the order received by the factory. This procurement is of two type : a. procurement from the local suppliers is performed in two ways: I. through tender, when goods are required emergency II. purchasing of preparatory item directly from suppliers b. Foreign : Materials are purchased through bidding tender 7

PRODUCTION FACILITIES

There are about 674 machineries, plant and equipment available in BMTF. These machines & equipments are basically of universal type which can be utilized for production of light to medium range mechanical products. The production facilities that exist in the factory are: a. b. c. d. e. f. g. h. Pattern: Pattern making both wooden and metallic. Casting: Casting light and heavy ferrous and non-ferrous metals. Forging: Yearly production capability is 1500 M T. Machining: Machining like turning, milling, shaping grinding, honing, broaching, jig boring, gear making etc. Heat Treatment: Heat treatment for both forged and machined components. Surface Treatment: Surface treatment including Galvanizing. Assembly: Vehicle (including body manufacturing), Machinery and equipment assembly facilities. Manufacturing: Manufacturing of machines and spare parts for wide range of machines and equipment.

There are five major facilities in BMTF. These are :1. 2. 3. 4. 5. Central tooling department (CTD) Machine shop Forge shop Foundry shop Assembly shop

There are ancillary facilities for these major ones. These are :1. 2. 3. 4. Pattern shop Load body surface preparation shop Galvanizing shop Forge heat treatment shop

In spite of these, BMTF has compressor house, transformer room, power house, main and temporary stores and maintenance department. 8

Central tooling department (CTD) It has two sections 1. The lathe and milling section 2. Sharpening section Under the lathe and milling section there are few machines. Such as : a. Vertical milling machine I. To produce mainly spiral and helical gears II. For slotting III. For making keyway IV. For squaring job V. For drilling VI. For boring b. Special lathe i. For screw cutting ii. For threading iii. For boring c. Celtic lathe i. To make jigs and fixtures. These jigs and fixtures are then used in other shops. d. Column drill machine i. To make screws and threads e. Copy lathe machine i. Gaze measuring device ii. To examine a gaze such as vernier and micrometer f. Vertical jig boring machine i. It can operate automatically and can perform many operations. It can produce product for automobile engine parts and auto tempo gear boxes. g. Horizontal jig boring machine i. It can be operated both manually and automatically. 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. It has universal tool and cutter grinder, broach sharpening machine to sharpen tools of milling and 9

plainer machine. It also has circular saw sharpening machine to sharpen wood cutter automatically. Machine shop

BMTF can be proud of its rich machine shop. It performs the tasks of machining finished products of casting, die casting etc. this machine shop is equipped with all general and special machines. All most all kind of machining is possible here. The specialized machines are enable to produce all kinds of gears, drills, taps and turning tools. In this shop there are some machines which are the only one piece in whole through the country. The total capacity that can be generated is about half million machine hours per year. Some major machines are : a. b. c. d. e. f. g. h. i. j. 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, tempering, carburizing etc processes.

Forge shop

The forging facilities include modern die making for mass production, stamping, free forging and heat treatment including normalizing, annealing, hardening and tempering. Numerous forged products are available here, that maintain the best quality. The forging capacity of this shop is 1500M ton per year. Major facilities are as follows : a. b. c. d. e. f. g. Copy milling machine Automatic hydro-copying machine Drop forging hammer Pneumatic hammer Mechanical press Screw press Straightening press 10

h. i. j. k. l. m. n. o. p. q.

Horizontal forging machine Hardening and tempering double furnace Loading machine Continuous heat treatment installation Vertical hardening and tempering furnace Washing machine apron type Gdel hammer Gathering machine Crack detecting machine Hardness testing machine

The major forged products are : a. Electric line hardware which are satisfactorily being used by rural electrification and Power Development Board (PDB) b. Open ended spanners c. Perforated steel plank d. Railway components

Foundry shop

The mechanized foundries o BMTF are the largest in Bangladesh having a combined output of about 5000 tons per year. 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, automatic molding machine and manpower for manual molding. b. 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. Cores are made by using sand mixer and core drier. c. Hollow product making by using cores.

d. Ferrous casting : For casting ferrous products, cupola furnace for mass production, crucibles for low volume production, manpower, material handling system (overhead cranes, cranes) are used. e. Non-ferrous casting : this uses tilting furnace and dies from forge shop are supplied.

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f. Die casting : BMTF uses high pressure die casting and it is capable of producing one million die cast parts per year. This facility offers us the 630 ton builders die casting machine with its excellence in making quality products. Typical die cast products are electric fan parts, auto and motorcycle spares, bicycle parts etc. g. Cleaning of the finished good by sand blasting machine. Assembly shop There are mainly two lines in assembly shop. They are: a. Isuzu line b. Toyota line Under the Isuzu line there are certain sequences for doing assembly. Those are: 1. Load body surface preparation 2. Paint booth 3. Axle line a. Axle attachment b. Leaf spring attachment c. Disc wheel attachment d. Tire attachment e. Suspension 4. Pipe line a. Piping b. Harness attachment c. Bracket attachment d. Air tank attachment e. Gas governor 5. Engine and transmission line a. Engine sub assembly b. Transmission sub assembly c. Radiator attachment d. Pitman attachment 6. Transfer installation action line a. Transfer b. Propeller shaft c. Fuel tank d. Air cleaner 12

7. Cabin a. b. c. d. e. are: 1. Spot welding 2. Metal a. b. c. d.

installation Dash board Instrument cluster Steering column Seat Trimming

Under the Toyota line there are also some sequence for working. Those

section Gas welding Brazing Soldering Finishing

3. Painting section a. Surface preparation for painting b. Wash primer c. Final painting 4. Chassis section a. Axle attachment b. Leaf spring attachment c. Wheel attachment d. Engine sub assembly 5. Trimming a. Dash board attachment b. Piping c. Glass attachment 6. Final section a. Setting of deck and cabin b. Installation of all items of deck and cabin c. Air bleed attachment 7. Material handling and distribution a. Box opening b. Checking of CKD components c. Distribution 8. Inspection a. Engine b. Clutch and brake c. Horn and lighting d. Painting 13

9. Auto electric section a. Main position i. 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. 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. Convoy position i. 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, such as: 1) Assembling of 3 ton truck from Completely Knock Down (CKD) to Completely Build up Unit (CBU). It was not done earlier. As a case of product diversification, army management find out this product diversification and implemented it in the field. 2) Assembling of 1 ton pickup from CKD to CBU. 3) Modification of 3 ton truck into a mobile workshop for use of defense personnel in battlefield. 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. 14

5) Modification of 1 ton truck into ambulance to carry patient

Pattern shop

The foundries are served with In-house pattern making facilities. BMTF has a huge and large storage of almost all type of pattern of different products made in Bangladesh. Two types of patterns are made in this shop. 1. Wooden pattern 2. Metallic pattern Wooden patterns are easy to machine and wood can be brought at relatively lower cost. Generally for low volume production these patterns are used. Metallic patterns are used in case of high volume of production means mass production. The equipments for pattern making are: 1. Circular saw machine 2. Universal milling machine 3. Sanding machine, etc. When any drawing of some types of cast products are provided, then first a wooden or metallic pattern is made. Its raw material is supplied by the store and material handling shop. Then following the specifications and using machines, patterns are made. While producing the pattern, required allowances and tolerances are provided. Tapers and graphite coating is also provide with those better ejection of molds. Then the patterns are supplied to the foundry according to the demand.

Forging heat treatment shop

The heat treatment of the surfaces of the products which are forged in forge shop are performed in this shop. Several heat treatment facilities are here including following machine: 1. Thread rolling machine 2. Short blasting machine 15

3. Hardness testing machine 4. Crack detecting machine Here are three types of furnaces: 1. Hardening furnace 2. Tempering furnace 3. Quenching furnace. Load body surface preparation shop

BMTF has a complete facility for preparation of surface of load body i.e. car, truck body and other large body. At first acid bath of dilute sulfuric acid is given to load body o removing rust. Then etching is done by water on it for neutralizing the acid and then again rust remover is applied. Then it is heated in an oven so that red oxide coating can be set in the body properly. After heating red oxide is painted over it because other painting colors are better set on it and red oxide is rust resistive. Then any surface color such as, generally gray, black, navy blue, green according to the demand is painted on it. Generally six times coatings of the painting is required to get the final look. The flowchart of surface preparation is given here:

20 x 12 x 8

Acid bath ( Dilute H2SO4 ) Removing rust

Water bath ( neutralizing )

Oven ( 125-130C) 30-45min

Red oxide painting

Surfacer Al-Karim

FLOW CHART OF LOAD BODY SURFACE PREPARATION

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 PRODUCTS OF BMTF
Past Products of BMTF

During the operative period of BMTF (under BSEC Management), the factory used to produce a variety of products mainly: 1. Agricultural Sector: i. Irrigation pumps ii. Power tillers

2. Transport Sector: i. 3 Wheeler Auto Tempo Shujon including some spares

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3. Textile: i. Reeling machines ii. Spinning frame 4. Machine Tools: i. Lathes ii. Drill iii. grinding machines etc.

5. Jute Mill Spares: i. Faller bars, screws, slides ii. Cutting blade iii. Lifter bracket iv. Crank through

6. Paper and Fertilizer mill spares 7. Spares for chemical Industries 18

8. Spares for Electric fan Industries 9. Railway Hardware i. Points and crossing ii. Crossing body iii. Trap switch iv. Dog spike v. Anti creep V-anchor vi. Elastic spike vii. Screw coupling viii. Swing hanger ix. Coupling draw bar

10. Electric Line hardware

Production under Army Management

After taking over, the army management decided to go for production as soon as possible. Few of the machineries and production facilities were not operational and needed huge maintenance and repair works. There was no working capital and skilled manpower either. The team of officers with their 19

hard work and sincerity could establish the line of assembly for ISUZU trucks as well as its body manufacturing. With the prudent decision of assigning assembly and manufacturing of USUZU chassis, BMTF started take off. Gradually, 1 ton Pick up and Ton jeep was included in the list. It is to be mentioned that, all these production lines were absolutely new experience for BMTF but theses were all successful. Later on the management started venturing for public sector jobs. With lots of hard work and creativity they could start production of REB & PDB line hardware. In these process, a number of old employees were reemployed. Subsequently, few open bids were participated and won. The line production started with slight fault at the beginning. Now BMTF is fully capable to produce quality line hardware products and become an important supplier of REB and PDB.

3 Ton Isuzu Truck

Fuel Bowser

Ton Toyota Jeep

1 Ton Toyota Pick-up

Fuel Trailer

Ambulance

Mobile Workshop Van 20

A statistics of works done (till 04 Nov 2007) by present BMTF is given below: a. 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, 5000 Ltr Construction & Fabrication of Water Bowser, 5000 Ltr Construction & Fabrication of Fuel Trailer, 2000 Ltr Manufacturing of Water Trailer 250 Gallons Modification of Pickup Ambulance Composite Mobile Workshop Van & Store Bin Lorry b. 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 5,000 600 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

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.

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 7,646 2,000

Remarks

ACHIEVEMENT

After taken over, within one year of operation the factory was turned into a profitable one. The achievements are: a. Manufacturing defense stores which are being supplied to the defense forces and UN Peace Keeping Missions. b. Creating job opportunity for about 400 persons. installations by

c. Supporting number of industries/ manufacturing complex spare parts.

d. Saving foreign currency by local production of import substitute items.

ECONOMIC EFFICIENCY

Currently the army management team maintaining a reasonable inventory stock basing on present requirement to reduce financial overhead. 22

Raw materials are purchased well in advance, basing on basis where BMTF has become lowest in the tender. For this advance planning, now BMTF can deliver goods to the user end in schedule time avoiding unnecessary loss which created unpleasant environment in the past. COMPARISON

Management is responsible to formulate business strategy, idea and setting of corporate goals to maximize wealth of shareholders. During the time of previous management there was a lack of coordination, monitoring and understanding. Managements, staffs and workers relation were unhealthy. But now being under the control of army management BMTF has become a profitable industry. LIMITATIONS

BMTF is a state owned enterprise. Its management has a number of limitations and weakness, which make this organization in a disadvantageous position. i. It has been observed that in 13 years from the year of 1991, eight Managing Directors were posted out. It is very much disadvantageous to any factory. ii. Lack of experience of the officers in business management. iii. Lack of technical experts. iv. Lack of financial experts. v. Lack of marketing experts. vi. Poor promotional management. vii. Poor market survey to find out demand for any product. viii. Less initiative to develop new product. ix. Employees wariness due to lack of job security. x. Having no proper business strategy. xi. Poor administrative back-up. xii. Lack of knowledge in professional matter.

RECOMMENDATIONS

BMTF was handed over to army on 04 July 2000 from BSEC. Now it has been operated under MOD, where the management responsibilities lie with Bangladesh army. Though, army is not a business organization, even that the present management of BMTF pulling well. After studying of BMTF the following recommendations should be taken into account for benefit of the factory. i. Innovativeness 23

ii. iii. iv. v. vi. vii. viii. ix. x. xi. xii.

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.

ASSIGNMENTS
1. Job in Machine Shop

2. Job in Forge Shop 24

3. Job in Pattern and Foundry Shop

Wooden Pattern

Pressing The Molding Sand

Molding

Melting The Metal (Mild Steel)

Hot Metal Mold

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Cooling and Etching with Water

Finished Product After Machining

CONCLUSION
BMTF is a state owned Business organization. It was not design to earn profit rather it was established to support other local industries by supplying spare parts and services. This factory contributes into national economy by producing skill manpower, developed technology, saving of foreign currency and earning government revenue through VAT and IT and depreciation value. BMTF should be understood to its right perspective. It should not be compared with other private factories where they enjoy more freedom of action. At the same time it should not also be treated as an army organization, which does not give much flexibility in terms of commercial activities. Limitation of BMTF in terms of its technical ability, knowledge on commerce and finance of the army officers serving here, and existing rules and procedures should be taken into consideration while evaluating BMTF. A factory, which was closed down after 14 years of operation due to continuous losses, remained closed for another six years and lost most of its potentials. Expectations are very high but limitations are there. Though the progress and development is noticeable, yet opinion of the experts may be sought for appropriate utilisation of BMTF. Nevertheless, cooperation from all concern will remain a key factor for enhancing its business potentiality. BMTF is no more burdens to the nation, rather it is an asset and highly potential business organization to contribute to national economy under army management.

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