1.

INTRODUCTION

On 19.3.2019 we went to an Industrial visit to BULL MACHINES PVT LTD which is

located at Sulur, Coimbatore.The BULL machines is a highly equipped manufacturing company

which manufactures earthmovers and exports it across the globe.

Bull is the largest selling tractor attachment manufacturer in India. At BULL innovation

is a way of life where quality is first priority.Bull belongs to 54 year old AV group which has

diversified companies employing more than 2000 people.Bull is the Indian leader in loaders and

backhoes in its class and segment. Bull has two world-class manufacturing plants with state of

the art manufacturing facilitiesMore than 30,000 Bull products are running across the globe.Bull

has been recognized by the Ministry of Science and Technology as an in-house R&D

company.Backed by an extensive sales and service network with more than 100 resident service

engineers across the world.The construction equipment plant has a capacity of 3000 vehicles per

annum.World Wide sales and service network of 600 plus dealers and 7 branch offices across

India.Bull is innovation driven organisation with strong R&D team and holds many patents to its

credit.BULL Machines has already made an impact in the world market by producing world

class dedicated Construction Equipment vehicles, while it continues to remain as India's no 1

Tractor Attachment manufacturer for more than 16 years. The major competitors of Bull are

JCB, Mahindra and Caterpillar.

Bull mainly aims on quality. According to BULL low aim is a crime. Bull is a customer

centric and object driven.

ABOUT THE MANAGEMENT:

AV. Varadharajan is a Group Founder & Chairman of BULL. He started his first

company in 1962 after his Bachelor of Engineering from PSG college of technology in 1959.

V. Parthiban is a Bull Founder and Managing Director.

CONSTRUCTION EQUIPMENT:

World class backhoe loader maintaining highest efficiency, operator comfort and safety

parameters with ROPS & FOPS accreditation.

 Bull HD 76_4WD.

 Bull HD 76_2WD.

 Bull HD 96_4WD.

 Bull HD 100

 Bull Loader HD76.

 Bull Smart 60 BHL.

 Bull HP 60 Smart Loader.

TRACTOR ATTACHMENT:

With 25+ types of products on 108+ tractor models, BULL continues to retain its number 1

stature in Tractor attachment Business in India. More than 40 types of bucket options

 Agri bull

 Front end loader

 Backhoe loader & dozer

  v2 Sugarcane loader

 Ultra loader

 HD Ultra sugarcane loader

 Telescopic loader

 Radial loader

 Bull Dozer

LIGHT EQUIPMENTS:

A latest product of innovation with hydraulic dumping option BULL Barrow multiplies

labour efficiency manifold.

SOFTWARE USED:

BULL runs on mist modern systems like SAP and CRM. The software helps us to get

access to process going on in the plant, every process is uploaded in the software. The

informations like raw material purchase, stock availability, getting orders and finally upto the

delivery of goods everything is available in the software.Every company will check the

OEE(Overall Equipment Efficiency), and it should be 100%.OEE helps to know how the

finished vehicle will be capable enough to work efficiently. The overall efficiency should be

affected by the following parameters:

1. Machine availability.

2.Job shifting( the worker may shift to some other department during that course of time).

3.Maintanence.
MILESTONES:

2015-Most Powerful machine in India among its Category Bull HD 100 Backhoe loader machine

was launched.

2013-Bull HD 76 Backhoe loader machine was launched in International Exhibition Excon 2013

2012-Harvester technology transferred to an Indian multinational company.

2011-World’s first Bull Smart - 60Hp hydrodynamic driven Backhoe loader was launched in

International Exhibition Excon 2011.

2010-Second state of the Art plant constructed with 3000 vehicle per annum capacity.

2009-First Backhoe loader prototype test.

2008-Tie up with world leader in tractor market.

2006-“Bull Smart” Backhoe loader project was kick started and the design work started.

2004-Recognised as in house R&D by ministry of science and technology and continuing.

2003-Mahindra markets the products and sells in name of - Bull Mahindra.

1998-Manufactures tractor attached Backhoe loader/dozers.

1997-BULL machines pvt.ltd starts its operation for manufacturing tractor attached loaders.

1962-Mother company was founded.

BULL MACHINE
 2. PROCESS BRIEFING

The processes carried out in the BULL EQUIPMENTS are:

1. Laser cutting

2. Welding

3. Grid blasting

4. Painting

5. Assembly

6. Test drives.

1.LASER CUTTING:

Laser cutting is a technology that uses a laser to cut materials, and is typically used for

industrial manufacturing application. Laser cutting is a manufacturing process which can

eliminate the need for machining on many engineering jobs, enabling you to save money on

manufacturing costs.Laser cutting is mainly a thermal process in which a focused laser beam is

used to melt material in a localised area. A co-axial gas jet is used to eject the molten material

and create a kerf. A continuous cut is produced by moving the laser beam or workpiece under

CNC control. There are three major varieties of laser cutting: fusion cutting, flame cutting and

remote cutting.

The requirements for cutting are as follows:

a) high power density and therefore small focused spot size

b) long depth of focus to process thicker materials with a reasonable tolerance to focus position

variation.
In BULL EQUIPMENTS laser cutting is the first technique carried out after the purchase of raw

materials.

2.WELDING:

Bull equipment uses Arc welding and MIG welding are used to join the metals which is

already cut using laser cutting.

Welding is a manufacturing process that is usually used to join two metal parts together.

This process is done by melting the two workpieces and adding filler material. When this molten

material cools down, it becomes a strong joint. Different energy sources can be used, but the

most common one is the electric arc.

 ARC WELDING:

An electric current is passed through an electrode and creates an arc when it is close to

the base material. This arc is created because of the differences between the electrode and the

base material. This arc generates heat and melts the material. Arc welding is the most common

type of welding used by manufacturers because it can be manual, semi-automatic or even, fully

automated. Two kinds of electrodes can be used in arc welding. They can be consumable or non-

consumable.

 MIG WELDING:

MIG welding machine will continuously keep filling the joint being welded and

electrodes do not need to be changed out between welds.

3.GRIT BLASTING:

Once the welding process was done properly, next process is grit blasting which involves

remove the unwanted contaminants and gives finishing to the material.

 Grit blasting is a process where abrasive particles are accelerated and forcefully directed

against a surface. These high-speed abrasive particles remove contaminants from the material's

surface and condition the surface for subsequent finishing. Grit blasting as a technique of

abrasive cleaning or surface preparation using sharp particles. In this technique, the surface in

question is impacted at high velocity by hard, angular particles to such extent that unwanted

material on the surface is removed, and a clean, active metal surface is exposed. It covers such

processes as removal of scale, corrosion, paint and other surface films.

4.POWDER COATING AND PAINTING:

After the grit blasting process gets over the various finished products are now ready for

powder coating or painting.

Powder coating is a type of coating that is applied as a free-flowing, dry powder. The main

difference between a conventional liquid paint and a powder coating is that the powder coating

does not require a solvent to keep the binder and filler parts in coating and is then cured under

heat to allow it to flow and form a "skin". The powder may be a thermoplastic or a thermoset

polymer. It is usually used to create a hard finish that is tougher than conventional paint.

Painting means applying the appropriate colour for the parts of the machine. Painting is

done accurately and now the parts are ready for assembly purpose.

5.ASSEMBLY :

The last process in the earthmover manufacturing is assembly. Once all the required

materials are available without any shortage the assembly should be done.
There are various stages in the assembly process :

1. Axle

2. Pump, engine and transmission.

3. Tank ( oil and diesel tank).

4. Wheel

5. Cabin

6. Frontend loader

7. Backhoe loader.

In this arrangement the earthmover parts are assembled and the whole machine is ready to use.

6.TEST DRIVES:

Pre delivery inspection is done after all the process. Test drives are made by the workers

and check whether the whole machine is working properly. After proper testing the vehicle is

delivered to the customer.

 3. QUALITY CONTROL TECHNIQUE

At bull quality is the first and overriding priority with strong quality systems driven on

SAP and maintains standards similar to car manufacturing industry. Bull has an excellent team

dedicated to quality.

Quality control in manufacturing industry can be defined as the oversight of aspects of

the manufacturing production. The goal of implementing manufacturing quality control is to

produce products that conform to industry, company and consumer expectation every time. This

system monitors everything from the parts that are manufactured to the employees that put them

together. When quality control is utilized properly the end result is the maximum efficiency of

the designed products.

The quality control techniques used in BULL MACHINES are:

 ABC analysis

 Two bin

 Kanban

 JIT system

 TQM

 5S.

ABC ANALYSIS:

In material management, the ABC analysis( or selective inventory control) is an inventory

categorization technique. ABC analysis divides an inventory into three categories:

 “A items” with very tight control and accurate records.

  “B items” with less tightly controlled and good records.

 “C items” with the simplest controls possible and minimal records

BULL equipment uses ABC analysis provides mechanism for identifying items that will have a

significant impact on overall inventory costs and also categorize the stocks that will require

different management and controls.

TWO BIN TECHNIQUE:

Two bin inventory control is an inventory control system used to determine when items

and materials used in production should be replenished. The two bin inventory control is mainly

used for small or low value items.

 First bin- just enough to last from the date a new order is placed until it is received for

inventory.

 Second bin- enough to meet current demand over the period of replenishment.

In BULL the two bin technique is used for material control which helps in best quality products.

KANBAN SYSTEM:

Kanban is a scheduling system foe lean manufacturing and just-in-time manufacturing.It

helps to avoid supply disruption and overstocking of goods at various stages of manufacturing

process. Kanban visualizes both the process and the actual work passing through that process.

The four foundation principles of the Kanban Methodology are provided below:

 Start with what you are doing.

 Agree to pursue incremental, evolutionary change.

 Initially, respect current roles, responsibility and job-titles.

  Encourage act of leadership at all levels.

In Bull machines Kanban method provides technology teams a great set of principles for

visualizing their work, delivering products and service continuously and getting customer

feedback more often and with greater speed.

JUST IN TIME (JIT) INVENTORY:

Just In Time manufacturing also known as just-in-time production is a methodology

aimed primarily at reducing times within production system as well as response time form

suppliers and to customers.

In BULL , JIT system helps to production of goods to meet customer demand exactlyandin time.

TOTAL QUALITY MANAGEMENT(TQM):

BULL Machine’s Total Quality Management(TQM) focuses on increasing customer

satisfaction while continually reducing costs.

5S METHODOLOGY:

There are five 5S phases. They are:

 Sort

 Set in order

 Shine

 Standardize

 Sustain.

BULL machines uses these 5S and manufacture their product.

 4. LAYOUT

LAYOUT:

Layout is the process of calculating the position of objects in a space.Master plan or blue

print of a printed or published work that lays out the arrangement of its different graphic

elements. It establishes the overall appearance, relative importance, and relationship between the

graphic elements to achieve a smooth flow of information and eye movement for maximum

effectiveness or impact. Often alternative layouts are prepared to explore different arrangements

before the final layout is made for printing or production.

There are two types of layout in manufacturing:

1. Process layout.

2. Product layout.

PROCESS LAYOUT:

The process layout clearly explains where the items are placed and sequential process of

manufacturing. In manufacturing , process layout is a design for the floor plan of a plant which

aims to improve efficiency according to its function. The production line should be designed to

eliminate waste in material flows, inventory handling and management. It is based on the nature

of the process through which the product should move in the course of manufacturing.

PRODUCT LAYOUT:

In product or line layout all machines that are needed to produce a product are

sequentially available.It is used at the time of assembling the parts which convert into the

finished one.
PROCESS LAYOUT DIAGRAM:

This layout of BULL helps to know about the process and its sequential order.
 5.LEARNING OUTCOMES

 The industrial visit helps to learn many new things about how the manufacturing is done

and quality control measures.

 This visit was highly useful for the students in terms of practical knowledge.

 It is used to observe and learn as to how theoretical knowledge are put into action,

thereby aiding practical knowledge.

 It bridges the gap between theoretical and practical learning.

 We become more aware of the process done in the plant and also learn how to follow the

industry rules and practices.