Industry 4.0
Final Project Report
Submitted by:
GROUP 11
MEMBERS –
SUJIT SONAWANE
P20103
BHASKAR VATS
P20051
NISHANT PODDAR
P20091
SOUMYA SHARMA
P20098
RISHAV KUMAR
P20110
Date: 20th March 2022
Contents
Introduction ................................................................................................................................................... 3
Product 1: Classroom Jammer ...................................................................................................................... 4
Process Flow Diagram .............................................................................................................................. 5
Product 2: VVPAT ........................................................................................................................................ 7
Process Flow Diagram .................................................................................................................................. 8
Product 3: I 7 Processor Card ..................................................................................................................... 10
Process Flow Diagram ................................................................................................................................ 11
Potential techniques for Industry 4.0 transformation at BEL ..................................................................... 12
Inventory Management with the help of Industry 4.0 – “Smart Inventory System” .................................. 13
Current Scenario ..................................................................................................................................... 13
Problems in current scenario ................................................................................................................... 14
Proposal .................................................................................................................................................. 15
Process Flow ........................................................................................................................................... 15
Benefits ................................................................................................................................................... 15
Added Advantages against challenges faced ...................................................................................... 16
Cost Savings............................................................................................................................................ 16
Lost sales............................................................................................................................................. 16
Labor cost............................................................................................................................................ 17
Cost Structure.......................................................................................................................................... 17
Variable Cost2 ..................................................................................................................................... 18
Market/ Demand ..................................................................................................................................... 18
Defect Management System with the help of Industry 4.0 ........................................................................ 19
Current Scenario ..................................................................................................................................... 19
Problems in Current Scenario ................................................................................................................. 19
Proposal .................................................................................................................................................. 20
Benefits ................................................................................................................................................... 20
Cost Structure ......................................................................................................................................... 21
IIoT enabled Cyber Security Cell ............................................................................................................... 23
Current Scenario and Challenges ............................................................................................................ 23
Proposal .................................................................................................................................................. 24
i
Benefits ................................................................................................................................................... 24
Cost Structure.......................................................................................................................................... 24
Manufacturing of Component using Industry 4.0 - Additive Manufacturing ............................................. 25
Current Scenario ..................................................................................................................................... 25
Problems in Current Scenario ................................................................................................................. 25
Proposal .................................................................................................................................................. 25
Benefits ................................................................................................................................................... 26
The chosen transformation .......................................................................................................................... 27
Proposed Model .......................................................................................................................................... 28
References ............................................................................................................................................... 33
ii
Organization: Bharat Electronics Limited
Introduction
At the brink of independence when India gained the capability to make its own choices from an
administrative standpoint, the government initiated a handful of undertakings that bloomed into
massive organizations in modern India helping the nation stand on its feet by bolstering production
and service capabilities. Today these organizations have been granted the title of Navratnas. One
of these 9 organizations is Bharat Electronics which operates in the aerospace and defense
electronics area and is under the aegis of the Ministry of Defense.
Starting in 1954, BEL started off by manufacturing communication equipment in its initial years
such as Radio Transmitters for All India Radio. In its youth, the company moved on to producing
advanced equipment such as Radars and Black and White CR Television sets. Also, the company
ventured into Research and Development Wing. In a way, BEL has been the backbone of the
Indian Media Transmission. Eventually, the company moved on to other clients such as Indian Air
Force. Through its 70 year journey, the company has moved in to international locations, set up
multiple manufacturing units across the country and moved deeper into the manufacture of more
sophisticated and technologically advanced equipment for various government clients. In 1996,
the company achieved a turnover of 10 Billion INR.
Today, the company operates in numerous spaces Defense Communications, Naval Systems,
Avionics, Electro-Optics, Simulators and Batteries among many other things. The company aims
to become a world-class enterprise in professional electronics while being customer focused
globally competitive areas through innovation.
With almost 10,000 employees, the company has revenue of 33,000 Crores INR. Going ahead the
company is involved in international tie-ups with brands such as General Electric as well BHEL.
3
Product 1: Classroom Jammer
About: This device blocks out all the communication frequency bands in the vicinity of 35-40
feet. It is efficient in blocking 1G, 2G, 3G, 4G, 5G, Wi-Fi, and Bluetooth signals.
Its prominent features are:
● The device is certified with CABSEC
● It works on a 220 V supply and has an output of 5 Watts
● Frequency Band Power:
Band Name
Frequency
● CDMA & GSM900
● 869 – 894 MHz & 935 – 960 MHz
● GSM 1800
● 1805 – 1880 MHz
● 3G
● 2110 – 2170 MHz
● 4G/LTE-TDD
● 2300 – 2400 MHz
4
● Wi-Fi & Bluetooth
● 2400 – 2500 MHz
Process Flow Diagram
5
6
Product 2: VVPAT
About: This device works with the Electronic Voting Machine which consists of a Control Unit
and Ballot Unit. This functions as the unit which displays and stores the vote cast by the voters.
Prominent features:
● It is embedded with digital signatures that make it tamper-proof.
● It uses a thermal printer whose print does not fade away for at least 5 years.
● It also displays the printed vote to the voter for 5 seconds.
7
Process Flow Diagram
8
9
Product 3: I 7 Processor Card
About: This processor is a part of the Integrated Air Command and Control System (IACCS)
which is an automated Air Defense command and control center.
Prominent features:
● 4.2 GHz frequency
● 64 GB storage capacity
● Encrypted operations keep the data safe from hacking
10
Process Flow Diagram
11
Potential techniques for Industry 4.0 transformation at BEL
1. Smart Inventory Management System (For whole plant)
2. Defect Management System (For manufacturing lines)
3. Cyber-Security
4. Additive Manufacturing
5. Augmented Reality
6. Cloud Computing
12
Note: After discussion, our group selected first four processes on ruled out the rest based on
feasibility grounds.
A detailed analysis of each Industry 4.0 transformation at BEL is given below
Inventory Management with the help of Industry 4.0 – “Smart Inventory
System”
Current Scenario
Currently, BEL has a manual inventory management system, where every inventory item is
counted manually and recorded over an excel sheet in-store PC. There is one store for inventory
keeping of the plant, where all the incoming raw material is stored. Upon receiving any raw
material order, the store manager and assistant manager do the incoming inspection and count the
material and keep every raw material to their described store space. After which, data is updated
on the PC.
Every day, according to production requirements manufacturing department gives the requirement
of different raw materials to the store manager on the raw material requirement sheet. With the
help of the assistant manager, the store manager manually collects every part and issues it to the
manufacturing department. This practice is done separately for every manufacturing line. After
issuing the material, the store manager updates the raw material sheet and tracks the inventory.
Small components like resistors, capacitors, etc., are ordered in bulk and are issued without any
requirement sheet. There is no track for such small materials.
For new orders, the store manager makes the list of raw materials required according to inventory
left and gives that to DGM store operations. DGM further place the order for every part according
to requirement.
Many critical components like ICs, Chassis have a longer lead time, and sometimes whole
manufacturing line stops if one critical component is not in the inventory. If the store manager
forgets to order some components on time, manufacturing gets delayed by days. Also, there is
much human error while counting and maintaining the data, which delays production. Sometimes
inventory is going under stocked, and many times it is overstocked.
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Process flow of Current System
Items counted
manually by
Store Manager
Inspection and
the count data is
stored in PC
Daily manufacturing
department give
requirement to the
Store and Assistant
Manager
New orders
according to the
inventory left
Collection of
every part,
different for
different
manufacturing line
Problems in current scenario
S. No
1
2
3
4
5
6
7
8
9
Direct Issue
Indirect Issue
Overstock and under stock
Production stops
Inconsistent tracking
Production delays
Warehouse inefficiency/ Space management Supply chain complexity
Human error/ Inaccurate data
Inefficient order management (Increases cost of order)
Limited visibility
Poor communication
Inventory loss
Loss sales
Frequent counts for inventory management Overpromised orders
Time consuming
Manual Documentation
14
Proposal
To create a “Smart Inventory System,” where the Internet, software, wireless sensors, and other
advanced technologies will work together to improve the inventory management system, increase
warehouse efficiency, and improve manufacturing lines. It will enable a system to react more
efficiently to production changes and increase operational efficiency with continued improvement.
It will provide a single, scalable and real-time view of inventory and demand that will help grow
sales, save costs, and increase customer satisfaction. It will also enable an automated purchase
process based on real-time information and data, and orders will be automatically triggered with
the correct quantity at the right time.
Also, to place and draw inventory automatically from described store space, robotics will be used.
Process Flow
Warehouse
Robotics moving
raw materials in
and out of
warehouse
Manufacturing
Sensors keeping
track of real time
inventory
Data Analytics:
Real time data
updating on servers
Internet
Automatic order
placing notification
to DGM
DGM placing order
Benefits
With the help of the Smart Inventory System (Industry 4.0), BEL will likely get the following
benefits:
1. Real-Time Capability: Industry 4.0 enables everything in real-time, including raw
material counting, data recording, documentation, raw material monitoring in a real-time
manner.
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2. Decentralization: It will enable the intelligent inventory system to make decisions
autonomously, aligning with industry goals.
3. Interoperability: Human and innovative inventory system will be connected; it will ask
Store DGM before placing an order and provide updates about inventory on the spot.
4. Modularity: Smart inventory system will quickly adapt to changing demand and
production speed, and it will ensure minimum disruption in ordering raw material, which
will prevent overstock and under-stock.
5. Increases Business competitiveness: It will enhance global competitiveness by using
advanced technologies.
6. Increased productivity and revenues: It will enhance operational efficiency, lower
operational costs, and save inventory stocking, which will increase productivity and
revenues.
7. Maximize Inventory ROI: With protection against fluctuations in demand and lead times,
fewer overstocks, and under stocks and loss inventories, ROI will be max from inventory.
Accurate inventory counts will help to avoid overpromising and losing sales.
Added Advantages against challenges faced
S. No
1
2
3
4
5
6
7
8
9
Challenges
Solution
Overstock and under stock
Orders based on real time data and production requirements
Inconsistent tracking
Automatic counting and updating of data
Warehouse inefficiency/ Space management Auto-bots to place raw material in inventory to use warehouse at full efficiency
Human error/ Inaccurate data
Automatic data generation with least errors
Limited visibility
Data recording on cloud, visible to every authorized person
Inventory loss
With accurate inventory, minimum inventory loss
Frequent counts for inventory management Automatic real time inventory
Time consuming
Minimum manual interventions
Manual Documentation
Auto-generated documentations
Cost Savings
Lost sales
Total turnover of company – INR 450 Crores
Revenue generated per week (without seasonality) – INR 8.5 Crores
16
Production halts due to insufficient inventory – Approximately 5 to 6 weeks in a year
Lost sales due to production halt – 8.5 * 6 = INR 51 Crores
Cost saving on lost sales – INR 50 Crores (Approx)
Labor cost
*Labor used in contractual basis in BEL*
Total contractual labor in production lines – 48
Wages – INR 12000 per month
Total wages for 6 weeks – INR 864000
Cost savings on Labor – INR 864000
Apart from this, cost savings on overstock and under stock, lost inventory.
Cost Structure
Fixed Cost1
S. No. Fixed Costs Involved
1
2
3
4
5
6
Sensors*
Conveyor system for incoming
inventory
Conveyor system for outgoing
inventory
Software Cost
Training Cost
Other infrastructure cost**
Price (INR)
8000000
30000000
30000000
295000
100000
10000000
78395000
Total
*Total SKU’s = 2000, so total sensors required = 4000, cost per sensor = INR 2000
**Special Purpose machines required for movement of different types of inventory in the
warehouse
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Variable Cost2
S. No. Variable Costs Involved/ month
1
2
Cloud Space*
Software subscription cost
Price (INR)
150700
22500
Total
173200
*Connectivity charges + Messaging charges + Device shadow & Registration charges + Rules
Engine charges
Other variable costs involved:
1. Maintenance cost
2. Spare parts, etc.
Market/ Demand
With the current market competition with DRDO, ECIL, and other small private players, it is very
easy to lose an order if BEL’s technology is not advanced and the product’s quality is at par.
Components like resistors and capacitors create antistatic charge if they are kept open and unused
for longer time, so the fresher the raw material is, the better is the quality of the product.
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Defect Management System with the help of Industry 4.0
Current Scenario
Currently, the process is designed in such a way that the testing is done manually with the help of
certain instruments. So, if I particularly talk about Classroom jammer process, PCB testing,
module testing and Jammer testing happens manually with the help of instruments such as multimeter and spectrum analyzer. This makes the process very clumsy and time consuming. Also, the
person in charge of these testing has to note down each and every data manually in to the system
which makes this process extra dependent on manual effort.
Since, the most important process which is testing and validation is dependent on human effort
there’s a possibility of mistake happening at different levels such as

While performing the test

Noting down data in to the system

Improper use of the instrument
This could possibly lead to ineffective manufacturing process.
Now because of this manual effort it gets really difficult to handle the defects properly within the
process.
Problems in Current Scenario
S. No
Direct Issue
Indirect Issue
1
Manual Overhead
Improper Inventory Planning
2
Improper Testing
Poor Goodwill
3
Manually Controlled Assembly line
Customer Dissatisfaction
4
Human Error
Last minute hustle
5
Defective Tools
Extra Expenditure on maintenance
6
Time Consuming
7
Error in manufactured instrument
19
Proposal
Now that we have identified the problem in the process and the issues happening due to the
problem in the process, we recommend a solution to overcome all the concerning problems. Our
proposal is to modernize the manufacturing assembly line. A Smart Assembly System will help to
get rid of all the issues happening due to the problem.
A Smart Assembly System will have the below mentioned components.

Interconnected Machines over internet

Integrated Testing Tools

Automatic RFID Scanner

Sensing Devices
Explanation of the proposal in details:
For example we will talk particularly about Classroom Jammer
So, the initial sensing device fitted before PCB assembly will be able to sense and identify all the
components provided as input. These components will move forward in to PCB assembly unit
where they will get assembled. Now the assembly will move forward for PCB testing. Here, the
integrated Multimeter will test the assembly and give the output in the digital screen .The sensing
device integrated with Multimeter will record this data and send the same to cloud. From cloud
the data will be fetched in to the Ware House Management System and in the data falls under the
safe range then the Assembly is good to move forward else a message will be displayed on the
digital screen to discard the assembly to save time. And like wise at every stage a testing tool will
be integrated with a sensing device in the assembly line along with a digital screen to display
output. Here if the assembly is good to move forward then the same message will be passed on to
the next machine so that it will understand that it has to perform operation on the upcoming
assembly.
Benefits
With the Smart Assembly System in place, BEL will likely to get the following benefits.
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1. Automated Assembly Line: Fully automated Assembly line with interconnected machines
that will make the human intervention as minimal as possible
2. Control: Full control over the process can be imposed as there will be sensing device at
every milestone in the process
3. Data Collection: Ease in data collection as it will be happening automatically and will be
getting stored in Cloud
4. Defect Management: The defective instruments can be easily identified and scrapped at an
early stage
5. Time Saving: As it is an automated process with everything being interconnected to each
other this will save a lot of time. It has minimized the manual effort
6. Forecasting: Data collected can be used to forecast the percentage error that could occur in
the process
7. Improved Productivity: As manual intervention has been minimized with defective
products getting eliminated as early as possible, the productivity will get improved
8. Better Inventory Management: This will help to manage inventory well by keeping the
defective rate in mind
Cost Structure
*Cost of each smart sensor (IoT sensors) is $38
*Average cost of image sensing device is $73
*Average Cloud server cost per hour = $0.54 (for AWS)
*Cost of software = $5714.28
For Classroom Jammer, we need
Smart sensors = 4 nos.
Image Sensors = 1 nos.
Cloud service based upon the requirement
Additionally BEL will incur cost of integrating sensing device, testing tools in to the assembly
line.
21
*These are rough figures taken from internet
22
IIoT enabled Cyber Security Cell
Current Scenario and Challenges
Bharat Electronics Limited, being a defense PSU has almost all its clients either from the Armed
Forces or Government entities that require confidentiality and secured network.
To counter the risk of data leak, all of BEL’s work is carried out in an “Intranet network”. This
network not only facilitates sharing and accessing files with a unit, it also enables file sharing
across locations in India, be it regional offices, corporate offices, or manufacturing units.
However, an incident of Air Force data leak from an official at BEL – Ghaziabad made it clear
that the system was not protected enough. For the same, we propose an integrated “Cyber Security
Cell” powered by Industrial IoT.
The global industrial trends and rapidly progressing technology forecast that it is necessary for
every organization to transform themselves into a digitally enabled entity to survive in the longer
run. The more digital a company is, the more it is prone to cyber-attacks.
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Proposal
To create an encrypted system with the help of Industry 4.0 with no possibility of data breach
whatsoever, Integrated Cyber Security Cell with IIoT.
With this system, we will be able to offer our customers; an unreachable data environment that
safe keeps the technology and its usage for the ulterior aim of National Security.
Also, it will help us to emerge as a superior manufacturer of defense products adding to our value
proposition than our competitors, namely Defense Research and Development Organization
(DRDO), Electronics Corporation of India (ECIL), Hindustan aeronautics Limited (HAL) and
some private players like Paras Defense and Space Technologies Limited.
Benefits
Advantages of this technology over the existing security protocols in the organization are:
1. Enhancing Customer Trust
2. Proving to be better than competitors
3. Protection of intellectual properties
4. No impact on productivity and performance of products
5. Continuous inventory monitoring
6. Real time access to operational data
Cost Structure
Element
Cost (INR)
Employee Training
1,00,000
Software Licenses
1,05,420
Asset Up gradation
2,30,000
Backup Storage Server/Cloud
1,50,700
Insurance of unprecedented events
3,20,000
Total
9,06,120
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Manufacturing of Component using Industry 4.0 - Additive Manufacturing
Current Scenario
Currently, BEL has nine manufacturing units in India that produce different products ranging from
Radars, Military Communication devices, Night vision devices and Electronic warfare systems.
Precision manufacturing of components is very essential because even a minute error in the process
may lead to a significant reduction in the efficiency of the final product. In the current
manufacturing process at BEL, still, conventional methods are used to develop products like air
defense systems. Conventional manufacturing methods are unable to create products of complex
designs also, because of this method generation of waste of materials required for manufacturing
is more. Due to this, the overall cost of the final product is also increasing, and the efficiency or
accuracy is also decreasing. To counter these disadvantages, modern methods of manufacturing
should be adopted to BEL to develop products of higher quality. Due to the usage of obsolete
technologies by almost all of the defense manufacturing players in India, about 80% of the air
defense system equipment and spare parts are imported by India.
Problems in Current Scenario
Sr.No
1
2
3
4
5
6
7
Direct Issue
Indirect Issue
Inaccurate manufacturing according to the Design of Equipment Faulty final product
Time and labor required for the process
High labor costs and production delays
Faults in the molding equipment
Inappropriate sub-assemblies and dimensions
Faults in handling the assembly line process
Facing Untimely interruptions
Inefficiency in the development of intricate designs
Decreased product utilization
Generation of a high amount of waste during manufacturing
Increasing the overall cost of the product
Less efficiency of the Final Product
Proposal
So identifying the problems due to conventional manufacturing, we propose to use additive
manufacturing for the development of PCB for the I7 processor card, which is a part of the
Integrated Air Command and control system (IACCS)
To start with PCB prototyping and mounting of the components on the PCB board is very vital as
it is a very complex and critical part so to ensure a functional end product. For the extrusion
process, we will use a header that will drop the droplets of the required metal on board. These
25
materials then start to form layers and accumulate layer by layer. Further conductive gels can be
used to fill the gaps. With this, we can build circuit boards that would fit any functional
requirement and can be built in non-planar geometry as well. The layer by layer production
technique gives the freedom to mount the components horizontally/diagonally or in a curved
manner. With additive manufacturing, we can build customizable surfaces, which in turn help to
place components in various ways. This would also help to fasten the production process, which
is notoriously slow for parts like PCB when build through conventional methods.
So here, instead of using traditional techniques which involves material removal and cutting
process, we here make use of the additive manufacturing process to build a complex PCB from
the ground up.
Benefits
Traditional manufacturing techniques require lots of effort and time to manufacture tools to create
required subsequent parts. Additive manufacturing requires little or no tooling, which helps to
speed up the design process stage of BEL equipment.
1. Cost savings on the prototype: Rapid prototyping by conventional manufacturing machines
like CNC machines are very expensive, and the material costs involved also add to it. On the other
hand additive manufacturing, one can easily make the required changes by printing new parts and
checking if they fit the requirements
2. Better suited for the production of a small number of units: If any project demands a lesser
number of parts to be produced, additive manufacturing is more flexible and economical in costs
compared to setting up machines to do the same in a traditional manner
3. Reduces material wastage: Traditional Manufacturing involves various processes like forming,
milling etc which leads to wastage of material but with additive manufacturing, you can print only
the parts you want
4. Inventory optimization: In the case of Traditional Manufacturing, materials are stored in
various forms like raw, semi-assembled, fully assembled, which might lead to having a lot of
26
obsolete parts. With additive manufacturing, you can store part dimensions and information and
print them on demand, thereby having to keep fewer inventories.
5. Design Freedom: Due to additive manufacturing, designers can provide designs that would be
intricate but will also be crucial in the proper development of the final product. Overall it will
motivate the designers to improve their designs.
Comparison
Implementation
Cost (INR)
Cost Savings
Smart
Inventory
Management
System
78395000
Defect
Management
System
Cyber Security
Additive
Manufacturing
746877
906120
-
500864000
-
-
-
The chosen transformation
Now, we will compare and contrast the broadly described four possible technology upgrades for
different processes at Bharat Electronics Limited on the basis of cost of application, money saved,
and importance of advantages, market trends, feasibility, priority and goals of the organization.
Cost of Implementation: Inventory Management > Additive Manufacturing > Cyber Security >
Defect Management
Cost Savings: Inventory Management > Defect Management > Cyber Security> Additive
Manufacturing
Return on Investment: Investment of approx. 8 Cr. saves more than 50 cr. of lost sales in the
inventory management project.
Since, BEL is also lagging behind on the automation front, we believe that the Inventory
Management Project will boost the confidence of the employees and would encourage them to
implement more such projects in future. Hence, we would like to apply the Industry 4.0 concept
in the “Smart Inventory System”.
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Proposed Model
Suppliers
Approved PO
Raw
Materials (RM)
DGM
Auto Generated PO
using WMS
Warehouse
Raw Materials (RM)
Purchase Order (PO)
Manufacturing
Unit
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The issue with the current inventory model is that in case the warehouse runs out of the raw
materials then the manufacturing unit will remain idle until the warehouse gets replenished and
that will take some time to happen. One more issue is every time the DGM of the warehouse has
to place and order manually and in case he forgets then the halting issue will happen. Also, he has
to manually update the record in system if any raw material moves in and out of the warehouse.
This makes the job more cumbersome and every single time the person has to feed in all the details
without fail.
To overcome all the issues mentioned we have placed and online ordering system that sits between
manufacturing unit and warehouse. Now, there is no need for a person from the manufacturing
unit to come with a physical copy of Purchase Order to get raw materials from the warehouse. The
person can directly place and order from the online ordering system and it will move directly to
the warehouse and at the same time all the data will move to SAP HANA Cloud, where SAP will
be storing all data in cloud. Now, the person sitting in the warehouse will receive the Purchase
order from the manufacturing unit in their Warehouse Management System (WMS) which will be
integrated with SAP as well. Now in the warehouse that particular Purchase order will get
converted in to Sales Order and the warehouse in-charge will fulfill the order in the system. Once
that is done, the Automated Guided Vehicles (AGV) will move to the respective location in the
inventory and pick up the raw materials and place them in boxes. These boxes will be having a bar
code and then the AGV will place these boxed in the conveyor belt. The conveyor belt is equipped
with bar code scanner and visual sensors. As the box moves through the belt, the bar code scanner
will scan the barcode and will send the details to the SAP system. Also, the visual sensor will scan
the volume of the units present inside the box and the same will be shared with SAP. The units
transferred out of the Warehouse will automatically get updated in the Front-end system which is
WMS and there is no need to manually update it in the system.
Now another use of implementing SAP HANA is that the data stored in the cloud related to the
orders coming from manufacturing unit and the orders that are placed to suppliers to get the raw
materials will be analyzed by the data analytics team and the same will be used to forecast the raw
materials required for upcoming months or quarters or years. This will help the warehouse to
maintain a safety stock level in their inventory and they will never run out of the raw materials.
Also, the WMS is capable enough to place an order without anyone’s supervision as and when the
29
inventory level reaches the reordering point. Now, since this is a government project and Ministry
of Defense is connected to this project, the orders cannot be placed directly unlike other private
firms. So, the order placed automatically through WMS will move to DGM for approval once the
DGM approve the order, it will move automatically to suppliers system/ SAP system and then
supplier will fulfill it before warehouse runs out of the inventory.
This will enable to warehouse to maintain its inventory in a smart way without much manual
intervention. The data stored in the cloud will have multiple uses for the organization and analytics
team will use it accordingly.
EXPECTED CHALLENGES
The selected transformation will bring its own challenges in the implementation phase of the plan.
There will be restraint from the employees, the management, and the organization as a whole.
Upon discussion with BEL officials, the provocations are boiled down to two broad categories;
Organizational and Implementational challenges.
They are under the light of the facts that a) The median age of the organization is close to 45 years.
b) The ratio of the young generation employees to the old generation is 1:4.
c) The average tenure served in BEL is around 20 years.
ORGANIZATIONAL
Employees are not willing to accept change: The technology up-gradation that is brought along
with this transformation might not be welcomed by all, as some employees are settled in their
comfort zone and do not understand the importance of this change.
30
Employees reluctant to learn: Having served in the same organization for two decades, people do
not feel the need to learn new things as the job does not demand upskilling as well as a PSU offers
job security.
Orthodox Management Structure: The organization structure was designed way before and
undergoes little or no change. This has led to a slow and non-flexible structure that has many levels
on the way of any approval.
IMPLEMENTATIONAL
Huge initial investment: Any project of this value (~INR 8 Crores) will be thoroughly scrutinized
before taking into consideration implementing the same.
Current Infrastructure: BEL’s current infrastructure is not promising. It currently has a limited
extent of automation. More than the production of new products, the majority of the work is repair,
rework, and maintenance of existing products.
Dedicated team to operate the new system: As the new system will be installed by a third party
vendor, we need a team that understands the in-out functioning of the entire system to handle crisis
situations.
STRATEGY
The above-mentioned challenges are both mitigable and non-mitigable. The non-mitigable
challenges are the management system and approval procedures which are changed only under the
circumstances of an organizational change or privatization.
As per the infrastructure is concerned, the budget amount of the project includes all the necessary
machinery and equipment required for the system.
Hiring a new team or skilling an interested set of people can be planned ahead and performed
promptly as per the project timelines with little additional costs.
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The mitigation of challenges associated with employees will be of paramount importance in the
success of the Inventory Management System Project and hence only an adaptive strategy will be
able to overcome this issue.
In this regard, a three-step plan is laid out:
Brief: A fair number of sessions will be conducted to stress the requirement and advantages of the
project to convince employees that it will save time and money.
Train: Training will be given to the department employees in order to ensure smooth running and
working of the project as well as the advanced technology used in the system.
Test: Their learnings will be tested through regular tests that will ascertain employees’ knowledge
and dedication towards the development of the organization.
The implications of the implementation of the Inventory Management System are wellacknowledged and necessary measures will be taken from time to time to ensure a flexible and
smooth process. The suggestions given by BEL officials have also been included in the report to
keep a check on the feasibility and practicality of the project.
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References
1. https://bel-india.in/Default.aspx
2. https://www.businessnewsdaily.com/15928-best-inventory-management-software.html
3. https://aws.amazon.com/iot-core/pricing/
4. https://www.ge.com/digital/iiot-platform/cyber-security-trust-center
5. https://home.kpmg/xx/en/home/services/advisory/risk-consulting/cyber-securityservices/industrial-internet-of-things-cyber-security.html
6. https://blog.capterra.com/how-much-does-network-security-software-cost/
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