Need Analysis Survey - Design Clinic Schemedesignclinicsmsme.org/Design Awareness Programme...

| Dhananjay Shahane

Need Analysis Survey

Date : 04 January 2011

MSME cluster, Pune

Fabrication shops, Machine shops Welding units CO2, Argon, SS, Brazing

Painting shops powder coating Auto painting booths

Repair shops, garages Hardware shops in neighbor hood

Team : Satish Komeragiri | Shrikant Chandane | Jitendra Jagtap | Hrishikesh Burude

Cluster Level

Macro Industry

Cluster capability

Core business and cluster scenarios

Micro Industry

Fabrication shops

Welding units

Repair shops

INDEX

Introduction & Back ground

Need Analysis Frame work

Matrix

Cluster study Mapping

Data collection

Data Analysis

Observations

Design intervention

Process

1/4/2011 Confidential NID MSME Design clinic Need analysis Survey 2

Pune:

One of the prominent industrial city of India, in the state of Maharashtra and with advanced manufacturing industries

– the description below looks into the hinterland of the city Pune and also in general on the large scale factory-based

industries of the state.

Introduction | Observations | Design intervention

Agra

Pune

Surat

Gurgaon

Chennai


Introduction & Background

Salient observations:

Most of the MSME industries have used their traditional knowledge for their technology source in both the pre or post

liberalization periods; advanced large scale industries formidably have no linkage with the MSMEs, proving Pune to be a

relatively poor industrial city.

Number of non-ancillary units has increased over the period – it also appears that large factories have not established supply

linkages with the MSMEs.

A slight increase in the involvement of domestic R&D institutions as suppliers of knowhow over the period has been observed.

Collaboration with domestic companies has increased in post-liberalization period

Though Pune city is known for its large manufacturing enterprises, but in post liberalization period a spurt in the number of

repairing and service industries has been observed.

Salient observations:

In post liberalization period growth is observed in sectors

with NIC codes 15, 18, 22, 24, 25, 26, 27, 28, 29 31 and

36.

Over the two periods, pre- and post-liberalization, Pune

district MSMEs did not experience any structural change

evidenced through shifts in dominant NIC codes.

The large scale factories with NIC codes 15 (though

downward), 17, 24, 29, 31 and 36 - have specialization

and dominance in the state.

Units of MSME and factories of ASI share a few NIC

codes, such as 15, 29, and 36; however, most MSME

units which opened post-liberalization are under code 28.




Reference to the Govt report

And analysis after consolidation of SSI and other

departments.

Need Analysis Survey Frame work

Categories

Flower bedsGrillsFencingGarden benches

ShelvesRacks, outdoor sculpturesFountainsOut door accessories

Make or Buy decisionIncoming material In process delivery of finished goodsTransportation

Control box making, panel makingCPU, enclosures

Cabinets -Floor standing Wall mounted & desktop

Layout and Material HandlingManaging inventory

Industrial product fabrication, Aluminum doors & windows, Garbage trolleys

Machine requirements -Bending , welding , cutting Forming machines

Power assisted, Manual toolsHand tools, Hydraulic & Pneumatic Tools

Automotive related fabrication & welding jobs.Home related Main safety door indoor railings, stair cases etc

Worker safetyWorkplace layout Ergonomics employee well beingSocial Cultural aspect


Out Door Industrial Material alternatives Indoor products

Business Manufacturing Tools Human Aspects


Matrix Material

• CRS, MS, Aluminum, LCS

• Special material

• Special processes

• Machinery requirement

Production Processes

• Manual semi automatic

• Investment Out sourcing

Resources• Skill set requirements Local

availability

• Training needs Attrition rate

• Infrastructure Electricity Transport availability

Procurement & Sourcing• Inventory Vendor

Sourcing

• Material Availability Lead time

• Payment recovery



Cluster study and Mapping


Fabrication shops

Project Team –

Internal Resource allocation

Material Procurement frame work

Out sourced specialized

processes

Transportation

vendors

Hard ware shops

Raw material vendors

Process

Raw material procured as per project order

Material processing ,

In - house – outsource decision

Sending to other cluster partners members

Collaborative work with other MSME‟s.

This could lead to the modern movement of co-

operation and there by the cluster development

could be faster and reach to the village level .

It will also strengthen the sustainability of the

business and bring true meaning to the SEZ .

In fact the cluster development should also get

Certain percentage allocation to bring self

sufficiency at regional / local level.


Cluster study and Mapping


Raw material

Special processes-

CNC

Laser cutting

CNC Bending

In-house Assyprocess

Other component

procurement

Painting & finishing

Opportunities

The Third Census defined clusters as a district

with 100 or more registered units manufacturing

the same ASICC 2000 code product, or for

unregistered units a district having 500 or more

units producing the same product.

As for the registered clusters there are 1223

clusters in 26 states covering 321 products with

16.99% of total gross output; Kerala had highest

number of such clusters; and there are 819

clusters of unregistered units in 25 states covering

250 products and with a share of 34.63% of total

gross output.


Plywood supplier

Hardware supplier

Computer HW suppliers

Component suppliers

Vendor

Powder coating

Spray painting

Manual paint house

Special paints

FRP painting

CNC cutting

Power press

Machining shops

Turning shops

Patten makers

Model makers

Regional purchase

Local purchase

Macro level data collection


Product study

Ergonomic conditions

Process Flow

Manufacturing process

Packaging

Storage

Distribution

Communication


Key Factor affecting the product mfg time

Product

Sub system breakup

Electronics

Mechanical

Hydraulic

Pneumatic

Mechanism

Patented process etc.

Market need

Design

Development

Feasibility

Testing

Validation

After sales support

End of life cycle

Recycle, reuse

Purchased items

Customized – out sourced

Standard items –fasteners,

consumables

In-house processing

Primary Processes

Machining

Finishing –

Functional

Secondary

Coloring , storage,

Packaging, dispatch

Fixtures , Jigs

Understanding the process

• Macro level analysis

• Identify Other stake holders

• Understand bottle necks

• Flow chart , time estimate

• Alternative process

• make – partner - buy decision

• Primary Tools - power assisted / manual

• Secondary tools – loading unloading, transport, material handling

• Cycle time calculation, reduction optimizing process

• Total product time requirement , total cycle time break up

• Critical path

• Areas of improvement

• Risks management

• External factors – social, cultural, human, infrastructure, labor related, policy related

• Improving quality



Category : Small cabinets & Control Panels

Company : Steel Made Furniture

Location : Shivane- Kothrud

Contact Person:

Mr. Chintamani Tol, [email protected]


Case study 1

1/4/2011 Confidential NID MSME Design clinic Need analysis Survey

Dhananjay

Observations

• Initial product is in Acrylic , alternative process – sheet metal

• Process improvement – thermo-forming – CNC laser cut and bending

Process time - 4 days to 2 days, reduction in wastage

Batch size : 10 units

• Previous method of assembly - Acrylic forming , gluing, Buffing – Packaging, transportation

Process time - 2weeks for 5 units 21 days for 10 units

• New process

Laser cut CNC, welding , grinding, powder coating

Process time - 1 week for 15 units

Rejection – no rejection



Procurement -

• ProcurementUnderstanding the bottle necks and lead time for procurement is critical

• InventoryManaging the cash flow and also the lead

times , JIT concepts can be elaborated for effective use of space and facilities

• StoragePrepare storage will help organize material better and effectively with minimal damageand easy for accessing in case of need.

• Plant layoutTo minimize the material handling and reduce cycle time to finish the process.

• Other itemsFloor cleanlinessStorage racksDust Corrosion



• Alternative material leading to reduction in process time,

• Reduction in breakages & damage during transportation

• Simple to control mfg process.

• Reduction in no of vendors .

• Design variants possible as per color options.

• Ergonomically easy design. Simple and less number of moving parts result in quicker assembly.

• Easy assess for the printer and power cords.


Sheet Cutting & Bending



Sheet Cutting & Bending

Other itemsFloor cleanliness – Proper markings on floor

for in process inventory, incoming material, raw material etc.

Storage racks –

Providing proper storage racks and cabinets for employee well being , their cloths incase there is dress code for workers.

Dust accumulation

Ways to reduce dust formation and also to reduce dust and air pollution .

Noise pollution- Reducing and channeling the noisy areas for the rest working environment.

Corrosion prone area and oil spillage . Proper storage and access including safety of workers.



Opportunity mapping


Shop floor Same welding machine is shared by more than

4 people

and is using the radial access structure . This needs

separation of each workman’s area in order to avoid

accidents.

StoragePrepare storage will help organize material

better and effectively with minimal damage

and easy for accessing in case of need.

Plant layoutTo minimize the material handling and reduce cycle

Time to finish the process.

MSME description

Location Shivane Industrial Estate Pune

Contact information Mr. Chnitamani Tol Phone number - 9822545132

Description and scope Redesign, New product development

Existing status and opportunity Visual identity, branding and communication design

Scope Investment in technology, modernization and design

collaborations.

Describe the scope Operations and process innovation from design perspective.

Design opportunity I Workstation and tooling design, shop floor revisit to plant layout

Details of market and competition study NA

Study for the need Employee training and skill up‐gradation required.

Ergonomic and environment factors As per photographs have scope for further improvement.

Packaging and logistics Need to design packaging as per clients projects elated

design opportunities.

Exhibition /Display design opportunities. NA

Study of infrastructure setup from Do not have in-house support currently

design perspective

Scope for design intervention for YES

inter cluster communication


Unit wise Design Audit Report:


Category : Garden furniture, Grills, Doors


Location : Karve nagar - Kothrud

Contact Person:

Mr. Sandeep Survanshi,

[email protected]


Case study 2

Dhananjay

• Need of fixtures and sample for references.

• Need for alignment fixtures and quick guises for holding the parts that are welded.

• Safety of operators and eye protection gear.



Observations

Grill fabrication



• Need of fixtures and sample for references.

• Need for storage of finished grills.

• Guides for holding the parts that are welded.

• Proper material handling .

• Floor layout for improving the efficiency.

Grill fabrication



• Wall mounted boards for displaying the tools and easy access.

• Proper DIY kits for daily on site workers before they move on the site in the morning.

• A front area of the shop.

• A sample work of the garden bench.

Observations



• Storage racks for the in coming material.

• Proper storage facilities for the paint and

• Cabinets for the workers to keep their clothing and expensive tools.

Opportunity


1/4/2011 Confidential NID MSME Design clinic Need analysis Survey 24| Aakruti consultant

• Proper drinking facilities for workers and also cleaning the material.

• Cloths hanging on the walls. Need cabinets for cloths.

MACRO Level Data Collection


Cluster data

Number of units Products Turnover Employees Export Communication Trade fare participations

Sandeep enterprises Grills, fencing, garden benches.

25 NO YES

Renuka Enterprises Stainless steel . Fabrication , kitchen trolleys.

30 NO YES

Shree Mech industries Industrial panels 15 NO YES

OM Steel Fabricators Home furniture 15 NO YES

Deshpande trolleys SS trolleys, kitchen trolleys

10 NO YES

Accord furniture Home furniture. Office furniture , cabinets,

60 NO YES


Category : Dust bins and

Heavy machinery enclosures


Location : Shivaji Nagar

Contact Person:Sai Industries Pune


Case study 3

shrikant

Observations• Initial product ,Tubular structure and sheet metal

• Process improvement – CNC laser cut and bending

Process time - 8 days to 12 days, reduction in wastage

Batch size : 5 units

• Previous method of assembly - Pipe cutting ,Bending ,Rolling , – Packaging, transportation

Process time - 2weeks for 5 units 21 days for 10 units

• New process

Laser cut CNC, welding , grinding, powder coating

Process time - 1 week for 15 units

Rejection – no rejection



Observations

Cutting process old method and time consuming

Process time high

Handling method are not proper.



Observations

Procurement and storage is not properly done

Method for improvement to be suggested

As per requirement the storage should be done

Proper covering for procured material.



Observations

Cutting for the sheets and bending is done manually

Fixtures not used for bending

For cutting accuracy may not be possible.

Proper radii for the bend parts difficult to get



Observations

Angle cutting machine and the process to be improved

Square tube bending and cutting

With total improvements are required



Observations

Sheet metal cutting and

Angle bending for the sheet for tray making

Improvement

In cutting and Bending



Observations

Old material is stored for the reusage

Not stored properly

No racking is done

It is marked on the ground.

Storage for the Oils and material



Observations

Steel rolling machines

Drilling machines

Improvement in

All process of Drilling and

Bending



Observations

Testing machines

Bending machines

Not properly done



Observations

Old machineries

Old methods

Welding table

And proper methods

Good skills utilization



Observations

Grinding machines

Grindings are not done on worktable

Bending





Cluster data


Sai Industries Fabrication 70 NO YES

Gulhane Industries fabrication 15 NO YES

Hardikar’s School benches

NO YES

Saps engineers School Benches

25 no no


MSME description

Location Singhagad Industrial Estate Pune

Contact information Sai Industries - shrikant chandane




collaborations.










design perspective






Category : Shelves & Racks



Contact Person:Shrikant Chandane


Case study 4

shrikant




Observations

• No Storage bins storage open to air storage

• Out side for larger parts and raw material

• Fabrication on roads

• Components racks

• Manual work automation possible

• No Floor marking for punches & dies

• Clear walk ways and NO entry zoning



Observations

• CNC laser cutting

• Bending

• Brazing /soldering/spot welding

• Cutting shear

• Press

EPS worldwide pvt.ltd Pune.

CNC laser cutting and bending

Sheet metal parts .



Observations

• Proper incoming material storage

• Safety of GAS cylinders ,

• Carbon CO2 welding

• Brazing /soldering/spot welding

• EDM or small customized parts

• Press

Soudamini Instruments ,Kodrud,Pune.

This company is manufacturing miniature

models of Trains and big construction

equipments.

Graphite die for spark erogen cnc work .



Observations

• Storage bins

• Components racks

• Floor marking for dies

• Floor marking for punches & dies


COPMPAY PROFILE

• Company is involved in making

kitchen equipment in SS sheets.

• Heat protected boxes and puff

injected walls to protect the heat.

• Food items to be kept away from rust

so SS.is used.

• Stocks methodology is properly

maintained.

• Method of mfg is quite systematic.



Observations

• Assy line

• Jig saws, Bending machines

• Finished product area

• Semi finished good storage area


MSME description

Location Karve nagar Industrial Estate Pune

Contact information Shrikant chandane




collaborations.










design perspective








Cluster data


Suyog equipments pvt ltd. Fabrication shop

35 NO NO

SMC engineering consultant

Fabrication shop

10 NO NO

Saudamini Equipents SS Fabrication shop

25 NO NO

Pinacle Industries Artistic , statues, animals in steel

15 NO YES

GANE SH Fabicater Doors and grills 20

EPS worldwide pvt.ltd Pune

CNC cutting and bending

60 NO YES


Category : Shelves & Racks



Contact Person:

Shakil Shaikh , [email protected]


Case study 5

Jitendra


Company Profile

• Steel Made Furniture manufactures steel furnituresuch as racks, wardrobes, office cupboards.

• SMF has in house cutting, bending, spot welding,welding, paint shop facilities

Steel Made Furniture



Observations

• SMF mainly manufactures wardrobes.

• Due to low production requirement (2 -4per day), whole team of 6 people startmaking cupboard or other furniture withcutting the sheets in the morning andfinish the furniture by evening.

• According process flow the machineriesare used.

• Process

– Metal Sheets are first cut and the bent intodesired shapes

– Rectangle racks are made by spot welding

– Furniture parts are then welded together

– Welding areas and other parts are finished

– Finished furniture is then painted





Observations

This unit has good raw material storage facility

Waste material is dumped in the overhead shelf




Facilities –

Shearing

Bending

Spot welding

Arc Welding

Drilling

Paint Shop




Design Interventions:

Aesthetic design can change the regular look of

the wardrobe

Nicely treated edges for safety.

Painting quality can be increased by using

Powder coating.

Graphics can add new meaning for ex.

Children bedroom wardrobe

Storage spaces can be relooked as per

modern usage





Cluster data


Cabinet manufacturer Furniture, cabinets

NO YES

Ravindra Furniture Furniture, cabinets

NO YES

Raj furniture Furniture, cabinets

NO YES

Happy house Furniture, cabinets

45 NO YES

Kamalapurkar Cabinets NO YES

Good will Furniture Office furniture

Anandi Interiors Home furniture

30 NO YES


Contact Person:Sujay Wayse , [email protected]


Category : Industrial Product Fabrication

Company : SEAPL

Location : Bijaleenagar, Chinchwad

Case study 6

Satish


Company ProfileSuyash Engineering & Automation Pvt. Ltd.

manufactures Special purpose equipments .

SEAPL mainly manufactures control panels, hydraulic

power packs, bearing press machines.

Most of its work is done in metal fabrication.

SEAPL has in-house welding, turning , bending, shearingfacilities.

Suyash Engineering & Automation Pvt. Ltd.



ObservationsSEAPL has specialization in manufacturingHydraulic Power Pack.

Power packs are mostly manufactured as percustomers requirement.

As per the capacity required the reservoir capacity,motor, pump capacity varies and accordingly overalldimensions of the power pack changes

Maximum parts are manufactured by fabrication.

Power Packs external cover is made of basicfabrication which give boxy and non contemporarylook.

Within his existing facilities, using bending andPressing an aesthetical pleasing exterior cover designcan be highly possible.




Facilities -

Bending

Turning

Welding

Shearing




Design Interventions :Investing in Aesthetic design of the product can

make it competitive with the International Players in

the Market

New designed product can be produced in metal

fabrication using improved processes such as laser

cutting, bending and pressing.

Even some parts can be produced of FRP for greater

possibilities in aesthetic design.

Design exercise also can help him to know where to

target his product in the market.



Contact Person:Induce design Pune

Category : Industrial Product Fabrication

Company : SEAPL

Location : Bijaleenagar, Chinchwad

Case study 6


Hrishikesh


Scenario:

A small scale fabrication unit working for small

scale Clients.

Sheet Metal Fabrication Unit: NAS

Job:Sheet metal Enclosures, Electrical & Electronics

Panel boxes.

Problem Areas:

Defined by Proprietors & SupervisorsRaw material Procurement/ Availabity

irregularities

Lack of STD accessories availability and its

customization

Skilled workers availability and turnover rate

Input drawing/data inaccuracies

Design revisions



Raw material Segregation & Storage method Lack of

knowledge of STD accessories availability, newer

manufacturing techniques.

in the market to origin Designer/Draftsmen and

Manufactures

Workers Education and lack of use of STD procedures

Input drawing/data management and revision/change

request procedures

Making method inaccuracies & human error induced

rework

Lack of Inspection procedures

Lack of Capability/Capacity & Tool Database

communication to

Undefined working areas and WIP, Finish Goods,

Tools & even Scrap storage

Origin Designers

Scrap material Management & Creative use


Observations


Raw material delays / Availability

Lack of STD accessories / hardware

availability and its customization

Skilled workers availability and turnover rate

Input Drawing / Data inaccuracies

Irregularities

Design revisions

Raw material Segregation & Storage method

Lack of knowledge of STD accessories

availability & newer manufacturing techniques

in the market to Origin Designer/Draftsmen

and Manufactures


Procurement


Workers Education and lack of use of STD procedures

Input drawing/data management and revision/change

request procedures

Undefined working areas and WIP, Finish Goods,

Tools & even Scrap storage

Making method inaccuracies & human error induced

rework

Lack of Inspection procedures

Lack of Capability/Capacity & Tool Database

communication to Origin Designers


Facilities



Valuable contributors

Induce Design


NIC Code

(2-Digit)

Nature of activity

15 Manufacture of food products and beverages

16 Manufacture of tobacco products

17 Manufacture of textiles

18 Manufacture of wearing apparel; dressing and dyeing of fur

19 Tanning and dressing of leather; manufacture of luggage, handbags, saddlery, harness and

footwear

20 Manufacture of wood and of products of wood and cork, except Furniture; manufacture of articles

of straw and plating Materials

21 Manufacture of paper and paper products

22 Publishing, printing and reproduction of recorded media

23 Manufacture of coke, refined petroleum products and nuclear Fuel

24 Manufacture of chemicals and chemical products

25 Manufacture of rubber and plastic products

26 Manufacture of other non-metallic mineral products

27 Manufacture of basic metals

28 Manufacture of fabricated metal products, except machinery and

Equipments

29 Manufacture of machinery and equipment n.e.c.

30 Manufacture of office, accounting and computing machinery

31 Manufacture of electrical machinery and apparatus n.e.c.

32 Manufacture of radio, television and communication

Equipment and apparatus


Annexure 1


NIC Code

(2-Digit)

Nature of activity

32 Manufacture of radio, television and communication

Equipment and apparatus

33 Manufacture of medical, precision and optical instruments, Watches and clocks

34 Manufacture of motor vehicles, trailers and semi-trailers

35 Manufacture of other transport equipment

36 Manufacture of furniture; manufacturing n.e.c.

37 Recycling

40 Electricity, gas, steam and hot water supply

41 Collection, purification and distribution of water

50 Sale, maintenance and repair of motor vehicles and

Motorcycles; retail sale of automotive fuel

52 Retail trade, except of motor vehicles and motorcycles;

Repair of personal and household goods

60 Land transport; transport via pipelines

63 Supporting and auxiliary transport activities; activities of

Travel agencies

64 Post and telecommunications

71 Renting of machinery and equipment without operator and

Of personal and household goods

72 Computer and related activities

74 Other business activities

85 Health and social work

92 Recreational, cultural and sporting activities

93 Other service activities



References:

„Concept note on Study on the Role of Business Schools/ Management Institutions in shaping ESR in MSME

Sector in India‟- UNIDO (http://www.weplayfair.com/UserFiles/File/ESR%20Inducing%20Factors

/UNIDO_Concept%20Note_Business%20schools.pdf)

Report, „Micro and Small Enterprises in India, An overview 2007‟, by Ministry of MSME, Govt. of India

(source: http://dcmsme.gov.in/ssiindia/MSME_OVERVIEW.pdf.)

MSME Third Census (2001-02) (http://dcmsme.gov.in)

http://www.unido.org/fileadmin/import/75386_070913_Sess1202_SircarIndianMSMEs.pdf , Presentation by

Jawhar Sircar, Development Commissioner Ministry of Micro, Small & Medium Enterprises,Government of India

Biswas, Indranil and Chakrabarti, Milindo, “Can Indian Micro Small and Medium Enterprises (MSME) Sustain

Globalization with the Present Technology Mix? A Disaggregated Study According to Sources of Technological

Know-How”, http://ssrn.com/abstract=1284892, working paper series

„GENERAL REVIEW STUDY OF SMALL & MEDIUM ENTERPRISE (SME) CLUSTERS IN INDIA‟-A Report.

(www.ifmr.ac.in/sefc/UNIDO%20Review.pdf)



http://www.weplayfair.com/

http://www.weplayfair.com/

http://dcmsme.gov.in/ssiindia/MSME_OVERVIEW.pdf

http://dcmsme.gov.in/

http://www.unido.org/fileadmin/import/75386_070913_Sess1202_SircarIndianMSMEs.pdf

http://ssrn.com/abstract=1284892

http://www.ifmr.ac.in/sefc/UNIDO Review.pdf

Need Analysis Survey - Design Clinic Schemedesignclinicsmsme.org/Design Awareness Programme...

Documents

Transcript of Need Analysis Survey - Design Clinic Schemedesignclinicsmsme.org/Design Awareness Programme...