Need Assessment Survey for Cottage & Small Scale Industry …designclinicsmsme.org/Design Awareness...

Need Assessment Survey for

Cottage & Small Scale Industry Association

Design Clinic SchemeDesigner- Ashok Mondal

Content

Introduction------------------------------------------------------------- 1

About South 24 Parg-------------------------------------------------- 3

Cluster level report--------------------------------------------------- 6

Unit Level report------------------------------------------------------ 22

Conclusion------------------------------------------------------------- 69

I would like to thanks Cottage & Small Scale Industry Association (CSSIA) Chief Advisor/President/Secretary and entire team for organizing the 'Design Awareness Programme and showing me their work also letting me be part of their work life to accomplished the program.

I would also thanks “Design Clinic Scheme; National Institute of Design”, who has given me an opportunities to accumulate an intensive report.

My special thanks to each individual unit member of this cluster's who has given me their great support during the design audit without their kind involvement & assistance I would have not been able to understand cluster background & their present status. Thus I come up with such informative, structural and analytical and design intervention opportunities.

Acknowledgment

1

Introduction

Design Clinic Scheme for Design Expertise to MSMEs, a unique and ambitious design intervention scheme for the country's large micro, small and medium scale enterprises, is an initiative of Ministry of MSME, Government of India has been launched under National Manufacturing Competitiveness programme. The main objective of the Design Clinic Scheme is to bring MS&ME sector and design expertise into a common platform and to provide expert advice and solutions on real time design problems, resulting in continuous improvement and value addition for existing products.

This model brings design exposure to the door step of industry clusters for design awareness, improvement, evaluation, analysis and design related intervention. Design clinic scheme will assist industrial clusters to open a channel for design information inflow for creative, innovative and futuristic approach towards the product, process, operations, manufacturing and business design. The scheme will help generate insight for opportunity identification and design intervention for competitive and breakthrough solutions for MSMEs.

The objective of Design Clinic scheme is to enhance industry competitiveness and productivity with the help of design intervention at various functional levels . Design Clinic Scheme wil l help MSMEs to develop product/process/business expertise through design intervention at multiple level interactions. Design awareness seminar, design awareness programme and design projects will help MSMEs in various stages to develop competitiveness. The goal is to help MSME manufacturing industries move up the value chain by switching the production mode from original equipment manufacturing to original design manufacturing and hence original brand manufacturing.

The overarching approach in implementing the scheme will be to bring Indian MSME and design experts on a common platform. This will enable the MSMEs to access expert advice and cost-effective solution for their real-time design problems, with some financial support from the Government. The expected outcome of such interventions is new product development or discernible design improvement and value addition for exiting product.

For easy percolation of design thinking and philosophy and maximum benefit for MSME units the Design Clinic Scheme is divided at 3 broader levels. These activities are helpful in smooth transition in to several levels of design intervention in industrial and business activities of MSMEs.1. Design Awareness Seminar2. Design Awareness programme a. Need Assessment Survey b. Design Clinic Workshop3. Design Projects

Design Clinic Scheme for MSMEs

National Institute of Design

The National Institute of Design (NID) is internationally acclaimed as one of the foremost multi-disciplinary institutions in the field of design education and research. The BusinessWeek, USA has listed NID as one of the top 25 European & Asian programmes in the world. The institute functions as an autonomous body under the department of Industrial Policy & Promotion, Ministry of Commerce & Industry, Government of India. NID is recognised by the Dept. of Scientific & Industrial Research (DSIR) under Ministry of Science & Technology, Government of India, as a scientific and industrial design research organisation.

NID has been a pioneer in industrial design education after Bauhaus and Ulm in Germany and is known for its pursuit of design excellence to make Designed in India, Made for the World a reality. NID's graduates have made a mark in key sectors of commerce, industry and social development by taking role of catalysts and through thought leadership.

2

About South 24 Pargana.

Rajpur

South 24 Parganas

Historical BackgroundThe nomenclature 24-Parganas has been in vogue since 15 July 1757 when Mir Jafar whom the East India Company had just established as Nawab of Bengal ceded to the Company the rights of 24 mahals. The treaty by which the session is recorded says that, all the land lying to the south of Calcutta as far as Culpee, shall be under the Zemindari of the English Company and all the officers of this Zemindari shall be under their jurisdiction. The revenue to be paid by it (the company) in the same manner with other Zemindari. The Parwana notifying effect to the Treaty mentions the name of the 24 units of granted land.

The District of 24-Parganas started taking shape under Clause Nos.2, 3 and 9 of the Regulation of 1793. The respective jurisdictions of the civil and criminal courts for the district and revenue jurisdiction of the District Collector were demarcated by the Regulations. This arrangement remained valid till 1800

The present district of South 24 Parganas came into existence on 1st of March, 1986. It then comprised of two sub divisions- Alipore and Diamond Harbour and of 30 blocks. Presently there are five sub divisions (Alipore, Baruipur, Canning, Diamond Harbour and Kakdwip), 29 blocks and 7 Municipalities.

3

General Feature

South 24 Parganas is, indeed a complex district, stretching from the metropolitan Kolkata to the remote villages up to the mouth of Bay of Bengal, Apart from its staggering size and population, the district administration has to contend with problems typical of metropolitan living in the urban area such as high population density and overload civic infrastructure and in complete contrast, the rural area the lack of transport and communication facilities and weak delivery systems. 84% of the population lives in the rural areas, where development is taken care of by the panchayat bodies. The remaining 16% population is looked after by the Kolkata Municipal Corporation and seven municipalities.

The Sundarbans, the largest mangrove forests on earth, are spread over 13 of the29 development blocks in the district. Due to its peculiar geographical location and the dictates of geography, the means of transport and communication in this region are not well developed, with all the attendant consequences. Lack of irrigation has meant mono-cropped agriculture. Breaches in earthen embankments and cyclonic storms mean loss of life and destruction of crops and property on a regular basis. Any development strategy in this ecologically fragile environment must be carefully designed and implemented.

Demographics

Rajpur is located at It has an average elevation of 8 m (26 ft). According to the 2001 census,

Rajpur Sonarpur Municipality has area and 2population of 55.30 km , and 336,707 respectively.

Males constitute 52% of the population and females 48%. Rajpur Sonarpur has an average literacy rate of 78%, higher than the national average of 59.5%: male literacy is 83%, and female literacy is 73%. In Rajpur Sonarpur, 9% of the population is under 6 years of age.

Education

There are many primary, secondary and higher secondary schools in this area. Some popular of them are, Sonarpur Vidyapith, Rajpur Vidyanidhi High School (local name : Bangla School), Harinavi DVAS High School, Subhashini Balika Vidyalaya, Kamrabad High school for Boys and Girls, Padmamani Balika Vidyalaya, Atulkrishna High school, Sri Sri Sarada Vidyapith, Sonarpur Sishu Vidyapith, Shishu Niketan, etc. There is also one general college (Sonarpur Mahavidyalaya) under the University of Calcutta.

22.41°N 88.42°E .

4

Geographical Location Area Rainfall and Temperature

Latitude- North- 20’20”South- 22’06”East- 88’20”West- 88’60”

Area in Sq.km- Total- 8165.05

Annual Raifall in millimeters- 1750 mm to 1770 mmTemperature in Centreegrade degree- Maximum- 36.3 C

Minium- 13.6 CRelative Annual Humidity- 71% to 85%

General information about the District

Ÿ Total number of blocks- 29Ÿ Total no of Grampanchayat- 312Ÿ Total no of Municipalities- 7Ÿ No. of Island in the District- 37Ÿ No of Police Station- 33Ÿ Population growth rate- 20.89%

Land Utilization Statistics

Ÿ Cultivate Area- 4,06,215 HectareŸ Area under Forest- 1,70,580

5

Cluster Level Information

6

Cottage & Small Scale Industries Association

Cottage & Small Scale Industries Association, South 24 Pgs (CSSIA) was established in the year 1991 with an initial membership of 50 SSI units representing tiny & small-scale enterprises of the said district. Presently our membership strength is over 500. Our activities had been praiseworthy towards promotion of tiny & small-scale units of diversified interests i.e. Engineering, Ceramics, Food Processing, Surgical Instruments & others. CSSIA plays an important role as an associate for promotion & development of the small units in the district along with the survival of them through proper implementation & execution of the Govt. policy and procedures. We are also conducting up gradation & Skill Development Programmes for the existing units to combat with their foreign competitors in the era of globalization and liberisation of economy. Further we are rendering sincere support to overcome unemployment amongst the youths of the district by conducting Entrepreneurship Skill Development Programmes, held from time to time. We are happy that with a view to helping the members and their staff, a Mutual Co-operative Society has been set up and it has been smoothly functioning for 13 years.

We have also developed 'Self Help Group' comprising of female members of our locality. They have undergone training of Entrepreneurship Skill Development Programme under guidance of MSME-DI, Govt. of India.

Silpa Banijya Mela, South 24 Pgs., is one the major events organized by our association for continuously six years at a stretch. Silpa Banijya Mela is an example of our endeavor for the promotion of small and tiny entrepreneurs in our district. It is immense pleasure to inform you that they are involved in manufacturing of Sanitary Napkin and re progressing smoothly.

Cottage & Small Scale Industries Association, South 24 Pgs. organized “Swanirbhar Mela” for the first time in the year of 2010. The Mela was organized in association with National Small Industries Corporation Ltd. (NSIC) and supported by Federation of Associations of Small Industries of India (FASII). This Mela encourages the ladies mostly.

The product displayed in the mela was mainly handicraft items manufactured by the entrepreneurs of the district.The mela has created a stir among the small & tiny entrepreneurs. The association has given priority to the artisans of the handicraft products who are having EM-Part II registration of the District Industries Centre, South 24 Parganas.

We are sure that the Mela will generate sense of self dependence among the youths of the district, both male & female.

7

Cottage & Small Scale Industries Association

Silpa Banijya Mela, South 24 Pgs., is one the major events organized by our association for continuously six years at a stretch. Silpa Banijya Mela is an example of our endeavor for the promotion of small and tiny entrepreneurs in our district. It is immense pleasure to inform you that they are involved in manufacturing of Sanitary Napkin and re progressing smoothly.

Cottage & Small Scale Industries Association, South 24 Pgs. organized “Swanirbhar Mela” for the first time in the year of 2010. The Mela was organized in association with National Small Industries Corporation Ltd. (NSIC) and supported by Federation of Associations of Small Industries of India (FASII). This Mela encourages the ladies mostly.

The product displayed in the mela was mainly handicraft items manufactured by the entrepreneurs of the district.The mela has created a stir among the small & tiny entrepreneurs. The association has given priority to the artisans of the handicraft products who are having EM-Part II registration of the District Industries Centre, South 24 Parganas.

We are sure that the Mela will generate sense of self dependence among the youths of the district, both male & female.

8

Main Road towards city Main Road connect to the cluster

Road within the cluster

General Information (Unit Details)

S. N. Name of the Unit Contact Person Contact Details

1 Dieco Mr. Jagadish Das Bagani N. V. Lane, Malikpur, Rajpur+91 9831608306

2 Amar Ghosh & Co. Mr. Amar Ghosh N. S. Bose Road, Harinavi +91 98305 91787

3 D. K. Enterprise Mr. Dibyendu Ghosh Shyamkhola, Jagaddal +91 98366 78358

4 Das Engineering Works Mr. Swapan Das T. G. Road, Harinavi +91 90079 03899

5 Fine Engineering Works Mr. Polash Ghosh Kumorpara Road, Rajpur +91 98367 52123

6 Ghosh Engineering & Company Mr. Sanjib Ghosh Champhati Main Road + 91 98302 77589

7 Gloery Enterprise Mr. Soumen Das 8/1/A, Chowbaga Road, Kolkata- 39+91 98306 85203

9 Mridula Asbestos Product Mr. Nirapada Kayal Kedar Ashram, Kodalia +91 94330 92486

10 Lucky Engineering Works Mr. Sanjay Ghosh 2, Kumorpara Road, Gazipur +91 98366 08060

11 K. B. Engineering Concern Mr. Dabdas Mondal Kumorpara Road, Gazipur +91 033 27015387

9


S. N. Name of the Unit Contact Person Contact Details

12 Polmit & Co Mr. Dilip Kumar Pal T. G. Road, Harinavi+91 98304 34762

13 Micro Engineering Works Mr. Prosenjit Modak 18, R. N. B. Road, Kodalia+91 98307 14186

14 T. K. Engineering Works Mr. Tarun Kumar Neogi Gazipur, Rajpur +91 98366 08060

15 Start Trading Corporation Mr. Salil Ghosh 2, Kumorpara Road, Gazipur+91 98381 15810

16 Win Power Mr. Tapan Ghosh N. S. Bose Road, Narendrapur+91 99035 64510

17 Indowebal Surgical Pvt Lted Mr. Debasis Mondal Ukilpara, Baruipur+91 98313 90412

18 Swapna Enterprise Mr. Biswajit Ghosh N. S. Bose Road, Rajpur+91 98312 33220

19 G. M. Enterprise Mr. Golokendu Ghosh T. P. Lane Raipur+91 93397 88775

20 Maya Engineering Works Mr. Susil Kumar Sau Samali, Nahazari, Rajpur +91 92394 15157

21 Varsa Mechanical Power Mr. Sanat Ghosh J. S. Road, Baikanthapur +91 92393 50870

10


22 Primes Corporation Mr. Pradip Chowdhury T. G. Road, Harinavi+91 03324779859

23 Moonlight Engineering Co Mr. D. P. Neogi 2, Kumarpara Road, Rajpur+91 33247789101

11


S.N Nature of Work Product No. of Unit

1 Press and wielding Train compartment light fitting, Fan fitting, Side lamp fitting, Tail lamp fitting etc

01

2 Fabrication work P.C.C. control desk 02

3 Fabrication work Different type of asbestos based product like hand cover, fire proof dress etc

01

4 Lathe machine work Parts for ceiling Fan 02

5 Rubber belt joining Conveyer belt for Food processing unit

6 Surgical Ophthalmic knife 01

7 Lathe machine work Spear parts for manufacturing industry

10

8 Manufacturing Dispensing pump 01

12

Supply Chain Management

Most of the units in this cluster are Micro level and they are components manufacture. Only one unit (Moonlight Engineering Work) have their own product. In this report there are around 10 units those who were venders of Moonlight Engineering Works.

Nature of business is job work. They were getting orders (with all the technical drawing and specification) from the different company and on the basis of that, they have to supply the final product. Most of the time, raw material all so provide by the company for quality control. The Entire business run by this process.

There are units, those who are supply to the RAIl, Defence and other Govt agencies.

Company or Venders

Getting orders with all the technical drawing

and specification

Supply to the company or venders

Manufacturing by the unit

Present BusinessStrategy

Since they are suppling to the Govt Agencies, most of the time payment got delayed. Because of that, the micro level unit are not in position to manufacture the product in prior basis. Normally, payment cycle is after 60 days.

13

Opportunity (Employment Generation)

Most of the units are more then 30 year old. Previously generation wise they were getting labor.

Labor From- Surrounding area Payment Mode- Monthly basisWorking Time- 8:00 a.m. to 5:00 p.m.Education- Below 10th pass

Now a days labor crises is one the major issue and most of the unit are shortage of labor both skill and un-skill.

Ÿ Labor paymentŸ Hard Work Ÿ Government Scheme (100 days job

grantee) Ÿ Over all growth of this sector Ÿ Health and Family Security Ÿ Satisfaction Ÿ Union related issue Ÿ Training and Appreciation

Employment (Labor)

Semi Skilled Unskilled

Training and up gradation

I. T .I. college Diploma college

Course Design Theory- 30%Practical- 70%

Course duration- 1 year or 1.5 year

3 months training compulsory with MSME unit

Placement in MSME unit

Appreciation as per the work

Skilled

14

Raw Material

Steel (MS), sheet metal are the major raw material which being use by most of the unit. Raw material are available in Kolkata market and unit were purchasing locally.

Normal Store capacity- one monthTransport- Van or truckSupply- Through venders

Price of the material is totally depend on the Market and material price increasing day by day which directly effected to the unit in terms of cost of production. Micro and small level unit are not able to buy material for future because of the cost.

Intervention (Opportunity)

Ÿ Quality controlŸ Material CostŸ Transportation costŸ Time Ÿ Availability of the material

Raw material Bank

Purchase from the market

Quality testing

Unit can purchase from the association

Transport to the unit

Raw material bank can set up by the association

6 month material can be store at association

Purchase direct from the company with quality certificate. So that direct linkage can be made

Quality testing at laboratory (Institute level)

Unit can buy as per their requirement from the association

Ÿ Low cost from the existing market

Ÿ Quality assuranceŸ Time consumingŸ Less hazard

15

Manufacturing Process

Most of units (11units) of this clusters are flowed casting method.

Getting order from OEM

Product with technical specification

Foundry and Casting

Transport to unit

Send to casting unit

Drill and reaming

Machining process by Lathe machining

Turning

Tapping

Grinding

Polishing

Packaging

Lodging and Transporting

Raw Material

Pattern making

Molding process

Core making

Closing

Melting

Fettling (Short basting )

Boring

Facing

Shaping

Raw material acquired from local market, as per the market availability.Ÿ Time consumingŸ Quality control Ÿ Transportation costŸ Cost Ÿ Labor intensive

During sand castingIssueŸ Dimensional accuracy

Ÿ Material required more

Ÿ Surface finishing

Ÿ Blow holes

Ÿ High labor cost

Ÿ Low production cost

Recommendation during sand casting Ÿ Pour as quickly as possible

Ÿ Change gating system; e.g., use several smaller gates in place of one

large gate

Ÿ Apply thermal management techniques within the mold (e.g., chills

or exothermic material) to control solidification direction and rate

Ÿ Avoid sharp transitions between thin and thick sections

Ÿ Taper thin sections to facilitate establishment of appropriate

solidification gradients

Ÿ Strengthen the weak section with additional material, ribs, etc.

Ÿ Pour metal at lowest possible temperature

Ÿ Design gating system for rapid but uniform filling of the mold,

providing an escape path for any gas that is generated

A group of units (at least 4 units) can come together and go for Die

casting

Advantage

Less Timing

Reduce cost

Improve productivity

Nil blow holes

Smooth surfaceŸ Time takingŸ Human involvement Ÿ Transport through cycle ven

Lathe machine work the cutting tool selection is an important factor, tools experience high temperature, high stress, rubbing friction, sudden impact and vibration. Recommendation Carbon steels of 0.9 to 1.3% or Stellite tools

cotton or plastic begs are using for packaging.

Truck or small matador are using for transportation

Aluminum oxide or seeded gel aluminum oxide bass wheel abrasive can be use for better result

Labor intensivehigh Skill or semi skill

16

Material Handling System

In the present scenario of the cluster the material handling process is more sensitive to labor productivity than the manufacturing center as material handling is more labor intensive. The cluster required to develop a simple process, which will be control and better perform. Good material handling systems give you control on productivity. Distribution, manufacturing, and warehousing are the areas where material handling plays a major role. There is a scope for reducing labor and enhancing productivity by emerging design process in material handling. A good material handling system will enhance the speed and throughput of material movement through the supply chain.

Present Scenario Material order in local market

Unloading the incoming material from transport vehicle.

Moving the unloaded material to assigned storage place in warehouses.

Lifting the material from its storage place during order picking.

Moving the material for inspection and packing

Loading packages/bags/cartons on to transport vehicles.

Moving material to sand casting unit

Return material from sand casting to lathe machine unit

Recommendation : This system will contribute to industries, optimize life cycle of equipment, produce a system most suited to the environment. The flowing four points is essential for the manufacture unit.

Ÿ Life cycle optimizationŸ Environmentally conscious manufacturingŸ User-friendlinessŸ Contribution to industry productivity

Material and ling system

Casting Lathe machining Inspection

Material storage

Production line

Un finish product

Finish product

Packaging

Delivery

Environmental and Social condition

Information system

1. Container2. Room

Within the unit trolley can be use for transfer the material

Trolley for unit

Finish product store

Material store Trolley for unit

17

SWOT Analysis

Ÿ Capability to produce low volumes competitively and capture niche markets

Ÿ Mostly micro level unit Ÿ Availability of low cost human resource Ÿ OEMs quality standards are mostly achievable Ÿ Products demand in the market Ÿ Good entrepreneurial skills Ÿ Good mechanical (ledge machine) skills Ÿ Raw material available locally Ÿ Oldest component manufacture cluster Ÿ Good connectivity with the state capital

Strength

Ÿ No long term vision or policy Ÿ Lack of Information Dissemination (Technical knowhow,

Information on standards, Processing techniques, Ÿ Design criteria's) Ÿ Product design & engineering capabilities constrained due to

absence of economies of scale Ÿ Lack of Tooling and die manufacturing facilities Ÿ Lack of skilled manpower for near future Ÿ Lack of well equipped facilities for product testing and Ÿ research & development Ÿ High cost of financing and leasing Ÿ Lower margin and higher competitionŸ Lack of coordination with the unit owner Ÿ Government support and promotion for the cluster Ÿ Lack of knowledge for product export

Weakness

Ÿ Potential for high market growth Ÿ Export potential in niche markets Ÿ Domestic replacement parts market Ÿ Global spare parts market of discontinued vehicles Ÿ To improve production process for cost effective productŸ Only component manufacture cluster in the State

Opportunity

Ÿ Poor brand identity Ÿ Regional conflicts Ÿ Labor cost day by day increase Ÿ Raw material cost increaseŸ Only component manufacturing

Threats

18

Issue

Ÿ Raw material bank (quality control)

Ÿ Local laborŸ Lack of unit owner interaction Ÿ Pollution Ÿ Cluster and residential

complex are same placeŸ Marketing trough dealer and

sub dealer Ÿ Information Dissemination

(Technical knowhow, Information on standards, Processing techniques, Design criteria's)

Ÿ Exposure visit

Ÿ Participation on national level fair

Ÿ Interaction in between cluster

Ÿ Different types of awareness program

Ÿ New product development

Ÿ Owner visionary Ÿ Management efficiency Ÿ Raw material quality controlŸ Skill laborŸ Material handling processŸ Casting unit (distance around 40

km from the cluster)Ÿ Space inside the workstation Ÿ Ergonomic Ÿ Man machine interface Ÿ Visual identity (catalogue,

visiting card, website)Ÿ Cost competitive marketŸ Labor training and appreciationŸ Work environmentŸ Production capacityŸ Next generation not interested Ÿ Individual marketing Ÿ Single man unit

Unit Level Cluster Level

Ÿ Morden technology, design innovation R and D/ international market

Ÿ (Bangladesh, Nepal, Srilanka etc)

Ÿ Chines productŸ Open marketŸ Climate change

Ÿ Less aware of different types of scheme

Ÿ Less communication with the different type of Govt. organization

Ÿ State level buyer seller meet

Ÿ Exposure visit to other industrial cluster

Ÿ Different type of SME bank loan procedure

Ÿ State level industry policy

National Level Global

19

Visual Communication

Visual communication for MSME unit's play important role in the present market scenario. At present, very few units have their visiting card; most of the units don't have product catalogue or website. At the basic level units have to create visual identity to establish their brand in the present cut-throat competition. To create a brand identity for their business enterprise the foremost thing is to promote products and services.

Recommendation Initially, at a cluster level, promotional clothing (caps, t-shirt) can be the solution. They can have the name of their company including the website, contact details, message, slogan and logo imprinted on the promotional clothes. It can be distributed to existing and potential customers, clients and other business associates at trade shows, fairs and other such corporate events at yearly basis. Another benefit that, promotional clothing has is that the more long lasting impression it will have. This will evade the need for constant marketing

Internal CommunicationŸ Manufacturing process chartŸ Signage inside the unit like material store, tools and equipment,

pathways, un finish product final product etcŸ Safety interactionŸ Moral thoughts

Outside Communication Ÿ Product imageŸ Logo, website, product catalogue, visiting card etc.Ÿ Packaging materialŸ Company poster in local area

References

20

Recommendation

Since this is the only cluster for component, spear parts manufacturing in West Bengal. There is good market which already exists. The Cluster must have clear vision and target and for that they need to have proper strategy.

Target

Ÿ Development of long term vision, mission, regulatory policy and set clear direction for development of this cluster in the next 5 years

Ÿ Information dissemination in the clusterŸ Good coordination within the unit member Ÿ Cluster must have library (product catalogue, brochure, journal

etc)Ÿ Awareness program for quality control, product innovation

(Design), marketing, Export etcŸ Raw material Bank at cluster Ÿ Casting unit within the cluster area to ensure product quality

as well as save time and costŸ Creating awareness regarding importance of forming

networks/consortiumsŸ Formation of business networks (2 networks in year 1)Ÿ Capacity building of entrepreneurs and trade associationsŸ Skilled labor development progarm through training at I.T.I or

Diploma collage Ÿ Labor- security, appreciation, motivation Ÿ Regional, National and global market expansionŸ Product standardization, quality improvement, R and D facility

Ÿ Good coordination within the unit member Ÿ Raw material BankŸ Cluster map prepare Ÿ Skill labor development programŸ Casting unit within the cluster Ÿ Visual identity at cluster level as well as unit level Ÿ Encourage entrepreneurs for formation of networksŸ Trust building exercises and different type of awareness

seminar or workshop like Design Clinic SchemeŸ Linkages with different type of national and international

Business Support OrganizationŸ A master plan to set clear vision, mission, regulatory

policy and line of direction for development of this cluster in next five years would be prepared. On the basis of master plan long term activities would be highlighted.

Short term Strategy

Long term Strategy

Ÿ The testing labs, product innovation lab and research and development facilities would be upgraded in collaboration with different type of Design, Engineering and technical institutions

Ÿ Organize Buyer seller meet on yearly basis Ÿ Exposure visit to different industrial cluster in the country Ÿ Exposure visit to different country Ÿ Regional, National and global market expansionŸ Encourage the entrepreneurs to be a member of global

supply chain

21

Design Audit Unit wise

22

Name of the Unit- Star Trading Corporation Unit owner- Salil Ghosh No of workers- 4 persons Working Time- 8:30 a.m. to 5:30 p.m.Nature of Works- ManufacturingProduct Category- Downrod for Ceiling FanMarketing- Local Fan industry with in the Kolkata

Contact Details: Salil Ghosh Address- 2. Kumorpara Road Gazipur, Rajpur

Name of the Unit- G. M. Enterprise Unit owner- Golokendu Ghosh No of workers- 12 persons Working Time- 8:30 a.m. to 5:30 p.m.Nature of Works- ManufacturingProduct Category- Shaft for Ceiling FanMarketing- USHA, Khaitan, orient and local Fan industry

with in the Kolkata

Contact Details: Golokendu Ghosh Address- T.P Lane RajpurMobile no- 09339788775

23

Raw Material Management

Sources of Raw material- Kolkata market Delivery- After order placing 15 to 30 days Material- MS pipe (TATA, Bharati) Storage- For 30 days Requirement- 7 to 10 ton per month

Getting order form with product specification Order for material Supply to unit Storage Transfer for production

Normal timing 15 to 30 days

Transport medium matador van

Material quality testing have to be introduce

Process

Both is unit per month material requirement is 20 ton (10 ton each unit). Recommendation- This two unit can come together and purchase material for at least six month Material Testing- Unit can directly contact with Material Research Institute (Jadavpur University area)

Advantage Ÿ One time transportation cost (for

both the unit)Ÿ Bulk amount purchase (company

provide quality control certificate Ÿ Material cost will be reduce Ÿ Fulfil the time commitmentŸ Rapid production process Ÿ Less labor involvementŸ Cost competitive

Material kept within the production area Star Trading Corporation G. M. Enterprise

24

Manufacturing process

Raw material

Cutting

Drilling

Centering

Scalding

Finishing

Zig drilling

Painting

Plastic packaging

Beg packaging (250 pieces)

Zinc plating

Tolerance testing

Grinding finish

Plastic packaging

Beg packaging (100 pieces)

Grinding

Polishing

For ShaftDownlod

Rust problemDue to moisture Zinc required 8 micron after that kept in distill water

Ÿ During drilling due to proper grip, accuracy is not maintain

Ÿ Grinding (Shaft)Ÿ Drilling (downlod)Ÿ Finishing

1 2 3

4

Delivery

25

5

6

Work station, Ergonomic, Space management

Ÿ Height and operating lever of the lathe machine (Machine interface)

Ÿ During drill, need have a proper grip for accuracy, hand gloves can be use

Ÿ Water leakage may cause accident during working

Ÿ Trolley can be use for keeping finish and un finish product.

1 2 3

4

5

67

8

Ÿ Raw material have to be kept in separate room, So that maximum space inside the workstation can be use.

Ÿ Generator room should be out side of the work station

Ÿ Need to have proper electric wiring to reduce electric consummation.

26

Product , Packaging, Marketing

Product:The existing product (shaft and downlod for cilling fan)

Analysis1. Final product rust problem (shaft)2. Final product surface finishing (downlod)3. Reference product in terms of quality and finishing

Logistic and Packaging:The existing product packaging, they are using plasmic cover, after that loaded in plastic begs (Quantity- 100 and 250 pic)

Transportation: Cycle van and Riskha

Marketing: At present, product supply to USHA, Khaitan,

Orient and other fan manufacture company in Kolkata. The normal billing cycle for USHA or Khaitan is after delivery 6 to 9 months. Because of the payment security, they are not interested for marketing out side of the state

Shaft for cilling fan

Downlod for cilling fan

Reference product

1

2

3

Visiting Card

27

Recommendation

Point to be Address

Ÿ Material Handling System

Ÿ Innovation in process (productivity)

Ÿ Electric wiring

Ÿ Light and Ambience

Ÿ Ergonomic (Man and machine interface)

Ÿ Tools and Equipments

Ÿ Health and Safety

Ÿ Packaging

Ÿ Visual Identity (visiting card, catalogue, website etc) Ÿ Display and Branding Ÿ Marketing and Competition

Ÿ Future Strategy

Material Handling System-

Innovation in process-

presently, raw material are purchasing from Kolkata market, normal delivery time is required 15 to 30 days. Now, both this two units, (Star Trading and G.M. Enterprise) can come together and purchase material directly from the company (at least for 3 months material. In this process they get quality ensure certificate from the company. After that, required a separate room for raw material storage, which can be easily accessible to the worker.

installation of lathe machine should be easy to operate, machine area should be clean properly after complete work, so that people can easily move, no water leakage, wall mounted rack can be instal and small trolley can be use inside the workstation for finish or un finish products.

- need a proper routing for electric wiring, so that electric consumption can be decrease

Spot light is required for working in a machine, which will help to do high precision work, also required

human productivity is one important aspect to increase the production

Star trading and G. M.

Electric Wiring

Light and Ambience-

Ergonomic-

Tools and Equipments-

Health and Safety-

Visual Identity-

adequate number of window, so that natural light can be utilize

, few small things like hand glups for drilling and other work is required, which will help to increase the productivity. Also lever of the lathe machine have to be visually mark

wall mounted rack or shelve can be install for keeping tools and other equipments. A small tool kit is necessary

maximum natural light can be utilize, height need to be increase,.

a company must have to be design visiting card, logo, product catalogue, website, which will help to create company brand in the market

showcase have to design, where all the finish product has to be display for client

online marketing have to workout, also explore the possibility for marketing outside of the state

Enterprise can come together and form a company, both this unit are similar nature (nature of product, product).

Display-

Marketing and competition-

Future Strategy-

28

Name of the Unit- Varva Mechanical & Power ControlUnit owner- Sanat GhoshNo of workers- 9 persons Working Time- 9:00 a.m. to 5:00 p.m.Nature of Works- Fabrication Product Category-

Marketing- NTPC, BHEL, Astrom etc.

P.C.C control desk and Automobile control panel

Contact Details: Sanat Ghosh Address- J. S Road, Baikanthapur, Mobile no- 09239350870

Name of the Unit- Win PowerUnit owner- Tapan Ghosh No of workers- 10 persons Working Time- 9:00 a.m. to 6:00 p.m.Nature of Works- Fabrication Product Category- P.C.C control desk automobile control panel Marketing- Different Electric department

Contact Details: Tapan Ghosh Address- N.S.C. Bose Road, NarendarpurMobile no- 09903564510

29


Sources of Raw material- Kolkata market Delivery- After order placing 30 days Material- Sheet Metal, thickness- 2 to 4 mm (TATA) Storage- 1 monthRequirement- 8 to 9 ton per month

Getting order with product specification Order for material Supply to unit Storage Production

Normal timing 30 days

Transport medium matador van


Process

Both is unit per month material requirement is 16 to 18 ton (8 to 9 ton each unit). Recommendation- This two unit can come together and purchase material for at least six month Material Testing- Unit can directly contact with Material Research Institute (Jadavpur University area)

Advantage Ÿ One time transportation cost (for

both the unit)Ÿ Bulk amount purchase (company


Material kept within the production area Win Power Varsa Mechanical

Product transfer to painting unit

Labor intensive, at least 5 to 6 people required for load

30


Sheet metal

Hand cutting as per drawing

Small cutting

Banding

Wielding

Assembling

Colour coating (powder coat)

Inspection

Loading in Matador for painting unit

Unloading

Acid dipping

Transport Zinc coating

Manual process

Finishing and grinding Drilling

Using hand cutter (time taking process)

Loading in Matador

By using Ball press(labor intensive)

By using small hand grander

Required at least 5 to 6 persons for loading and unloading )labor intensive)

1

23

4

5

31


6 7 8 9

Ÿ Metal sheet handling (required hand gloves for proper holding)

Ÿ For small banding (working table will be useful)

Ÿ Wielding Ÿ Drilling (accuracy)Ÿ Wielding markŸ After grinding, finishing is not done properly

10

Ÿ Required a cran for loadingŸ Drawing and cutting is not done properly

Few reference photograph given below, which required for product shifting and loading. The present process is very much labor intensive and anytime accident may happen.

Reference Photo

This can be use for shifting product within the unit

Cran for loading and unloading

32


Ÿ Both space have to organize properly, separate lane, which can be attached with the wall, for keeping sheet metal. Wall mounted rack will be help for keeping tool and other equipments. Some spot light need to install.

Ÿ Body posture during grinding, small height adjustable table which will help to do the grinding comfortable

Ÿ Electric wiring have to be done properly, so that electric consummation can be reduce

1 2 34

5 6 7 8

Ÿ Small working table required for drawing and cutting purpose

Ÿ Height of the table and hand gulps to hold properly.Ÿ Trolley for shifting product from one place to another

place.

33


Product:The existing product (

)

After assembling, the product need to send for painting, during shifting, it will be loaded in a matador.

Transportation: Matador

Marketing: At present, product supply to NTPC, BHEL through

OEMs and few dealer fan in Kolkata. The normal billing cycle for USHA or Khaitan is after delivery 6 months. Because of the payment security, they are not interested for marketing out side of the state

P.C.C control desk and Automobile control panel

Existing product

Visiting Card

After final instillation

34

Recommendation

Point to be Address

Ÿ Raw material handing process

Ÿ Innovation in process (productivity)

Ÿ Electric wiring

Ÿ Light and Ambience

Ÿ Ergonomic (Man and machine interface)

Ÿ Tools and Equipments

Ÿ Health and Safety

Ÿ Visual Identity (visiting card, catalogue, website etc) Ÿ Marketing and Competition

Ÿ Future Strategy

35

Name of the Unit- Mridula AsbestosUnit owner- Nirapada KayalNo of workers- 20 persons Working Time- 8:00 a.m. to 8:00 p.m.Nature of Works- Fabrication Product Category- Asbestos textile bass productsMarketing- Steel plant, Thermal plant, Coal mines

etc.

Contact Details: Nirapada Kayal Address- Kedar Ashram, KodaliaMobile no- 09433092486

36


Sources of Raw material- Ahmedabad and DelhiDelivery- After order placing 30 to 45 days Material- Asbestos thread and yarn Storage- 2 monthRequirement- 6 to 7 ton per month

Getting order with drawing and specification

Order for material over phone

Supply to unit Storage Production


Transport medium matador van from kolkata


Present Process

Unit per month material requirement is 6 to 7 ton Recommendation- Unit can purchase material for at least six month Material Testing- Unit can directly contact with Material Research Institute for testing

Advantage Ÿ One time transportation cost Ÿ Bulk amount purchase (company


Material kept within the production area Material store room

37


Fiber

Blending

Mixing (poly cotton or other fiber)

Roving

Carding

Spinning

Single yarn

Twisting

Braiding

Twisted rope

Braiding rope

Weaving

Light gauge wire

Twisting

Plied yarns Metallic yarns

Braiding

Coating

Twisting

Thread

Treated yarn

Rope Cloth Braiding cloth

Braiding rope Tai loring unit

Drying

Cutting

Stretching

Packing

Delivery

38


Ÿ Manually operated processŸ After drying, cloth have to be rolled Ÿ Cutting have to improve, in terms of

less wasting Ÿ Stretching need to be straight Ÿ Final product store Ÿ Packaging material

1 2 3 4

5 6

7

8

39


Ÿ Space have to organize properly as per the production requirement, light is very limited in a day time for that natural light can be use maximum to reduce.

Ÿ Seating posture during working, small height adjustable table which will help to do the work comfortable

Ÿ Electric wiring have to be done properlyŸ Sound pollution have to be workoutŸ Small wood roller will help for cloth raping

1 2 3

4 5 6 7

8

9

Ÿ Small working table required for drawing and cutting cloth

Ÿ Trolley for shifting product from one place to another place.

Ÿ Wall rack can be install for tools and equipmentsŸ Separate rack is necessary for keeping final productŸ Hygiene can to be consider during working

40


Product: Asbestos textile cloth product, product manufacture as

per the specification Analysis- Final product finishing and fitting (ergonomically) in compare to other product available in the market.

Packaging: At present, initial packaging done with polythene

and then bag packaging. Packaging have to design compare to the other company, also it will help to create company brand in the market.

Transportation: Matador and Van

Marketing: At present, unit have their own marketing team,

also they have showroom in Kolkata and dealer to few states in the country.

Existing product

Visiting Card

Avalibale in the Market

Company sine board at entrance Initial packaging Bag packaging

41

Recommendation

Recommendation

Ÿ Raw material- required a separate store or wall mounted rack

Ÿ Innovation in process (productivity)- certain machine need to upgrade to reduce the sound pollution as well as increase production

Ÿ Electric wiring- proper wiring with in workstation area

Ÿ Light and Ambience- Use natural light resources in a day time

Ÿ Ergonomic- Seating posture during working, height adjustable table and working table for cutting cloth

Ÿ Tools and Equipments- small tool box

Ÿ Health and Safety- since most of the employ were women, health and safety have to consider

Ÿ Visual Identity- visiting card, catalogue, website etc have to be design

Ÿ Marketing and Competition- since the unit have their

own marketing team, now they have to try to create their own brand in the market.

42

Name of the Unit- Amar Ghosh & Co.Unit owner- Amar GhoshNo of workers- 8 persons Working Time- 9:00 a.m. to 5:00 p.m.Nature of Works- Manufacturing Product Category-Marketing- Rail coach factory

Rail compartment light fitting, guard light

Contact Details: Amar GhoshAddress- N.S. Bose Road, HarinaviMobile no- 09830591787

43


Sources of Raw material- KolkataDelivery- After order placing 30 to 45 days Material- Sheet metal (1.2 to 2.5 mm) Storage- 2 monthRequirement- 4 to 5 ton per month

Getting order from RDSO drawing and specification





Material quality testing within the unit

Present Process

Unit per month material requirement is 4 to 5 ton Recommendation- Unit can purchase material for at least six month Material Testing- Unit can directly contact with Material Research Institute for testing



Raw material, Sheet metal Material store room

44


Manual Process

Sheet metal

Internal material testing

Cutting as per drawing

Bending

Wielding

Dry powder coating

Internal fitting

Internal inspection or quality control

Packaging (corrugated box)

Quality checking by Rail

Transportation

To

tal

pro

du

ctio

n p

roce

ss t

ime-

30

day

s

1 2 3 4

56

78

Ÿ Manually operated process Ÿ Hydraulic press machine being useŸ Press mold need to be redesign, Ÿ After pressing required time to

release the moldŸ product finishing after pressingŸ Simple mold and die can be design,

which will help to reduce time as well as product fining

Ÿ For product finishing small tool kit is required

45


Ÿ Space have to organize properly, the height of the wall, raw material can be store in one side, light is very limited in a day time for that natural light can be use maximum to reduce.

Ÿ Seating posture (ergonomic) during working with hydraulic press required a leg space , which will help to do the work comfortable

Ÿ Trolley can be use for keeping product from one place to another

Ÿ Small working table required for drawing and cutting and fitting

Ÿ Wall rack can be install for tools and equipmentsŸ Separate rack is necessary for keeping final productŸ Display rack for finished product Ÿ Spot light can be use for working with drilling machine

8

1 2 3 4

567

46


Product: Tail lamp fitting, Fluorescent light fitting, Fan

guard Analysis- Ÿ The products are heavy, Ÿ Finishing of the final productŸ Material required moreŸ Lengthy process for manufacture Recommendation- There is huge possibility for product design, which will be less material required, less process involvement and improve the product finishing

Packaging: At present, they are using corrugate box for

packaging. They collect empty box from the market, after that, they do the finished product packaging. But company name were not mention

Transportation: By Truck to Howrah or Sealdha Rail

Station and from their by rail.

Marketing: At present, unit have supply their product to

Rail R.D. S. O, (Railway Design Serves Organization) Chennai

Issue Ÿ Delivery time 3 months, after that unit have to pay

penalty charge.Ÿ Payment schedule normally 30 to 45 days Ÿ Because of the payment cycle, unit facing financial

problem

Rail (RDSO)

Delivery time 3 months

Fan guard

Marketing System

Tender submit

Work order

Raw material availability in store

Material purchase

Material testing

Production

Quality testing by RAIL

Delivery

Fluorescent light fitting

Tail lamp fitting

47

Recommendation

Recommendation

Ÿ Raw material- required a separate store

Ÿ Innovation in process (productivity)- the present mod or die have to redesign, considering the product finishing and releasing process

Ÿ Electric wiring- proper wiring with in workstation area


Ÿ Ergonomic- Seating posture specially when working with press machine required a lag space for working comfortable, working table is essential for sheet drawing, cutting and fitting


Ÿ Health and Safety- since most of the employ were long time with this unit, health and safety have to consider, so that new generation also take interest.

Ÿ Visual Identity- visiting card, catalogue, website etc have to be design, which will create company brand

Ÿ Design Project- There is huge potential for redesign

their existing product within Design Clinic Scheme. The new design product unit can send to RDSO as well DC MSME to get it approve from RAIL.

48

Name of the Unit- Polmit and Co.Unit owner- Dilip Kumar PalNo of workers- 8 persons Working Time- 9:00 a.m. to 5:00 p.m.Nature of Works- Conveyer belt joining Product Category-

Marketing- Through dealer and IFB international

Conveyer belt for cement industry and food industry

Contact Details: Dilip Kumar palAddress- T. G Road, HarinaviMobile no- 09830434762

49


Sources of Raw material- Rubber from Kolkata and PVC from Korea Delivery- After order placing 30 to 45 days Material- PVC Storage- 2 month

Getting order with specification






Present Process

Recommendation- Unit can purchase material for at least six month Material Testing- Unit can directly contact with Material Research Institute for testing



PVC material for food processing unit Material kept outside of the unit

50


1 2 3 4

5

6 7 8

Ÿ Manually operating processŸ Cutting tools have to be design Ÿ Mold for joining to belt length need to be

increase Ÿ Mold- inside the curve have to be workout,

so that mold get release easily Ÿ The length of the curve mold can be redesign

for better productivity Ÿ Operating leaver have to redesign, which

will help to operate the machine comfortable with minium pressure.

9Ÿ When joining wall belt with conveyer belt, after heating, (90 mints required to fix) facing difficult to release

51


Ÿ Raw material can be store in separate place, so that maximum space can be utilize, since this conveyer belt length wise it is big, longer space very much required.

Ÿ The tools have to design like cutting tools, knife etcŸ Ambience, specially light have to arrange properly.Ÿ Waste material specially from PVC material can collect and

new product can be develop Ÿ Small working table required for drawing and cutting and

fittingŸ Wall rack can be install for other equipmentsŸ Spot light can be use for working with drilling machineŸ Hygiene have to be consider

8

1 2 3 4

5 6 7

9

52


Product: Conveyer belt for cement industry and food

processing(Tea unit) industry

Packaging: no packaging material has been use. normally

in roll form they are sending

Transportation: By Truck or Van

Marketing: the marketing have done through dealer and

IFB international. It is only conveyer belt unit in West Bengal. But the next generation are not taking interest for take it further.

Office within the unit Belt for food processing unit

Belt for cement and other industry

Front side of the unit

53

Recommendation

Recommendation

Ÿ Raw material- required a separate store

Ÿ Innovation in process (productivity)- the present mod or die have to redesign, considering the easy releasing process


Ÿ Ergonomic- working table is essential for belt drawing and cutting


Ÿ Health and Safety- since most of the employ were long time with this unit, health and safety have to consider, so that new generation also take interest.

Ÿ Visual Identity- visiting card, catalogue, website etc have to be design, which will create company brand. Even the product, which they were sending to the dealer, unit name is not mention.

Ÿ Waste material- lot of waste material after cutting PVC or rubber belt, new product can be design from waste material

Ÿ Design Project- There is potential for redesign their

existing their tools, which will help to increase their competitiveness within Design Clinic Scheme

54

Name of the Unit- Moonlight Engineering CoUnit owner- Soumen NeogiNo of workers- 45 persons Working Time- 7:00 a.m. to 5:00 p.m.Nature of Works- Manufacturing Product Category-Marketing- Franchise and dealer

Dispensing pumps and Spear parts

Contact Details: Soumen NeogiAddress- 2, Kumarpara Road, RajpurMobile no- 09830925468

55


Sources of Raw material- KolkataDelivery- After order placing 30 days Material- Alumina, brass etc Storage- 2 month

Getting order Order for material over phone

Casting Supply to unit Machining work

Normal timing 30 days



Present Process

Recommendation- Unit can purchase material for at least six month Material Testing- Unit can directly contact with Material Research Institute for testing



56


Getting order

Manual Process

Raw material

Casting unit

Supply to unit

Machining process by ledge machine

Assembling

Quality Testing

Packaging

Transportation

Casting unit is quite far around 30 to 40 K.M from the main unit. Thus facing problem for quality control

1 2

3

4

5 6 7

Moonlight engineering have very good set up compare to other unit. The workers are good at skill level. the manufacturing process are quite systematic. They have their own assembling section, quality testing, finish product store, packaging etc. During production, they keep monitoring all the small part which effect the process.

57


Fire Extinguisher Parts assembling section Electric Section

Parts assembling section

Testing section

Tools chart with name

Keys Finish product store section Neo Matric testing

58


Ÿ White working in assembling section, height of the table can be increase and leg space is required.

Ÿ The stand for product, also add wheel so that it will easy to transfer

Ÿ Height of the chair while working on drilling machine need to adjust

Ÿ Small box have to be design, which can be fit into rack for keeping parts

Ÿ Small tool box for individual workerŸ Signage for workplace areŸ Trolley for keeping product for transfer

different section

1 2 3 4 5

6 7

8

59


Moonlight is quite establish company in this sector. Their manufacturing process is systematic, they have R&D department. They also got quite few award from the Central Govt.

Product: Nozzle and spear parts

AnalysisŸ Product finishing Ÿ Weight 1.1 to 1.3 kg depend on length

Packaging: corrugated box for packaging

Transportation: By Truck or Van

Marketing: Moonlight engineering is quite stable company.

They have their frenches and dealer through out country. There are suppling Indian Oil, MIDCO, Avery India ltd, Bharat tube corporation, Rose enterprise, Bhrat petroleum, Gulf oil corporation, SAIL etc. The company have their own website for (http://moonlighteng.co.in) online marketing.

Visiting Card

Product packaging

Final product (Nozzle)

Front side of the unit Transportation

60

Recommendation

Recommendation

Ÿ Innovation in process (productivity)- they have to shift from sand casting to die casting for better quality as well product finishing

Ÿ Ergonomic- Seating posture have to workout specially in assembling section


Ÿ Health and Safety- since most of the employ were long time with this unit, Labor welfare have to be consider, so that new generation also take interest.

Ÿ Visual Identity- Company have visiting card websit etc. but the design is not good. For creating more impact in the market, they have to design their product catalogue, visiting card website, design wise the must have relation

Ÿ R&D- Since they have R&D department, they have to strengthen in term of product design or new product development

Ÿ Design Project- There is potential for design project for

existing product ,within Design Clinic Scheme

Ÿ Workstation- signage within the workplace area for better productive, trolley can be use for transfer product from one place to another place.

Trolley Trolley Signage

Tool box

Moonlight

Customer

Service

Delivery

Marketing Sales

Manufacturing

Quality management system

R & D

Long term research and development

Collaboration technology and Design

Co-work with technology and design department

Mass production capability

Adopt new technology Continue improved

quality control and instant feedback system

Material handling system

Competitive price and stable quality

User research

Present market trend

Satisfied lead-time for product delivery

Technical and compliance test support

Instant respond to the client

61

Name of the Unit- D. K. Enterprise Unit owner- Dibyendu GhoshNo of workers- 12 persons Working Time- 9:00 a.m. to 6:00 p.m.Nature of Works- Lathe machining Product Category- Electric pipe line joinery Marketing- IFB International, Tattor

Internation Address- Shyamkhola, JagadalMobile- 09836678352

Name of the Unit- Glory Enterprise Unit owner- Soumen DasNo of workers- 3 persons Working Time- 9:00 a.m. to 5:30 p.m.Nature of Works- Lathe machining Product Category- Spear parts Marketing- Suppler to Moonlight Address- 8/1/A, Chowbaga Road, Kol-39Mobile- 09830685203

Name of the Unit- DiecoUnit owner- Jagadish Das BaganiNo of workers- 7 persons Working Time- 9:00 a.m. to 5:00 p.m.Nature of Works- Dies and Tool dies Product Category- Fan impala Marketing- Suppler to Fan industry KolakataAddress- N.V Lane, Malikpur, RajpurMobile- 09831608306

Name of the Unit- Maya Engineering Unit owner- Susil Kumar SauNo of workers- 12 persons Working Time- 8:00 a.m. to 8:00 p.m.Nature of Works- Lathe machining and CNC workProduct Category- Spear parts Marketing- Rail, Defense and Automobile

industry Address- Samali, Nahazari, Rajpur Mobile- 09239415157

62

Name of the Unit- K. B. Engineering Unit owner- Debdas MondalNo of workers- 5 persons Working Time- 8:00 a.m. to 5:00 p.m.Nature of Works- Lathe machining Product Category- Nozzle, angular chech valve Marketing- Suppler to MoonlightAddress- Kumarpara Road, GazipurMobile- 033-27015387

Name of the Unit- Fine Engineering Unit owner- Polash GhoshNo of workers- 4 persons Working Time- 7:00 a.m. to 4:00 p.m.Nature of Works- Lathe machining Product Category-Marketing- Suppler to Moonlight Address- Kumorpara Road, RajpurMobile no- 09836752123

Deep cape

Name of the Unit- T. K Engineering WorksUnit owner- Trun Kumar NeogiNo of workers- 3 persons Working Time- 9:00 a.m. to 6:00 p.m.Nature of Works- Lathe Machining Product Category-Marketing- Suppler to Moonlight Address- Gazipur, RajpurMobile- 09836608060

Spear parts

Name of the Unit- Lucky Engineering Unit owner- Sanjoy GhoshNo of workers- 4 persons Working Time- 7:00 a.m. to 4:00 p.m.Nature of Works- Lathe machining Product Category- Magazine cape and spear parts Marketing- Suppler to Venders Address- 2, Kumarpara Road, GazipurMobile- 033-27015378

Name of the Unit- Swapana Enterprise Unit owner- Biswajit GhoshNo of workers- 22 persons Working Time- 8:00 a.m. to 5:00 p.m.Nature of Works- Lathe machining Product Category-Marketing- IFB International, Pattor

International, ESAB India Ltd Address- N. S Boss Road, RajpurMobile no- 09831233220

Spear Parts

Name of the Unit- Micro Engineering Unit owner- Prosenjit ModakNo of workers- 22 persons Working Time- 8:00 a.m. to 5:00 p.m.Nature of Works- Lathe Machining Product Category-Marketing- Suppler to Venders Address- 18, R.N.B Road, GazipurMobile- 09830714186

Spear parts

63


All this unit are component manufacture, their process are same and supplying to the OEM. Sources of Raw material- KolkataDelivery- After order placing 30 days Material- Alumina, brass etc Storage- 1 or 2 month

Getting order Order for material over phone

Casting Supply to unit Machining work



Present Process

Recommendation- All this Unit can come together and forum a raw material bank, and purchase material directly from the company Material Testing- They can tie-up with any Research institute in Kolkata for material quality testing time to time.



After Sand Casting Raw material Raw material

64


Getting order

Manual Process

Raw material

Casting unit

Supply to unit

Machining process by lathe machine

Drilling

Turning and Grinding

Polishing

Bag Packaging

Casting unit is quite far around 30 to 40 K.M from the main unit. Thus facing problem for quality control

1 2 3

456

7

Issue Ÿ Accuracy during

drilling Ÿ Product finishing

after sand castingŸ Measurement during

lathge machiningRecommendationŸ All this unit can come

together and go for die casting, because at individual level die casting is costly.

Ÿ Quality assessment should be their in every stage of ledge machining work

Ÿ Continuos training progarm for workers

Delivery

89

65


Ÿ Height of the fan is very low, any time accident may happen

Ÿ A dedicated room required for doing precision job

Ÿ Small table needed for keeping drawing, while working with lathe machine.

Ÿ Display rack for finish product in every unit

1 2 3 4

5 6 7 8

139 10 11 12

Workplace have to be clean so that maximum space can be utilize

Raw material can be store in separate room

Marking of ledge machine switch not visible properly, it should be mark, so that easy to operate

Trolley can use for keeping finish product

Seating posture (ergonomic) working table need to design for better productivity

Manually made heating chamber, unit can purchase small oven for this purpose

Wall mounted rack can install for keeping tools and equipment

66


All this units are component manufacturers, after sand casting, they do the machining (ledge machine) work and supply to the venders, rather then quality, quantity is main concern. Some of the unit have CNC machine at their unit, they supply to RAIL, Defense and OEMs etc, but most of them are very micro level unit.

Product: Different types of component

AnalysisŸ Product finishing Ÿ Quality Ÿ Product packaging

Packaging: Plastic bag packaging

Transportation: By Cycle Van

Marketing: The units are getting orders from different

venders or OEMs with all the drawing and specification. Their job is to manufacture and supply to the venders within the schedule time. The present market is very much cost competitive, because of this, unit are not focus for the product quality. Also the payment cycle is one major problem for them as most of them are micro level unit. Few unit are directly supplying to Rail, Defense etc.

Visiting Card Product packaging

Angular check valve

Front side of the unit

Nozzle

Deep cape

CNC machine finishing product

67

Recommendation

Recommendation

Ÿ Approach-

Ÿ Innovation in process (productivity)-

Ÿ Ergonomic-

Ÿ Tools and Equipments-

Ÿ Health and Safety-

Ÿ Visual Identity-

Ÿ

the cluster member have to come together to compete the present market challenge.

sand casting bass product (unit) have to come together and shift to die casting. in machining work (lathe machine) quality have to be maintain.

while they were working with ledge machine, machine interface (marking) seating posture, height of the machine need to be workout, it will be help them to increase the productivity

most of the unit are small, very less working space, wall mounted rack can be install for keeping tools and other equipments.

labor is one of the important issue for most of the unit, due to other work (100 days job from Govt. scheme) Labor welfare have to be consider at a cluster level, so that new generation also take interest.

units have only visiting card, they don’t have any product catalogue or any display at their unit. For creating more impact in the market, they have to design their product catalogue, visiting card, website etc. Also required finished product display (showcase) at their unit.

Ÿ Workstation-

Ÿ R&D-

Ÿ Marketing-

in the production area, for keeping finished, required a trolley which can be use for transfer product from one place to another place. Also the place should be kept clean

at cluster level they start small R & D facility, which can be new product development, improve product quality. Introduce small library

all the unit can collectively start doing marketing, they can divide responsibility among themselves.

68

Conclusion

69

It was very reach experience while doing NAS. Most fo the unit in this cluster are very interior from the main road, transportation is one of the issue. Now it is time, they have re-think about their approach with the cluster members. As I mention in my cluster report, they have to set-up Raw material Bank, Tie-up with ITI colleges for skilled labor, casting unit within the cluster etc to competed to days market.

Design Awareness Progarm under Design Clinic Scheme

Prepared byAshok Mondal

Industrial Designer

Rajpur, South 24

Design Workshop

Objective:

1. To create Design awareness for the betterment of engineering equipment manufacturing Industries.

2. To create awareness about the benefits of Design Clinic Schemes.

3. To create, increase and strengthen interaction & cooperative approach among all the unit members within the cluster.

4. To spread awareness in communication design for better marketing

5. To provide information about branding and quality management principles

6. To understand the design process and its application for increase the productivity

7. To create awareness about the use of ergonomic for better productivity

8. To provide information for new product development for future design intervention and product diversification

Guest Speaker

Guest Design Speaker

Shri Manab Naiya, President, BAMWA

Shri Goutam Das, GM DIC, South 24 Pgs

Shir Ganesh Bhawal, Director RUDSETI

Shri Soumen Kumar Neogi, President, CSSIA, South 24 Pgs Shri Asit Sinha LDM, UBI, Baruipur

Shri Anjan Dutta, Chief Coordinator, CSSIA

Shri Ashok Mondal, Regional Coordinator (E & NE), NID

Shri Nirapada Kaya, Secretary, CSSIA

Shri Pinaki Chakraborty, Executive, CSSIA & Program Coordinator

1. Dr. Somnath Gangopadhyay, Associate Professor, Department of Ergonomic, University of Calcutta.

2. Mr. Anjan Dutta, Ex GM, UBI3. Mr. Kaustube Ray, Faculty of Communication Design,

St Xavier College, Kolkata4. Bhaskar MR Bhatt, Faculty NID

Design Workshop

Participator

Important Issue Addressed

Representatives from the different engineering components manufacturing units, member of Cottage & Small Scale Industry Association were participated in the workshop. Approximately 35+ attended the sessions every day.

1. Ergonomic Intervention for improvement of productivity of workers involved in the engineering components manufacturing sectors.

2. Detail discussion about financial issue like Bank Loan, Project Report, Credit ratio, RBI rules etc.

3. Detailed discussion on Need Assessment Survey report, identifying the problem areas and detecting the design intervention opportunities.

4. Discussion on identification of gaps in production process to improve quality for export and domestic markets.

5. Reflection on the need for design intervention like logo, branding, marketing and self promotion techniques.

6. Discussion on Internet and website being the essential tools to access the global market.

7. Detailed discussion on Total Quality Management (TQM) techniques for comprehensive improvement in the final output.

8. Detailed discussion on design process and new product development, use design as tool to increase manufacturing competitiveness

Design Workshop

Proceedings Of Workshop

Day-1: Inauguration

The programme was inaugurated by Shri Goutam Das, GM, DIC, Baruipur, South 24 Pgs, Shri Soumen Kumar Neogi, President, Cottage and Small Scale Industries Association, Shri Manab Naiya, President, BASIMAA, Shir Ganesh Bhawal, Director, RUDSET, and Shir Ashok Mondal, faculty for Design clinic Workshop. All the dignitaries were received with flower bouquet on behalf of BASIMAA at the start of the function. The program was started with the welcome address by Shir Nirapada Kaya, Secretary, CSSIA. Shri Ashok Mondal gave a short representation about next four days programme and requested the participants to remain to the programme schedule as far as possible for all five days.

Shri Soumen Neogi, President CSSIA, gave a vote of thanks to all the invitee guests along with the NID officials and the participants and concluded the days programme.

Design Workshop

DAY -2

NAS report:

The presentation was focus on NAS report. The major issue which was discussed, Raw Material Bank at a cluster level, the advantages, quality parameters, cost, transportation, availability etc. Then, Labor (employment generation) the model was very much convincing for them. All the ITI and Diploma institute student can play an important role.

Design Process:

This session mainly focus on the Design process which flowed by the industry. Starting from Design brief, then user survey, market survey, concept generation, material selection, prototype develop etc. How this process can adapt by the cluster. The different parameters of production process, issue of sand casting, material handling system, packaging and product delivery.

Key Points Discuss in detail

· About design· Design in today,s context · Important of Design in changing era· Fundaments of product design (Process, Ergonomic,

Aesthetic. Technology) · The power of industrial design · Good design and just engulf design · Design contribute to SMEs· Good design= Good business= Good culture

Financial System:

Mr. Anjan Dutta, Ex GM, UBI, talk about financial system, norms of RBI for SME, Loan process and Entrepreneur quality. Mr. Dutta discussed, how any unit can get bank loan, how to submit project fusibility report, credit ratio etc.


· Quality for Entrepreneual attitude· Principal of Managements · Financial management system· Billing and costing · Market and Business· Understand you customer better· How to approach for bank loan · How to prepare project fusibility report for bank loan · Sample calculation of profit and loss for one month as

example· Some common mistake of management · Present global scenario

Design Workshop

DAY -3

Basic Ergonomic and how to increase productivity:

Dr. Somnath Gangopadhyay, Associate Professor, Occupational Ergonomics Laboratory, Department of Physiology, University of Calcutta, talked about how ergonomics can help the workers of this manufacturing sector, improves their productivity. He explained various aspects of ergonomics and its benefits, how one can create a better and more comfortable working environment with its help. The discussion was very beneficial and worthwhile for the workers of this sector. Many instant solutions are suggested as on-the-spot remedies. Various examples of tools and equipment, different postures were shown and discussed that were ergonomically correct and can help to increase the productivity.


· About ergonomic· The application of ergonomic in workstation · Relation between Man, Machine and Environment· What is human productivity · Basic function of System· The execution and evaluation system · Non ergonomic Vs ergonomic representation · Efficient interactive system · Stress free condition · Indian working posture and its benefits · Application of ergonomic for better understanding · Application of ergonomic design

Design Workshop

Day-4

Communication design and use of communication design Mr. Kaustube Ray, Faculty at St. Xavier College, Kolkata, discuss about communication design and its application through case study. The presentation was stared with Brand identity, discussed about different brand, how brand can create image of any company in the market. It was quite interesting dialogue with the cluster members, as most them were wanted to implement. Most of units were impression that it is costly affairs, but this workshop, it was very clear and effective for them. They discuss their visiting card, product catalogue and how to improve it. Key Points Discuss in detail

· What is Brand identity · Case study of Amul Brand· About Logo· How logo can make your company image in the

market· Brand Positioning· How to identify your target market· Use of visiting Cards· Use of company website for better marketing · How to prepare your own website, logo, visiting card

with very minimal cost

Design Workshop

DAY -5

Total Quality Management and New Product Development Mr. Bhaskar MR Bhatt, Faculty of Product Design, NID, focused on total quality management, the principles of, methods to adopt TQM into the daily processes. The basic principles of quality were explained along with examples as to why quality is critically important. Concepts and principles of product quality versus process quality were shared with participants. Several simple techniques to detect the purity of purchased raw material were shared, which could enable most units to conduct tests on incoming materials. The process of production was then deeply analyzed.

Key points explained in detail:

· Principles of Total Quality Management (TQM)· Short term versus long term practices· Material tests to identify quality of SS, sheet metal etc. · Quality planning for each step of surgical instrument

manufacturing process

New Product Development

ndThe 2 presentation focused on NPD (New product Development) process, which would enable the units to design better implements. Using various examples, the differences between good and bad design were clearly illustrated. Myths such as design being only for large units, design being a 'cost' were dealt with through discussions and explanations.

Key points explained in detail:

· Good design versus bad design· Design as a sustained strategy· Design for manufacturability· Standardization and value engineering· Advantages of design

Design Workshop

Possibility for Design Project

1. Moonlight Engineering works- Brief- Redesign mobile petrol pump for rural area

2. Dieco-Brief- Redesign of die casting (implea, which is use for exhaust fan). The casting process, followed by the unit is manual. We need to redesign this machine and process, so that, it can be a semi/automation hydraulics system for ease and faster manufacturing

3. Garrison Engineering & Company- Brief- Redesign of Fire tender to meet the emergency requirements. User friendly design for fireman for faster preparation and fire extinguishing operation. Vehicle design to meet the international standard.

4. Indowebal Surgical Pvt Ltd- Brief- Redesign of ophthalmic knife and others ophthalmic instrument development, The product should be export quality to meet the international criteria

5. Amar Ghosh & CO-Brief- Redesign ceiling fan and lighting fixture for Rail compartment

Suggestion given during 5 days workshop

1. Raw material is one of the major concern for the cluster, the possibility of raw material bank has discussed in detail, initially the cluster can directly parches from TATA, Jindal etc and storing capacity for Six. Individual unit can buy material from the cluster.

2. Labor (Opportunity for employment)- Association can tie-up with any ITI or Diploma college and their student can employ at their unit at a later stage.

3. Material Handling system- The process of how to handle the material from raw stage to finished product. The different process was discussed like, material storage, transfer from one place another place, rack for un - finish, sem- finish and finish product.

4. Mini production house at a cluster level where sand casting, die casting, polishing, packaging and other facility will be available.

5. Ergonomic- within the work station area, different lighting, seating posture, tools and equipments, man and machine interface etc.

6. Communication- The association can develop a website, where all the unit member have their own pages and they can upload their products, process, contact details etc. to create a Brand

Design Awareness Progarm under Design Clinic Scheme

Prepared byAshok Mondal

Industrial Designer

Need Assessment Survey for Cottage & Small Scale Industry …designclinicsmsme.org/Design Awareness...

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