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Scientific glaSSwareambala cantt i haryana

DeSign awareneSS program report

DeSigneD anD DocumenteD by kulveer Singh bhati

DeSign awareneSS program reportmSme niD DeSign clinic Scheme

SupporteD by phD chamber

aSima

in association with

Designed and Documented by

kulveer Singh bhatiinDuStrial DeSigner . architect

[email protected]

Scientific Glassware I Ambala Cantt I Haryana

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table of content

neeD aSSeSSment Survey

i. introductionii. about ambala cantt industrial towniii. time frame

cluSter level macro StuDyiv. cluster information and Details of units 01. Detail Of Units 02. Demographic Distribution Of Units 03. Business Models 04. Product Range 05. Tools And Machinery 06. Process & Techniques 07. Labour Intense Process

unit level micro StuDyv. common problems and recommendation 01. Worker Related Problems 02. Pre Manufacturing 03. Manufacturing Processes And Techniques 04. Post ManufacturIng

vi. product Study 01. Product Design And Aesthetic 02. Branding

Vii. Unit Specific Problems, Remedies And Opportunity

vii. Swot analysis

viii. on a Serious note

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Kulveer Singh Bhati I Industrial Designer I 2013

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DeSign clinic workShop

I. Workshop Methodology

II. schedule of Workshop

III. openIng sessIon

Iv. guest lectures

v. dIscussIon And BrAInstorMIng 01. Manufacturing Processes 02. Packaging Ideas 03. Value Addition To Existing Products 04.New Designs In Existing Product Range 05. New Opportunity In Parallel Industries

vI. desIgn opportunItIes

vII. prototypIng

vIII. conclusIon

Annexures

photo credIts BIBleogrAphy

Scope of intervention anD SuggeStionS

i. Design intervention on Different production Stages ii. industrial Design opportunities

iii. Short term interventions iv. long term interventions

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introDuctionthe industrial heritage city of ambala cantt has more than 1200 scientific equipment manufacturers. More than 200 falls in the category of medium scale industries and traders. ambala cantt is the largest manufacturer of scientific glassware in the country.

The Ambala Cantt scientific glass manufacturers not only caters to the pan india demand but also export to various parts of the world including europe and uSa.

The scientific glassware industry began in India before independence. initially raw material used to came from england then it started in india as borosil be the first company to produce raw materials but due high completion from chinese material borosil stopped manufacturing glass tubes and the complete supply had shifted to china in last few years.

The Scientific Glass manufacturing is completely a skill based industry because of glass blowing processes. it makes the industry production limited. in last few years micro industries are coming up very fast most of them are set up by senior workers and traders. they have started the competition by reducing rates and quality. ultimately to sustain all industries are compromising on quality to keep cost low.

now lot of small and medium scale industries are going through a tough time because of low margins, extreme completion and old technologies.

Scientific GlaSSware


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ambala cantt

ambala cantonment is a cantonment town in ambala district in the state of Haryana, India. It is a major market for scientific products for school and colleges.The city is famous for producing great academicians.

locationit is next to ambala and is on the grand trunk road. it is some 200 kilometers north of Delhi and 50 km south from chandigarh.

climatethe climate of ambala over most of the year is a pronounced continental in character. it is very hot in summers and markedly cold in winters. may and June can be really hot with the temperature soaring to over 48°C,while in winter it can be as low as -1°c. ambala has a semi-arid as well as tropical climate.

DemographyAs of 2011 India census, Ambala had a population of 1,136,784, consisting of 640,044 males and 532,740 females. Ambala has an average literacy rate of 82.9%, with 88.5% of males and 76.6% of females literate. 11% of the population is under 6 years of age

economyAmbala is known as city of scientific instruments. It is a major scientific products market and is a hub for products like glass apparatus, microscopes, laboratory equipment etc. Ambala constitutes nearly 34% of the total production of scientific instruments produced in India.


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time frame

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neeD aSSeSSment Survey


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Cluster InformatIon and detaIls of unIts

01. Detail of unitS

02. Demographic DiStribution of unitS

03. BUSIneSS MOdelS

04. proDuct range

05. toolS anD machinery (a) hand tools (b) machinery

06. proceSS & techniqueS

07. labour intenSe proceSS


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01. DetailS of unitS

S.n. name of unit name of owner worker details

turn-over

contact details

01. Gupta Scientific industries

bhusan gupta 22 m01 f

1,5 Cr 3703/1 Ambala Cantt (T) 0171-2631837

02. glassco laboratoryequipments Pvt ltd

Sameer jain 200 m+f

27 cr manglai, Ambala cantt(t) 0171-6451250

03. Science Zone vikas gupta 8 m2 f

25 l 982-e, HBC, Ambala cantt(t) 0171-4005855

04. rama thermometer industries

Subodh goyel 2 m 45 l 987, HBC, Ambala cantt(T) 0171-2654534

05. D r glass works

Sunny aggarwal 5 m2 f

__ Plot no- 5, HBC, ambala cantt(t) 09416555191

06. JmD glass ware mahesh gupta 4 m 20 l 981F, HBC, Ambala cantt(T) 09416430332

07. Malik Scientific glass works

Surander kumar 1 m 25 l 2503, Bangali street, ambala cantt(T) 09416824347

08. amit enterprises amit bansal 11 m 1.4 cr 1222 Bengali street, ambala cantt(T) 0171-2643336

09. paras instruments co.

Subhash Jain 11 m03 F

70 l 5363 Punjabi Mahulla, ambala cantt(T) 0171-2644663

10. Kunal Scientific industries

Amarjit Saini 3 M 7 l Gausala Market, ambala cantt(t) 09812522856


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01. DetailS of unitS

S.n. name of unit name of owner worker details

turn-over

contact details

11. aD glass printers

Shyamlal Sharma 6 m 10 l Patel nagar, ambala cantt (T) 09466288038

12. SR Scientific industries

ravinder kumar Sharma

7 m 40 l patel nagar,ambala cantt(t) 09896068991

13. Parban Scientific glass works

ashok kumar 3 M 5 l Sikligar mahulla, ambala cantt(T) 0171-2618836

14. Sanky Screen printing

rampal Sharma 3 M 3 l P P Puram,ambala cantt(T) 09315899570

15. Standard scientific Glass works

S K Rajjanwal 8 m 35 l 12, Kardhan Road, Industrial Area, ambala cantt(t) 0171-2699517

16. Super lab glass works

naresh kumar 12 m 25 l Ram Bagh road, ambala cantt(t) 09896105944

17. aggarwal enterprises

prem chand aggarwal

4 m 8 l near hargolal post office, Ambala Cantt(t) 09896796269

18. Jain Scientific glass works

Himanshu jain 100 + 5 cr 14 Industrial estate, ambala cantt(t) 09896181044

19. Jain laboratory glassware co.

Jaswant rai Jain 10 + __ # 2580/29, Subhash Park Road, ambala cantt(t) 0171 - 4005584


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02. Demographic DiStribution of unitS

the entire glassware industry placed in a very close proximity of 10-15 Km radius in ambala cantt area, hSiDc industrial estate and outskirts on Jagadhari road.

the close proximity gives opportunity for small set-ups to grow and supply to big industries and traders. Since glassware has more then 1000 products so to manufacture all options is difficult since demand for few products is very limited. So it gave a good opportunity to small vendors/ industries to specialize in mass production on limited/ single products.

opportunitieSSince the entire cluster is within a close proximity it is also beneficial to implement different schemes like common facilities centre,


1503. BUSIneSS MOdelS

enD uSer

. laboratorieS. inStitution

out Station traDer

local traDer

SMAll/ MedIUMMAnUFACTUReRS/

inDuStry

microMAnUFACTUReRS/

inDuStry


1604. proDuct range

The product range in Scientific glassware industry is huge since a lot of products are customized for specific laboratory experiments/ use. Broadly it can be categorize on requirement basis as:

General products like volumetric flask, burettes, cylinders etc. the production of these products can be done faster and can be completely automatic in some cases.

labware/ customized products like separating/ dropping funnels, assemblies for various lab experiments. These products are highly customized and requires a very good workmanship.


17The broad categorisation of scientific glassware can be done on the following basis:

a. Volumetric & Graduated Glassware

burettes

volumetric flask measuring cylinder

Measuring, Graduated pipettes


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coil condenser

Flask round bottom, three neck

Flask round bottom, three neck


19B. standard joints, stoppers and adapters

C. still heads and splash heads

Tapered joints

flow control vacuum transfer adapter

Short path distillation reactor glass head

Dean stark trap


20d. separating/ dropping funnels

e. fractionating columns

Dropping funnel Pressure equalizing funnel

columns


21f. sintered glassware

H. General glassware

Membrane filter holder assembly

beakers

essential oils setup

bottels


22G. Interchangeable ground joint assemblies

Steam distillation unit assembly water distillations


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water distillations

05. toolS

Spanner Metal flatSewing awlplier

clipflat

Tri square chiselawlFlat file Round fileTaper file Half Round file

outside swing caliperinside swing caliper cylindrical tool


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Single chuck grinding machineburner

glass cutter calibration machine

marking set

glass cutter

Digital weighing machine

Single chuck blowing machine

Double chuck blowing machine

heat furnace

machinery


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borocilicate tubes 4mm Dia to 150 MM dia, lPG gas cylinder, packaging and finished products

Based on different requirements the glass tubes are cut to size in batch

The most important process, the glass is blown with help of lPG gas flame combined with oxygen cylinder

volume of each product is different after blowing, In water calibration process each product is measured and marked individually for required volumes

unit marking is done using screen printing process for various sizes

to release the stress from product that developed during after blowing process

wood wool or paper waste are commonly used to pack the products for transportation

06. proceSS & techniqueS

Storage

cutting

blowing

calibration

printing

annealing

packaging


260 7. labour intenSe proceSS

high Skill proceSS

glass blowingcalibration

marking

meDium Skill proceSS

glass cuttinggrindingprinting

packaging

general proceSS

Storagetransportation

glass cutting

blowing and shaping

grinding

calibration

marking

printing

annealing

packaging

Storage

transportation


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01. worker relateD problemS (a) lack of technical skills (b) labour shortage (d) Frequent job change

02. pre-manufacturing (a) raw material procurement (b) lpg gas

03. MAnUFACTURInG PROCeSSeS And techniqueS (a) Storage (b) cutting (c) blowing (D) grinding (e) calibration (f) marking (g) Screen printing (h) annealing (g) packaging

04. poSt-manufacturing (a) Storage (b) transportation

Common proBlems and reCommendatIon


2801. worker relateD problemS

Scientific glassware industry completely dependent on labour skills because of glass blowing process. blowing requires sharp skill and it takes years to develop skills because of complicated nature of the process. being labours a very important part of the industry, the units are facing following problems related to labours:

(a) lack of technical skillsas a practice new workers learn the skills under senior workers. The labour training requires lot of time and there are no training program, labourers are not technically trained and lacks technical knowledge to handle glass production. Since the production highly depends on labour skills. Ultimately quality of manufacturing goes down and it reflects in the finished products.

Recommendation:. Skill development program .technical training workshops

(B) skilled labour shortagein ambala cantt area small and micro industries has grown rapidly in past few years, most of these industries were started by senior workers/ skilled labours and ultimately there is shortage of skilled labours. Due to that in few industries production and quality has gone down.

Recommendation:. automation of units for selected items. introduce ways to retain good labour with incentives etc.

(B) frequent job changeAs mentioned there is a shortage of skilled labour, few industries are also facing problems due to frequent change by labours. it not only effects the production also is shows different quality of production since all labours have different ski sets and finishing levels.

Recommendation:. Standardization of production. introduce ways to retain good labour with incentives etc.

Skill development

required


290 2. pre-manufacturing

the pre-manufacturing stage involves procurement of raw material for glassware as well as basic energy requirements like lPG gas.

(a) raw material ( glass tubes)The raw material for the scientific glassware industry is borocilicate glass tubes in different Diameters ranging from 04 mm to 150 mm. the tubes are available in different qualities as A grade and B grade. The raw material for the whole market is 100% imported largely from china. local glass traders import raw material and supply it to units on retail prices.

(B) lpG gasThe scientific glass industry’s glass blowing process completely depends on lpg gas> so the demand for commercial gas is very high in the city. in fact to meet the gas requirement units buy it from black market. Till now the domestic cylinders were easily available with a little more margin with landing cost of lPG at Rs. 60/- but from ast 6 months even the commercial cylinders are not available easily hence the increased price of gas is effecting margins.

Recommendation:. lPG gas pipe line for glassware industries/ for industrial town. . easy availability of commercial gas cylinders.

Recommendation:. raw material procurement by cfc and make it available to units on nominal margins. . Demand for a local manufacturer of glass tubes.


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3. MAnUFACTURInG PROCeSSeS And TeCHnIqUeS

(a) raw material storagethe main raw material is in form of borocilicate glass tubes is very fragile material and requires a very careful storage to avoid breakage. the total wastage of industry is around 8-10% of total raw material procured and only storage wastage is more then 3-4%. It id due to improper system. only by improvising on raw material storage system units can reduce wastage and it will finally reflect into better profits.

edges of tube may get damaged while accessing material

recommendation and remedial solutions:. Dedicated space for storage..Segregation system based on tube diameters.. basic training to handle raw material.

Improper packaging while stored

Designopportunity

glass Storage system specially designed for glass tubes and for different diameters


31(B) CuttingThe first step of manufacturing starts with cutting of the tubes. As per the production requirement the tubes are cut for the complete batch at once and transferred to the blowing section from here. there are two ways to cut tubes with manually (glass cutters) as one by one piece and secondly with semi automatic machines in batch. The manually is a labour dependent job also edges of the tubes are rough after cutting. also there are some wastage in while cutting due to human error.

Semi-automatic cutting machine manual cutting

Proper lighting solutions

Use of proper uniform while working

Use of clear eye protection

Avoid storage around machine

Proper hand gloves, glass can incurred injuries while cutting

Dedicated space to keep finished goods and raw material to avoid breakage

recommendation and remedial solutions:.technical training workshops. time to time maintenance of machine and change of cutting blade.. Shifting to automatic cutting machines

Designopportunity

. locally developed cutting machine .paddle operated glass cutting machine


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(C) Blowingglass tube blowing is the most important stage of the entire process. During this stage skilled labours blow the standard glass tubes and shape them in final product.there are lot of challenges and shortcoming on workstation and processes that results into a bad working environment and subsequently a compromised product.

tools for shaping glass machinery


33Step 1

Fit glass tube on lathe chuck and start heating glass with low flame

blowing proceSS

Step 2

Gradually increasing the flame and till the time glass becomes soft to shape

Step 3

Start blowing calculated air by mouth or by pump operated by feet

Step 4

Shaping glass with a good balance of flame and air blow using a carbon die/ template

Template gets damaged due to heat and friction and results into defects on following products

Low grade/ no safety gears for workers effects their health

Heat generated from high flame makes working environment very hot and very difficult for worker

Better tools required since damaged tools leaves marks on surface of product

Wastage of Gas flame in between two blowing process

Step 5

After it comes to desired shape, cutting it with remaining tube

Step 6

Finishing bottom/ edges with help of special toolson rotation condition

Step 7

Removing finished product from chuck and keeping it to gradually reduce temperature

Designopportunity

. locally developed Automatic / paddle flame control machineto reduce wastage


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Recommendation and remedial solutions:. better working environment. mandatory safety gears to use by workers . highly recommended safety for use of lgp cylinders and other equipment . introduce ways to reduce wastage of lpg and raw material. alternative materials for template to avoid wear n tear. Better hand tools for good finish . technical training to staff for better blowing practices

Better tools required since damaged tools leaves marks on surface of product

Process space for workers to keep personal belongings clothes are prone to catch fire in this zone

Better furniture for worker to sit since it directly effects his performance and health

Dedicated space to keep raw material and finished goods

LPG gas cylinders are directly exposed and kept very near to high flame, are very risky

Weather control units in summers because of excessive heat generated by blowing process

Wastage of Gas flame in while changing glass tubes

Typical scenario around workstation of Glass blowing


Designopportunity

Workstation design, Urgent need of the industry

protection for worker excessive heat from blower


35(d) Grindinggrinding is a post blowing step to maintain the standard inner diameter for different products like Flask, Bottles etc. the process involves a single chuck motor with a metal tool fixed in front. There is a special coating on Od of tool to make it temper proof and maintain oD for long time.

Recommendation and remedial solutions:

.technical training for skill development workshops

. Finding alternative/ hard materials for tool making

. Safety gears needs to me introduce by employer

. need to enhance working area

Lighting levels are very low for working

Gloves for working with water for long time

Protection for eyes while working with glass

The tool’s outer diameter gets reduced after long use and it start reflecting errors in size of ID of final product

Designopportunity

finding alternative material for grinding tool to maintain diameter in long run


36(e) Calibration the celebration is the most important part for volumetric scientific glassware. each glassware has variations in wall thickness because of heat blowing and can not be marked with same template. So individual calibration of products is required. Any error on this stage can completely make product volume wrong and if the product is used in laboratory will project wrong result because of wrong volumes hence it is very critical to calibrate the glassware correct.

recommendation and remedial solutions:.technical training for workers. Better equipment for calibration . automatic calibration facility in cfc

1. automatic calibration machine

2. manual calibration Design

opportunity

locally developed automatic calibration machine


37Step 1

Filling water in volumetric peppet, the water filled a little extra from marking.

Step 2

The extra quantity of water is released and a particular volume is maintained by the worker

Step 3

Same water is released into a new empty product

Step 4

The water is crosschecked on digital weighing machine as per the water temperature the volume also differs. so the same volume is maintained

Marking is done as per water level

manual calibration

Its a very skill based job and completely depends on labour to labor

There are chances that water quantity may differ each time

Its a additional process and makes it time taking job

Designopportunity


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(f) markingpermanent marking is done post calibration and temporary marking on volumetric product. there is a special marking machine for manual marking with a base to rotate product and a diamond head to mark on outside the product. in this method of marking diamond head engraves on upper layer of product. it makes the product weak on neck. another limitation of manual marking is during the screen printing the printing does not cover the complete circumference of product due to matching issues.

Recommendation and remedial solutions:. Skill development program for workers. need to shift to automatic system for accuracy. automatic marking facility in cfc

Designopportunity

locally developed automatic Screen printing to avoid error and marking on outer part of glass


39(G) printing

printing of volumetric units and branding need to be permanently printed on products. as discussed earlier also each product has variations so after marking the surface/ length needs to be divided equally and marked. there are different ways of marking as Screen printing and chemical marking.

chemical markingit is used when no of products are very less and to avoid screen cost the marking is done manually and chemically etched.


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Recommendation and remedial solutions:. Skill development program .technical training workshops . automatic printing machines at cfc. proper storage system for screens. working posture of workers needs to be improved

Step 1

Selection of screen based on marking of product

Screen printing

Step 2

Preparation of paint commonly used colors are white and blue

Step 3

Application of paint on screen

Step 4

Rolling the product carefullyAgain a skill based job

Skilled based job, still variations can be there as well as alignment issues


Good quality paint required for a better printing

Step 5

Checking of product post printing

The printing does not cover the complete circumference of product due to matching issues

Storage system for screens required

there are different screens developed for different variations of markings and a screen is selected accordingly.


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(H) annealingHeating is required to release the stress of glass product developed during blowing process. it also make the printing permanent on product surface. post screen printing products are kept in a metal basket/ or directly on tray in a heat furnace and kept on heating for 2-3 hrs on a constant temperature of 540-560 c. post heating the products are kept out side furnace for some time to gradually cool down to room temperature.

there are breakages sometime during heating processand cracked product goes for scrap. it is also part of the total wastage.

Recommendation and remedial solutions:. Developing big furnaces for cluster level for batch annealing. provision can be made in cfc new age furnaces for save electricity consumption

Development of low power consumption furnace or Solar power furnace

Designopportunity


42(I) packaging

Packaging is equally important for glassware to protect products while transportation. the traditional ways of packaging are commonly used in almost all units. There are two filling materials mainly used as wood wools and paper cuttings. wood wool is a very heavy material and makes transportation costly. also it makes products dusty by the time it reaches destination.

Designopportunity

light weight and cost effective packaging design


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Recommendation and remedial solutions:. opportunity to design new packaging systems. innovative ways to make packaging lightweight and compact. common packaging design for all variations . Designing workstation for packaging

Step 1

Selecting the paper size for product

packaging

Step 2

Wrapping product in paper

Step 3

Keeping in box and filling the remaining space with wood wool

Step 4

Closing the box with tape

Individual boxes occupies more space and effort for packaging and cost

Wood wool makes boxes heavy which results into extra transportation cost

Wastage of paper and effort

For different product sizes different paper sizes are required

Step 5

Placing individual product boxes into a big box for transportation

Designopportunity

innovative design to pack different types of glassware in same pack


4404. poSt manufacturing

(a) storagePost production storage of finished products is required in glassware industries. reason being there are few products with a running demand and few special product with very rare demand but to meet the customers demand industries maintain certain inventories for both type of products.there are few products that dose not move for years and needs a good storage systems to keep it in good condition even after 2-3 years. most of the units in ambala do not keep good storage systems and it results into lot of breakage . alsopoor storage occupies more space and makes the workflow very slow.

Recommendation and remedial solutions:. Storage management systems needs to be designed. training to keep inventories minimum as per demand

Designopportunity



45(B) transportationambala glassware industries supply products locally and out of state. there are few industries they export material to europe, America and Africa. So the transportation plays an important role to reach out to costumers. most of the units currier their products due to small quantities. So for interstate level truck and trains becomes important.

Recommendation and remedial solutions:. Packaging designs to minimize breakage while transportation.. clear branding and labelling on packaging for better communication

Designopportunity

Design of packaging boxes to reduce breakage during transportation


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01. DeSign anD aeStheticS

02. branDing

produCt study


4701. DeSign anD aeStheticS

Scientific glassware products are completely a functional driven shapes and designs are same for decades. the main categorisation can be done based general ware like flask, bottles, pipettes etcCustomized products since lot of products go for laboratory experiments they are made for specific requirements of scientist/ users.

as far as the shape of product concerns there is hardly any scope for design, but there is a good chance for process design, packaging design, storage systems, tools, machineries can be designed and developed for the industry.

02. branDing

there is a good scope for branding in the industry on different levels. As first level only few units have branding, logo designed. most of the units still lacks a good branding. also products can be branded with scree printing friendly deigns. also the marking on volumetric glassware can be re-defined in terms of font, graphics etc.Communication signvages in industry, instruction manuals etc can be developed by units. entire packaging can be designed from individual box to big boxes for shipments.

as branding plays an important role in any industry this domain should be explored more.


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01. unit 1 to 19

(a) introDuction

(b) proDuct & proceSSeS

(c) workmanShip anD labour

(D) market

(e) buSineSS

(f) SuggeStionS given During naS

(g) remeDial DeSign SolutionS

(h) Scope of DeSign intervention

unIt speCIfIC proBlems, remedIes and opportunIty


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Gupta Scientific Industries is one of the oldest and pioneer in the glassware manufacturing. the root of the industry are from post independence period. the owner of the unit mr. bhusan gupta is a engineer and has experience close to 40 years.

Better storage design

Scope for packaging and workstation design

Low level of lighting on workstations

unit 01Industry name: Gupta Scientific worksnature of work: Manufacturing


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proDuct & proceSSeS orienteD

Speciality > Customized products with high quality

product range > The industry in all kind of scientific glassware general or laboratory.

Specialize in different laboratory assemblies.

Production quality and finishes > very good compare to the other units

key problem in process > Age old manual process, need for automation of process

visual identity and branding > Perfit India, weak

packaging > Basic wood wool filling and packaging used, need for redesign

it increases the weight hence more transportation charges

workstation and tool design > old workstation designs need to redesign of workstation

ergonomics and environment factor > Issues with working postures and ventilation , clear scope for improvement

Scope of new design and r&D > Wide scope to develop machinery for calibration, blowing and marking

Scope of technology modernization> good scope in calibration, blowing and marking etc

Scope for production in parallel > not interested

industries

labour anD workmanShip orienteD

Skilled/semi-skilled/non-skilled labour > 8 skilled, 6 semi skilled and 8 non skilled

need of labour training > Yes for blowing, cutting

common health problem faced by > too much heat during summers and ventilation labour

key problem faced from labour > no problems with labour, they are old and honest

UnIT SPeCIFIC PROBleMS, ReMedIeS And OPPORTUnITY


51market orienteD

How do you market/sale your products > unit > traders > out station traders > costumers

Who are the major competitors > no names

Competition within Ambala/rest of India > lot of competition coming from locally market also import from china and europe

product exhibition in any trade fair > ambala and Delhi

Any qualified marketing person > no

Do you feel need of inter cluster > yes, but difficult to achieve and implement in Ambala

communication

buSineSS orienteD

Problems like electricity, labour union, > locally made raw material and govt policies raw material, space, Govt. support to address small industries

Margins/ profits are sufficient ?? > not good these days, hardly 15-20%

Scope of infrastructure development > Yes, building and machinery both

Major challenges > finance and competition within cluster

Available space is sufficient or not > no

SuggeStionS given During naS . common facility centre. For improvement in workflow. ideas on better storage systems and packaging.

remeDial DeSign Solution

. light weight packaging materials instead of wood wool

. better storage system to reduce wastage

. better lighting provisions and ventilation in workshop

Scope of DeSign intervention

. branding and labelling on products

. workstation Designs

. Packaging design, Glass cutter design

Designopportunity


52Special opportunity

mr bhusan gupta has a very deep knowledge of the glass blowing and the manufacturing process. Also he has a very experienced team of workers in blowing, calibration and heat furnaces. it gives him an upper handin developing new products or customize products for specific laboratory use. the same can be made brand strategy to promote the brand.


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unit 02Industry name: Glassco nature of work: Manufacturing

Automatic set up for mass production

Large blowing section

Packaging section


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Speciality > Mass production with good and consistent quality

product range > The industry in all kind of scientific glassware general or laboratory. They specialize in different laboratory assemblies.

Production quality and finishes > very good

key problem in process > advanced machinery and automation of process

visual identity and branding > glassco

packaging > Better then others, can be redesign

workstation and tool design > can be redesign of workstation

ergonomics and environment factor > Minor issues, scope for improvement

Scope of new design and r&D > Scope for r&D in the processes of blowing

Scope of technology modernization> good scope

Scope for production in parallel > Can be, if profits are better

industries


Skilled/semi-skilled/non-skilled labour > all, infect they have started paying them on per piece basis, so the labours are paid as per their capabilities

need of labour training > yes for core processes

common health problem faced by > Heat during summers, not much

labour

key problem faced from labour > no problems with labour



55market orienteD

How do you market/sale your products > unit > out station traders > export

Who are the major competitors > local and abroad

Competition within Ambala/rest of India > lot of competition coming locally as well as from china

product exhibition in any trade fair > in and outside country

Any qualified marketing person > yes

Do you feel need of inter cluster > Yes, can be done, but Govt need to play role communication of mediator

buSineSS orienteD

Problems like electricity, labour union, > lpg gas and electricity some time

raw material, space, Govt. support

Margins/ profits are sufficient ?? > not very good now

Scope of infrastructure development > yes

Major challenges > finance and government support

Available space is sufficient or not > Yes

SuggeStionS given During naS

. For improvement in workflow and assembly line

. inter cluster development ideas


. light weight packaging materials for easy transportation



. branding and marketing

. workstation designs

. innovative packaging design for export

Designopportunity


56

UnIT 03Industry name: Science Zonenature of work: Manufacturing

Punching and cutting machine for packaging boxes

Blowing facility

Calibration facility, need for improvement

Workstation needs to be organized well with LPG cylinder out side


57


Skilled/semi-skilled/non-skilled labour > 4 skilled, 5 semi skilled, 3 non skilled

need of labour training > Yes, very much, moral education, honesty

common health problem faced by > not much, designer feels problems can be from excessive heat

labour

key problem faced from labour > Frequent change in job,



Speciality > packaging manufacturing inhouse

product range > 7-8 Types, measuring cylinders, conical flask etc

Production quality and finishes > average

key problem in process > old processes and unskilled labour need for advanced machinery

and automation of process

visual identity and branding > Science Zone, need to design branding and logo

packaging > In house facility, but old designs, need for innovation

workstation and tool design > need to redesign

ergonomics and environment factor > Minor issues, scope for improvement

Scope of new design and R&d > Require to progress further, Scope for r&D in the industry processes like blowing and calibration

Scope of technology modernization> never gave a thought

Scope for production in parallel > will continue in same

industries


58market orienteD

How do you market/sale your products > To traders local and out station, directly to customers By internet search costumers, scientific

business india website,

Who are the major competitors > local small units/ manufacturers

Competition within Ambala/rest of India > lot of competition coming locally

product exhibition in any trade fair > Ambala, delhi ( 2 years ago)


Do you feel need of inter cluster > yes, depends on setup

communication

buSineSS orienteD

Problems like electricity, labour union, > electricity some time, labour shortageraw material, space, Govt. support

Margins/ profits are sufficient ?? > average 20% and 10% profit


Major challenges > Competition from small players, reduces margins



. enhance packaging facility

. For improvement in workflow





innovation in packaging design . Separate packaging design for local transportation and export

Designopportunity


59

unit 04Industry name: Rama Thermometer Industriesnature of work: Packaging and Trading

Storage needs to be more organized for maximum utilisation of space

Finished products requires dedicated space, it will reduce wastage


60



Production quality and finishes > n/A

key problem in process > n/A

visual identity and branding > Ramin, god Shiva on business card as logo

packaging > Basic paper filling and packaging used, need for redesign

workstation and tool design > need to redesign of workstation

ergonomics and environment factor > Working on floor, issues with working postures and ventilation

, Clear scope for improvement

Scope of new design and r&D > Do answer

Scope of technology modernization> no answer

Scope for production in parallel > n/A

industries


Skilled/semi-skilled/non-skilled labour > 2 semi skilled

need of labour training > n/A

common health problem faced by > back ache

labour

key problem faced from labour > n/A



61market orienteD

How do you market/sale your products > unit > outside traders

Who are the major competitors > local small time players

Competition within Ambala/rest of India > ambala mainly

product exhibition in any trade fair > no


Do you feel need of inter cluster > don’t know

communication

buSineSS orienteD

Problems like electricity, labour union, > electricity sometime


Margins/ profits are sufficient ?? > not good these days, Profit 10-12%

Scope of infrastructure development > n/A

Major challenges > less margins and extreme competition

Available space is sufficient or not > ok


. working postures

. ideas on better storage systems and packaging.


. light weight packaging materials

. better storage system for better utilisation of space


innovative marketing modelspackaging design and workstation for packaging


62

unit 05Industry name: d R Glass nature of work: Manufacturing

Automatic machine to make beakers/ tubes etc

Glass cutting facility

Compartmental Packaging of tubes

Tubes ready for annealing


63


Speciality > Mass production of tubes/ beakers (2-3 products)

product range > 7-8 types

Production quality and finishes > Good and consistent quality in limited designs

key problem in process > need automation of process of cutting etc

visual identity and branding > d R Glass works, need for branding


workstation and tool design > Designer feels the machines are randomly arranged with basic

setup, urgent need for a work station

ergonomics and environment factor > there seems to be issues with working posture and safety gears

Scope of new design and r&D > May be, not sure

Scope of technology modernization> Automation of processes like cutting, calibration etc

Scope for production in parallel > not sure

industries



need of labour training > Yes for core processes like blowing, cutting to enhance their skills

common health problem faced by > no problems, designer feels there can be problems like skin burn,

labour excessive heat and eye problem

key problem faced from labour > Frequent job change, lack of commitment



64market orienteD

How do you market/sale your products > unit > traders > manufacturers

Who are the major competitors > local units and traders

Competition within Ambala/rest of India > locally, units are compromising on quality in competition

with each other, this issue needs to be addressed

product exhibition in any trade fair > -


Do you feel need of inter cluster > May be it will work, don’t have any idea

communication

buSineSS orienteD

Problems like electricity, labour union, > electricity and lpg gas


Margins/ profits are sufficient ?? > around 10-15%


Major challenges > Finance and small percentage of profit

Available space is sufficient or not > Shifting in a bigger space will ease the production operations


. Assembly line working method and benefits

. importance of light and ventilation


. Focus on Mass production of specific products

. attention to small details


. Design of more products with same machinery Designopportunity


65

unit 06Industry name: J M d glassware nature of work: Manufacturing

Very compact space with 4 workstations (10’ x 12’) workshop

Single chuck machine for blowing process

Oxygen cylinder storage outside


66


product range > 30 products, Beaker, burette etc


key problem in process > Age old manual process, need for modernisation in process and

technology

visual identity and branding > J M d Glass ware, need for branding

packaging > Basic, don’t know if the designing is required

workstation and tool design > compact and economic solutions to increase the efficiency

of workers, to improve working postures

ergonomics and environment factor > Issues are there with working postures, safety and heating problems

Scope of new design and r&D > not clear

Scope of technology modernization> latest tools and machinery will definitely benefit and improve the

production quality

Scope for production in parallel > don’t know

industries


Skilled/semi-skilled/non-skilled labour > 2 skilled, 2 semi skilled

need of labour training > Can look for it, but not sure what kind of training


labour

key problem faced from labour > no problems only 4 person in unit



67market orienteD

How do you market/sale your products > unit > local manufacturer > local trader

customers

Who are the major competitors > local and similar scale units

Competition within Ambala/rest of India > don’t supply out



Do you feel need of inter cluster > don’t know how it will work

communication

buSineSS orienteD

Problems like electricity, labour union, > electricity and lpg gasraw material, space, Govt. support

Margins/ profits are sufficient ?? > not much, only 10-15 %


Major challenges > finance

Available space is sufficient or not > Yes, but designer feels bigger space will

benefit


. To specialize in product range and concentrate on few only



. being a small unit they should shortlist few products and must focus on them only

. try to sell products outside through internet etc


. compact and economic solutions for workstationDesign

opportunity


68

unit 07Industry name: Malik scientific Glass Works nature of work: Packaging and Trading

Store of finished goods in unorganized condition

Showroom of malik scientific glass works

office space


69


product range > mini Distillation units and general lab glass

Production quality and finishes > n/A

key problem in process > n/A

visual identity and branding > Malik Scientific Glass Works, no need for branding since

traders put their brand name on products

packaging > Basic paper filling and packaging used, need for redesign

workstation and tool design > need to redesign workstation, currently working on floor

ergonomics and environment factor > Working on floor, issues with working postures

Scope of new design and r&D > Manufacturers may need, we don’t

Scope of technology modernization> no answer

Scope for production in parallel > n/A

industries


Skilled/semi-skilled/non-skilled labour > 1 semi skilled

need of labour training > n/A

common health problem faced by > nolabour

key problem faced from labour > n/A



70market orienteD

How do you market/sale your products > unit > outside traders > customers

Who are the major competitors > Minesh scientific , out side manufacturers

Competition within Ambala/rest of India > ambala mainly


Any qualified marketing person > nO, no need for marketing

Do you feel need of inter cluster > don’t know, how it will work and benefitcommunication traders

buSineSS orienteD

Problems like electricity, labour union, > lack of govt support to market products


Margins/ profits are sufficient ?? > Gross Profit 30-40%

Scope of infrastructure development > n/A

Major challenges > limited demand and extreme competition

Available space is sufficient or not > ok


. posture during packaging activity



. light weight packaging materials

. better storage system for better utilisation of space


packaging design and workstation for packaging


71

unit 08Industry name: Amit enterprises nature of work: Manufacturing and Trading

Workshop area looks a bit un-organized

Showroom cum office in a close proximity to workshop

Working table with a close proximity with LPG gas cylinder can be dangerous since its a high flame blowing job


72





visual identity and branding > Amit enterprises, logo is designed and looks good

packaging > Basic packaging, need for redesign

workstation and tool design > need to design the workstation

ergonomics and environment factor > Issues with working postures and ventilation ,

clear scope for improvement

Scope of new design and r&D > not much scope for R&d, designer feels there is a good scope for

r&D in tool design and processes

Scope of technology modernization> Always good to upgrade, but cost is more


industries



need of labour training > Yes for manufacturing processes like blowing, cutting

common health problem faced by > no but designer feels Heat during summers, not much labour

key problem faced from labour > Commitment and availability is a major issue, they also change jobs frequently even for a small elevation in salary



73market orienteD

How do you market/sale your products > unit > local trader> out station trader > costumer

Who are the major competitors > local traders and manufacturers

Competition within Ambala/rest of India > locally and outstation both



Do you feel need of inter cluster > yes but what is the method to achieve

communication understanding on that level

buSineSS orienteD

Problems like electricity, labour union, > electricity and lpg gas and off course support of govt on

raw material, space, Govt. support different levels

Margins/ profits are sufficient ?? > not always equal, in some products profits are nil


Major challenges > quality of products is a long term threat to entire industry, small players does not pay taxes hense its easy for them to sell products on very less margins, its effecting the quality drastically and ultematily no product for export

quality



. common facility centre



. Ways to improve quality

. Storage designed specifically for glassware products

. better working conditions


Redefine the workshop space and hand tools

Designopportunity


74

unit 09Industry name: Paras Instruments Conature of work: Manufacturing

Showroom cum office and workshop behind

Storage system

Finished goods holding unit

Calibration facility


75


Product range > 30-40 products

Production quality and finishes > below avarage

key problem in process > basic techniques and machinery like double chuck lathe, grinding

machine etc

visual identity and branding > Paras Instruments co, need to redesign since its an old design

packaging > has been explored enough by exporters but designer feels the need to redesign

workstation and tool design > Bad condition, urgent attention required

ergonomics and environment factor > no, but designer feels issues with space, working postures is there

Scope of new design and r&D > Scope for design is very less but r&D can play a vital role for future directions, specially reverse engineering of german products can be

use full for indian market

Scope of technology modernization> Very open scope for technology mordenization in tool making and

calibration kind of processes

Scope for production in parallel > glass manufacturing unit can be opened in india to avoid import

industries hence material cost Its difficult to work in home glassware sector due to extra manufacturing cost



need of labour training > Yes its always good to learn but course has to be industry specific

common health problem faced by > not much, but designer feels unit needs to create good environment

labour to work

key problem faced from labour > Shortage of good labours and commitment



76market orienteD

How do you market/sale your products > Unit > local traders/ manufacturers > out station > costumersWho are the major competitors > names not mentioned

Competition within Ambala/rest of India > local and out station both

product exhibition in any trade fair > In Ambala once, but not very good results

Any qualified marketing person > no, but marketing is a main problem

Do you feel need of inter cluster > cluster system possible with govt support

communication

buSineSS orienteD

Problems like electricity, labour union, > Govt support first and then electricity and lPG gas


Margins/ profits are sufficient ?? > average

Scope of infrastructure development > Yes, but its very costly only automation will cost you 4-5 cr Major challenges > quality with low price



. Improvement/ re planing the industry layout

. cfc


. layout re designing

. need specific storage systems


good scope in tool design and exploration on new materials Designopportunity


77

unit 10Industry name: Kunal Scientific Industries nature of work: Manufacturing

Workshop in a very cluttered condition

Raw material storage in a most un organized manner

Blowing section

Grinding section

Finished goods storage in same condition


78


Skilled/semi-skilled/non-skilled labour > 1 skilled, 2semi skilled

need of labour training > Ye, specially for quality production

common health problem faced by > no, but designer feels heat and smoke may be causing problems

labour

key problem faced from labour > no problems since only 3 guys running the unit



product range > 5-7 products

Production quality and finishes > Poor quality

key problem in process > basic techniques and machinery like double chuck lathe, grinding

machine etc

visual identity and branding > Kunal Scientific Industries, no idea about branding

packaging > not required since they supply only to local traders

workstation and tool design > Bad condition, urgent attention required

ergonomics and environment factor > no, but designer feels urgent attention required on working

postures

Scope of new design and r&D > no idea but designer feels role of r&D in tools and production

processes

Scope of technology modernization> no idea, but designer feels urgent need for upgradation in good machinery and hand tools

Scope for production in parallel > no clue at all, designer feels the unit should first focus on current job

industries


79market orienteD

How do you market/sale your products > Unit> local manufacturer/ trader

Who are the major competitors > no name

Competition within Ambala/rest of India > with in micro industries



Do you feel need of inter cluster > no idea, but designer feels small players can support big

communication industries on specific product range

buSineSS orienteD



Scope of infrastructure development > Yes, good machinery and tools Major challenges > cut throat competition and low price



. To improve quality

. to arrange workshop properly


. improvement in processes and tools

. quality improvement by constant focus on production


. workstation design

. layout of workshop


80

unit 11Industry name: Ad Glass Printersnature of work: Manufacturing and Printing

Screen printing posture and process in workshop

Finished product

Blowing process, tools and hand tools not up to the quality it results to bad quality product

Workshop entry and approach not convenient while shifting material


81


Speciality > Screen printing

product range > 4-5 products

Production quality and finishes > below average


visual identity and branding > aD glass printers

packaging > not required, only supply to local manufacturers

workstation and tool design > tools and hand tools needs improvement

ergonomics and environment factor > there are issues with working postures and ventilation of space

Scope of new design and r&D > no idea

Scope of technology modernization> Will be good, but don’t know the scope


industries



need of labour training > Yes, specially in screen printing


labour

key problem faced from labour > Only sometime, workshop strength only 6



82market orienteD

How do you market/sale your products > Unit > local Manufacturers/ traders


Competition within Ambala/rest of India > lot from micro scale industries

product exhibition in any trade fair > no idea


Do you feel need of inter cluster > no idea, but designer feels they can collectively make

communication more difference even they can control price of products also

buSineSS orienteD





Major challenges > low price/ margins

Available space is sufficient or not > yes


. arranging workshop on priority

. assembly line productions

. quality management


. improvements in local transportation to reduce wastage

. be cautious while using screens


. locally developed semi automatic screen design machine

. Screen storage system design

Designopportunity


83

unit 12Industry name: SR Scientific Industries nature of work: Manufacturing

Automatic blowing machine

Sky light enhances light quality inside

Storage of raw material in bad condition increases breakage


84


Speciality > Mass production of tubes/ beakers (2-3 products)

product range > 10-12 types

Production quality and finishes > Good and consistent quality in limited designs

Manual blowing quality not good

key problem in process > need automation of process of cutting etc

visual identity and branding > S R Scientific Industries, need for branding

packaging > not required, only local supply

workstation and tool design > Designer feels the machines are randomly arranged with basic

setup, urgent need for a work station

ergonomics and environment factor > there seems to be issues with working posture and safety gears

Scope of new design and r&D > If it is good for industry, but don’t know the scope

Scope of technology modernization> Automation of processes like cutting, calibration etc


industries



need of labour training > Yes for core processes like blowing, cutting to enhance their skills

common health problem faced by > no problems, designer feels there can be problems like skin burn,

labour excessive heat and eye problem

key problem faced from labour > lack of commitment, Frequent job change



85market orienteD

How do you market/sale your products > Unit > local traders/ manufacturers






Do you feel need of inter cluster > May be it will work, don’t have any idea

communication Designer feels it will contribute to collective growth

buSineSS orienteD





Major challenges > Finance and small percentage of profit

Available space is sufficient or not > yes, it might help


. Assembly line working method and benefits

. importance of light and ventilation


. Focus on Mass production of specific products

. attention to small details


. Design of more products with same machinery

. finished product container design for local transportationDesign

opportunity


86

UnIT 13Industry name: Parban scientific Glass Worksnature of work: Manufacturing

The workshop dose not have any opening for ventilation except door

Bad working conditions inside may increase health issues

Precision in job done manually


87UnIT SPeCIFIC PROBleMS, ReMedIeS And OPPORTUnITY


Speciality > Customized products

product range > 50 + products



visual identity and branding > Parban Scientific Glass Works, require branding

packaging > no need, supply locally only

workstation and tool design > old workstation designs need to redesign of workstation

ergonomics and environment factor > Issues with working postures and ventilation ,

clear scope for improvement

Scope of new design and r&D > Scope for r&D in ne processes of blowing can be done

Scope of technology modernization> no, but designer feelsGood scope in calibration, blowing and

marking etc


industries


Skilled/semi-skilled/non-skilled labour > 3 skilled

need of labour training > no need, already skilled

common health problem faced by > heat during summers, not much

labour

key problem faced from labour > no problems with labour, they are old and honest


88


. making provision for ventilation on urgent basis

. on new hand tools


. better space utilisation

. Use of latest/ better tools



. To focus on customized products

market orienteD







Do you feel need of inter cluster > no,


buSineSS orienteD

Problems like electricity, labour union, > lpg gas prices are very highraw material, space, Govt. support



Major challenges > finance and small percentage of profit



89

unit 14Industry name: Sanky Printingnature of work: Screen printing

The workshop is operational from the house

Complicated storage of screens

Storage of products in cardboard boxes may be increasing breakage


90


Speciality > Screen printing

product range > na


key problem in process > manual process, need for automation of process

visual identity and branding > Sanky Screen printings

packaging > not required, only supply to local manufacturers

workstation and tool design > workstation design for screen printing

ergonomics and environment factor > there are issues with working postures and ventilation of space

Scope of new design and r&D > no idea, designer feels it can be done for better and fast printing

Scope of technology modernization> Will be good, but don’t know the scope


industries


Skilled/semi-skilled/non-skilled labour > 2 semi skilled and 1 non skilled

need of labour training > Yes, specially in screen printing


labour

key problem faced from labour > Only sometime, workshop strength only 3



91market orienteD

How do you market/sale your products > Unit > local Manufacturers/ traders


Competition within Ambala/rest of India > lot from micro scale industries



Do you feel need of inter cluster > no idea, but designer feels they can collectively make

communication more difference even they can control price of products also

buSineSS orienteD

Problems like electricity, labour union, > electricity rates and frequent cuts effects production


Margins/ profits are sufficient ?? > very less

Scope of infrastructure development > no, but designer feels it can be enlarged to handle big

projects and automation of process Major challenges > low price/ margins



. Small techniques to avoid errors

. assembly line productions


. improvements in local transportation to reduce wastage

. Organized storage of screens


. locally developed semi automatic screen design machine

. alternative source of energy for furnace

Designopportunity


92

unit 15Industry name: Standard scientific Glass Worksnature of work: Manufacturing

Need for safety gears for workers like hand gloves

Improper storage for finished goods increases breakage and wastage

Unorganized storage like boxes, gas cylinders near to furnace can be dangerous at times


93


product range > The industry in all kind of scientific glassware general or laboratory.

Production quality and finishes > above average

key problem in process > Old manual process, Urgent need for semi automation

visual identity and branding > Standard scientific Glass Works

packaging > Few packaging design being used by entire industry, need for

redesign specifically for the category

workstation and tool design > tool design will help

ergonomics and environment factor > Issues with working postures, Clear scope for improvement

Scope of new design and r&D > It might help, need to define scope

Scope of technology modernization> automatic calibration and semi automation of different processes

Scope for production in parallel > no

industries


Skilled/semi-skilled/non-skilled labour > no information

need of labour training > definitely will improve the quality of production

common health problem faced by > no but designer feels Burns marks, eye irritation and heat problems

labour

key problem faced from labour > frequent job change and low quality production



94market orienteD

How do you market/sale your products > unit > local traders > out station traders

Who are the major competitors > no names given

Competition within Ambala/rest of India > local small industries and micro units

product exhibition in any trade fair > _


Do you feel need of inter cluster > Yes, But suggest the ways to achieve, its difficult

communication

buSineSS orienteD

Problems like electricity, labour union, > govt policies and rules enable small industries to

raw material, space, Govt. support grow

Margins/ profits are sufficient ?? > not at all


Major challenges > Govt bodies like pollution board, labour laws etc

designer feels the rules nd regulations needs to be revised



. Common facility centre and its benefit


. Skill development for labourer

. Workshop re layout for better assembly line, storage etc


. Development of tools and patterns for blowing


95

unit 16Industry name: Super lab Glass worksnature of work: Manufacturing

The workshop dose not have any opening for ventilation except door

Bad working conditions inside may increase health issues

Workstation condition are severe and needs immediate improvement

Most Unorganized storage system


96


product range > 50-100 different products

Production quality and finishes > poor

key problem in process > old processes are in practise

visual identity and branding > Super lab Glass works, need for branding


workstation and tool design > need to redesign of workstation

ergonomics and environment factor > issues with ergonomics of worker as well as working environment

inside, closed workshop and lack of ventilation

Scope of new design and r&D > don’t now

Scope of technology modernization> It will be good, not knowledge of latest technologies

Scope for production in parallel > no idea

industries



need of labour training > no, but designer feels its urgently required for the unit

common health problem faced by > no, but designer feels there will be problems with excessive heat

labour and bad atmosphere inside

key problem faced from labour > Frequent change in jobs, no commitment, unreasonable rates



97


. making provision for ventilation on urgent basis

. Requirement for new hand tools and benefit


. better space utilisation

. Use of latest/ better tools



. Focus on super specialization on certain products since setup supports only few products

market orienteD







Do you feel need of inter cluster > no,


buSineSS orienteD

Problems like electricity, labour union, > lpg gas prices are very highraw material, space, Govt. support



Major challenges > finance and small percentage of profit



98

unit 17Industry name: Aggarwal enterprises nature of work: Manufacturing

Workstation condition are severe and needs immediate improvement

Raw material is kept in open, more chances of breakage

Most Unorganized storage system


99


Speciality > Manufacturing of Botany equipment

product range > 50-100 products of general glassware


key problem in process > Old processes, need for semi automation

visual identity and branding > Aggarwal enterprises, requirement for a good branding exercise


workstation and tool design > The space in worksop not utilized well due to bad layout, hand tools

need attention

ergonomics and environment factor > issues with working postures and clear scope for improvement

Scope of new design and r&D > no idea how it can benefit

Scope of technology modernization> It will be good, automation will reduce cost and labour charges

hence good margin and finishes

Scope for production in parallel > If profits are good then can try it

industries


Skilled/semi-skilled/non-skilled labour > 2 skilled, 2 semi skilled

need of labour training > Will not mind to participate, if it benefits

common health problem faced by > no knowledge

labour

key problem faced from labour > commitment and dedication also their skills



100market orienteD

How do you market/sale your products > unit > local traders > out station traders > costumers

Who are the major competitors > no names

Competition within Ambala/rest of India > has gone up in last 10 years



Do you feel need of inter cluster > Yes, but always face a problem in equal response

communication Spl role of association needs to be more transparent

buSineSS orienteD


Margins/ profits are sufficient ?? > It has dropped in last 10 years, now some time we sell on rate or even less to retail client

Scope of infrastructure development > Yes, in machinery and tools Major challenges > wrong calibration is making an impact on end user, by showing wrong results in lab results



. for better planing of space

. alternative markets and possibilities


. reduce the wastage on each step



workstation design for blowing and cutting


101

unit 18Industry name: Jain Scientific Glass worksnature of work: Manufacturing

Well organized workstation

Out side provision for LPG and oxygen cylinders

Well organized workstationand well planned workshopsin a defined assembly process

Separate furnish room

Screen printing facility with a work station for screen selection


102





visual identity and branding > Jain Scientific Glass works, branding is good logo is well design

packaging > new packaging designs are adopted from export packaging standards, still packaging can be re designed for

various products

workstation and tool design > already separate tool design workshop, may be work can

be done on new materials

ergonomics and environment factor > Working postures needs attention, good scope for improvement

Scope of new design and r&D > R&d is required in tool development and locally made

automatic machines

Scope of technology modernization> Off course, specially in automation of processes

Scope for production in parallel > Can be tried as an pilot project

industries


Skilled/semi-skilled/non-skilled labour > no clear information

need of labour training > Yes, open to it

common health problem faced by > not any serious problem other then burn marks etc

labour

key problem faced from labour > quality of work and frequent job change



103market orienteD

How do you market/sale your products > unit > dealers local > dealers outstation > clients


Competition within Ambala/rest of India > local medium scale industries also imported glassware

product exhibition in any trade fair > in india and abroad as well

Any qualified marketing person > yes

Do you feel need of inter cluster > yes very much, all industries can grow together

communication

buSineSS orienteD

Problems like electricity, labour union, > govt support and policies not supportive and raw material, space, Govt. support energy supply like electricity and lpg gas

Margins/ profits are sufficient ?? > ok


Major challenges > finance and govt support






. light weight packaging materials instead fo wood wool


. improvement on packaging to suit export standards


. design ideas for storage of finished good


Designopportunity


104

unit 19Industry name: Jain laboratory Glassware co.nature of work: Manufacturing

Well organized workstationand well planned workshopsin a defined assembly process

Screen printing facility with a work station for screen selection

Calibration lab in a well defined space with basic facilities

Factory shed with proper natural light and ventilation

Workstation needs to be organized will, spl provision for LPG cylinder outside


105


product range > Manufactures all kind of scientific glassware general or laboratory.

Production quality and finishes > above average

key problem in process > lather for blowing and manual cutting machine, need semi

automation of processes for export quality

visual identity and branding > Jain laboratory Glassware co, branding is good logo is well design

packaging > packaging needs to be designed to target scientific glassware and aiming to reduce wastage while transportation standards, still packaging can be re

designed for various products

workstation and tool design > not very well organized, need a separate tool room

ergonomics and environment factor > working postures needs attention to reduces physical and mental stress, also safety gears to be made mandatory to wear while working

Scope of new design and r&D > R&d in developing automatic machines for calibration, marking, blowing and cutting. it will change the entire market quality and standard of production

Scope of technology modernization> Off course, specially in automation of processes

Scope for production in parallel > need to give it a thought, if works fine can be adopted industries


Skilled/semi-skilled/non-skilled labour > no clear information

need of labour training > yes will participate actively and give all possible support

common health problem faced by > not aware about it much except some burn marks etc

labour

key problem faced from labour > Skilled labour and increasing salaries are effecting production quality



106market orienteD

How do you market/sale your products > unit > Dealers local > Dealers outstation > clients


Competition within Ambala/rest of India > local micro and medium scale industries

product exhibition in any trade fair > Yes, in India


Do you feel need of inter cluster > Yes, together units can work like a big industry communication and can target big orders

buSineSS orienteD

Problems like electricity, labour union, > need of a local manufacturer of raw material raw material, space, Govt. support also electricity and lpg gas

Margins/ profits are sufficient ?? > very competitive


Major challenges > Dependency on imported machinery



. on mSme design schemes

. need for a product designer for heating and cooling equipment designs


. Re define a well organized workshop and store room

. improvement on packaging to suit export standards


. developing automatic machines for calibration, marking, blowing and cutting


Designopportunity


107Swot analySiS

strength. Ambala Cantt scientific industry is more then 60 years old and now well established in market.

. proximity to national capital and chandigarh gives more opportunities.

. well connected with rail and road network

. education level amongst unit owner is very high in some cases, se they set bench marks.

. exposure to international market

. formation of association to address concerns collectively.

. good skill set with in the industry.

Weakness.Dependency on old technologies.

. lack of r&D facility for development of tools and machinery

. Dependency on imported machinery

. Dependency on skilled labour

. Brand imag of cluster is bad due to bad quality products.

. inter cluster cut throat competition responsible for quality degradation

. lack of local manufacturer of raw material and complete dependency on china.

. lack of technical knowledge amongst workers

. micro scale industries are cutting costs due to less over heads and this trend is ultimately effecting entire cluster

. Poor quality of calibration is resulting into wrong results in labs


108

opportunities. Being the largest Scientific equipment industry, cluster has potential to lead in the category if improve quality and consistency.

.potential for locally developed machinery like calibration machine, marking and screen printing.

. finding alternative energy resources for furnace

. good scope for branding and labelling design

. Alternative/ parallel industrial products with same setup.

. Packaging design specifically for glassware industry to reduce weight and breakage of products while transportation.

. Work station designs to increase efficiency and addressing ergonomic issues.

threat. If the ignorance for quality and compromise with calibration/ volumetric marking of products continues the cluster will completely loose its reputation and as well as business.

. If the margins/ prices continue to fall many more units will shut business and quality will definitely dip.

. complete dependency on china on raw material gives it monopoly and it can be a serious danger for industry in case if china refuse to supply or increase rates.

. Being a skill based industry, lack of skilled workers can pose a serious threat to industry.

. health and ergonomically issues are being ignored completely and it can have severe effects on workers health.


109on a SeriouS note

i am constantly highlighting the issues of wrong volumetric measurement of glassware. the industry is constantly ignoring importance of calibration process, marking process and measurement printing on volumetric products. hence the products are going in market with 80-90% or more tolerance level/ accuracy level with actual measurement. once these volumetric products goes to laboratories like pathology labs etc they become responsible for wrong results because of inaccuracy in markings.

now one can understand the serious impact of a wrong medical result to a patient. here the main problem comes with insensitive attitude of manufacturer and lack of governing body to maintain standards.

the possibility of wrong marking during the following manufacturing process stages :1. manual calibration always have the chances of human error, low skilled labour, variation in room temp, fast speed of work etc 2. manual marking can be wrong due to unskilled labour or human error as well.3. Screen printing also leads to errors as most of the units makes some standard printing screens and try to use the screen most close to the making, but some time the difference in marking and screen is more, but units ignore it to save screen cost.4. variation in wall thickness of glass while blowing can also be responsible, lack of wall thickness measuring machine gives units completely ignore this aspect.

There is a urgent need for a governing body/ quality check body from govt of india to keep a check on cluster the production because it is ultimately effecting health of citizens if used in hospital labs or educating students wrong if used in school/ college labs.


110

there are different units involved in different parts of the glassware industries like manufacturing, trading and micro scale sub vendors to big industries. to address all their need and opportunities on cluster level the approach can be in phases as following:

1. Short-term interventions2. long-term interventions

these improvisations could happen at individual as well as group level. these interventions can come in various ways as schemes, awareness programs and upgrading of the set-ups itself. a phase-wise improvisation of the units will lead to better productivity and hence better results. the design clinic has a huge role to play for making these units understand the purpose and importance of such interventions.

sCope of InterVentIon &suGGestIons


111

sCope of InterVentIon &suGGestIons

Design of better storage system and storage processes

locally developed cutting machine

locally developed blowing machine, blow control machine and finding new materials for shaping tool,

locally developed calibration machine

locally developed automatic printing machine

Development of energy saving machines/ solar operated machines

innovative designs for light weight and low cost packaging

DeSign intervention on Different StageS of proDuction

Storage

cutting

blowing

calibration

printing

annealing

packaging


112IndustrIal desIGn opportunItIes


innovative design to pack different types of glassware in same pack

locally developed automatic Screen printing to avoid error and marking on outer part of glass

Workstation design, Urgent need of the industry

protection for worker excessive heat from blower

finding alternative material for grinding tool to maintain diameter in long run

. locally developed cutting machine .paddle operated glass cutting machine

glass Storage system specially designed for glass tubes and for different diameters

. locally developed Automatic / paddle flame control machineto reduce wastage

locally developed automatic calibration machine

Development of low power consumption furnace or Solar power furnace

Design of boxes to reduce breakage during transportation

SyStem DeSign packaging DeSign

alternative reSourceS

local Development machineS requireD


113sHort-term InterVentIons

TRAInInG PROGRAM: Specific skill development workshops, training camps and courses can enhance the level of workmanship of the labourers.

TOOl & eqUIPMenT: improvement in existing tools and equipment will lead to less fatigue and better product.

CROSS-IndUSTRY JOB: Since different units are specialised in different products and processes, hence there strengths can be combined to bring up products range.

AWAReneSS OF SCHeMeS: There are lot of financial schemes floated by the government which can be used by these units with proper knowledge of the same.

InFRASTRUCTURe IMPROVeMenT: there could be small improvements in the infrastructure of the unit as improving the height of workstation, proper lighting, storage solutions etc. which can result in improved productivity of the unit with lesser fatigue for the workers.

MARKeTInG: proper approach to the market will lead them to improve their product offering. it will also help them know the Dna that their product should have to compete with other products in same category.

deSIGn And BRAndInG: there could be designing of packaging to improve product status in market. it could also happen as a partial addition or improvement of an existing product.


114lonG-term InterVentIons

COMMOn FACIlITY CenTRe: Since many of the problems/requirements of these units are common, hence there could be a common facility centre to cater such needs. these centres can be well-sustained by mutual efforts from the government and the cluster itself. Such common resource centre can be developed after considering the common needs of the units.

ReSeARCH & deVelOPMenT: efforts to develop new processes, tools and strategies could result in better returns. this could happen at micro and macro level which could be supported by the units themselves.

TeCHnOlOGY UP-GRAdATIOn: phase-wise up-gradation of the technology will improve the productivity of the unit. they will also be able to reduce their dependency on less-skilled labour.

PROCeSS-AUTOMATIOn: Such advancements will lessen the mishandling of the parts while manufacturing. The quality control will be better which will result in less efforts while finishing.

DeSign clinic workShop

I. Workshop Methodology

II. schedule of Workshop

III. openIng sessIon

Iv. guest lectures

v. dIscussIon And BrAInstorMIng 01. Manufacturing Processes 02. Packaging Ideas 03. Value Addition To Existing Products 04.New Designs In Existing Product Range 05. New Opportunity In Parallel Industries

vI. desIgn opportunItIes

vII. prototypIng

vIII. conclusIon

desIGn ClInIC WorksHop


117

Discussion on current issues and initial findings

discussion on individual industry/ specific problems and remedial solutions

process by process discussion and opportunity findingprototyping initiation as proof of concept

brainstorming on new product design/ opportunity finding

brainstorming on innovative thinkingprototype displayDiscussion on way forward

Day 1

introDuction

Day 2

DetaileD DiScuSSion

dAY 3

proceSS mapping

Day 4

opportunity finDing

Day 5

innovative thinking

DeSign proJectSanD follow up

workShop methoDology

desIGn ClInIC WorksHop


118

day 1 SATURdAY 26.01.13

sCHedule of WorksHop 26 TO 30 JAnUARY


119

sCHedule of WorksHop 26 TO 30 JAnUARY day 2SUndAY 27.01.13


120

day 3MOndAY 28.01.13


121

day 4 TUeSdAY 29.01.13


122

day 5WedneSdAY 30.01.13


123opening SeSSion


124


125

WORKSHOP APPROACH:

The objective of the workshop was to share observations, discuss problems and find new opportunities collectively.

the best possible way to achieve our goal was to make the sessions more and more interactive. while it is important to highlight the problems in industry, processes, products on the same time solution also lies with in the same industry.

idea was to conduct interactive brainstorming sessions on all important touch points of the industry and try to initiate the innovative thinking process.


126gueSt lectureS

Mr. Ayush and Mr. Pravesh on creative management and entrepreneurship

Mr. Ankur Choudhary on integrated industrial development


127

Mr. Sunil Tyagi on Product Branding

Mr. Raja on Lean manufacturing and Six sigma


128

DiScuSSion anD brainStorming

Color coding for glass tube storage

Cross Staking to reduce breakage

Trolly to shift raw material

01. manufacturing processes

storage Concepts


129

Idea on calibration machine using principal of coffee vending machine

Idea on calibration machine using principal of coffee vending machine Bench press grinding process can be

adopted to bottle neck grinding for precision

Gobar gas as Alternative fuel for furnace for annealing


130

product sketches for prototyping

Cart design for Glassware workstation


131

product sketches for prototyping

Prototyping of material trolly in different stagesClockwise: Marking, Cutting pipeswelding parts, assembly.


132

Cart

Material Trolly final prototype

Trolly handle are tapered to make it ergonomically comfortable, and easy to push with heavy material.

Cutout in Wooden box to make it easy to lift

Wheels on rear position

Casters in front position to guide the trolly


13302. packaging ideas

Flexible design for template packaging can be used for different shapes

Air suspension for fragile glassware Air/ light weight material to create a layer to absorb impact during transportation


134packaging prototypes

Air/ light weight material to create a layer to absorb impact during transportation

PU foam as a filling material Internal structure to air suspend products


13503. Value additions to existing designs

Adding a silicon grip on neck of flask to hold when its hot

Make scoop cuts on cylinder neck to hold


136

Top: Same Cap design for different sizes of lab glassware

Bottom: Burette With marking

Left: Flask with additional threads to increase grip


137

Top: Reduction of thread pitch

Top right: Marking both ways

Bottom: Grip on bottle cap

Right: Horizontal designs of volumetricto reduce wastage


13804. new designs in existing range

Top: Attaching a handle for better grip

Multiple use of reagent filter bottle

Flask can be used as a water tumbler

New assemblies with improved joinery


139


14005. new opportunity in parallel industries

Top: Water filter design

Food grade heating rod in glass

Decorative ware for table top/ temples etc

Decorative ware for table top/ temples etc

Helmet in bulletproof glass

Top: decorative architectural features


141

Glass Umbrella and bucket

Decorative ware

window blinds in glass tubes

Hukka in bor osilicate glass

Glass wind chimes


142

Decorative lights Decorative lights

Products from waste

Electronics and gadgets from glass


143

a. proDuct DeSign

01. value addition to existing products02. new product designs03. Parallel industries in glassware . kitchenware . hukka industry . lighting industry . decorative ware, tableware etc

b. packaging DeSign

01. lightweight 02. cost effective for mass production03. Template to pack different shapes04. Design boxes to reduce breakage during transportation

c. workShop anD proceSSeS

1. Storage design for glass tubes2. workstation design for the following . glass blowing . tube cutting . grinding . calibration . marking . packaging 3. Mobility carts/ trollies for raw materialand finished goods4. Hand tools specifically designed glass work

Designopportunity


144

D. locally DevelopeD machinery for inDuStry

01. automatic calibration machine 02. automatic screen printing machine03. Automatic flame control burner04. test tube and culture tubing machine05. Socket printing machine06. beaker forming machine07. automatic glass welding machine08. automatic glass cutting machine09. pneumatic taper10. cover slip making machine11. automatic socket and cone forming machine12. laser wall thickness measuring machine13. True bore making machine14. automaic furnace

e. alternative reSourceS

01. Development of low power consumption furnace or solar power furnace02. finding alternative material for grinding tool to maintain diameter in long run


145

obJectivethe protoyping was done as proof of concepts to show the possibilities of different products from same setup.

DeSigndesigns were contemporary yet simple to make in 3 days time, also from different categories like trolly, kitchenware etc.

materialSborocilicate glass main raw material of the industry and available in local workshops.

prototypInG


146

prototype DiSplay on Day 5


147


148PROdUCT PROTOTYPe: KITCHenWARe

Range of kitchenware items

Oil dispenser Oil lamp


149PROdUCT PROTOTYPe: KITCHenWARe

Sugar dispenser

Water Bottle Spice Bottle

Milk glass for kids


150

Team NID Team NID Team NID

Team Glassware Team Glassware Future Generation

Team PHD


151

I am really amazed to see the strength of the Ambala Cantt scientific industry, its not only a heritage industrial town but also a exceptional production hub with more then 1200 units.

I would like to conclude saying that there are definite challenges on their way and going to increase in the coming years.

But the industry must realize their strength and key to success for them is advancement in technology, skill up-gradation and most importantly honesty in product quality the industry has a very bright future.

Team Glassware Team Glassware

Team PHDTeam ASIMA Team ASIMA


152

annexureS

checkliSt


153

photo creDitS

front cover photographS kulveer Singh bhati

proDuct photographSPage 17-22 Adams & Chhetendens Scientific glassware

naS photographSpage 06-16Page 23-104 Kulveer Singh Bhati

workShop photographSPage 105-151 Ankur Choudhary, Sunil Tyagi and kulveer Singh Bhati

back cover photographS kulveer Singh bhati

bibliography

webSiteS01. www.citymediaambala.com02. en.wikipedia.or03. www.grotal.com04. www.adamschittenden.com05. www.borosil.com

DocumentS01. aSima documents02. jasdan03. Thangarh Cluster04. Blue pottery, Jaipur

design awareness program report scientific …designclinicsmsme.org/design awareness programme...

Documents