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Need Assessment Survey and

Design Clinic Worshop

Raghudevpur Rubber Products Raghudevpur Gram PanchayatTaluka - Ulluberia Dist- Howrah, West Bengal

NAS & Report prepared by Jitendra Singh Rajput

Raghudevpur Rubber Moulding Cluster

Design Awareness Programme Report

I would like to thank and acknowleged efforts of Raghudevpur rubber cluster members for their whole hearted support to initiate the process, the months long activities at various levels and par-ticipation in concluding workshop. With out their dedication and commitment the benefits for such programmes and govt schemes would remain lost in a priece of paper.

NID- Design Clinic Sceme members’ continuous effort and personalized touch in each and every activity has made the whole job much simpler to achieve the desired objectives. East zone members, Sudev and Ashok Mondal have been a constant support in conducting the NAS and Design awa-rensess programm. Sudev’s personal interaction and explaination of design awareness programme had a long lasting prints in the mind of the members which has been visible during the whole pro-gramme. Ashok’s initiative with West Bengal government has made design clinic scheme reach to the remotest industrial clusters in the state, which is clearly evident in the rubber cluster as well.

Professor Somnath Ganguli’s emense knowledge and experitece of MSME and grass rute industrial situation along with diverse knowledge of industrial ergonomics has made one of the memorable and remarkable session on ergonomics in my learning. I’ll always be greatful for his effort and commit-ment toward the teaching, training and upliftment of Micro and small sector of industry.

I would like to thank Prof Shashank Mehta for his continuous guidance since my education years back then in NID to my associaton with Design clnic scheme. His confidence for me to take up various such activites has helped in evolving colloborative design thinking philosophy.

I humbaly acknowledge the efforts of Ministry of MSME Government of India and National Institute of Design for their fore sighted initiative for development of MSME sector. Design awarness has no meaing in the map of countires industrial scenario without the MSME units and sector’s ag-gressive participation in design activites.

Acknowledgement

With an objective of design awareness and design intervention for manufacturing competitiveness of MSME sector in India, ministry of MSME, Government of India and National institute of design has came up with design clinic scheme under the national manufacturing competitiveness programme(NMCP) in its 11th 5 year plan.

Design has been accepted worldwide as a strategic tool to align the business objectives of SMEs and dedicated focus has been put by European countries, Japan, USA and now China to upgrade their SMEs, catering to 85-95% of industrial sector across the globe. In India design awareness lacks due to its reach and application in MSME sector and has been perceived as mare a facial up liftment task. The areas addressed by design in such industrial sector are not only products, but process, inventory, logistics, packaging, communication, user interfaces, marketing etc. Design works as strategic element in collaboration with other business func-tions. Design clinic scheme addresses the MSME issues related to assimilation of design in their day to day activities and provide technical and financial assistance to meet the objective.

The scheme has been divided in 3 broader activities for easier accessibility, understanding and adaptation by MSMEs.1. DESIGN AWARENESS SEMINAR ( 1 day seminar ) – budget Rs. 60,000/- (fully support by the scheme)

2. DESIGN CLINIC Programme Budget 4,00,000/- Need Assessment Survey (5-8 Days) Design clinic Workshop (2-5 days ) 75% contribution by design clinc scheme 25% contribution by MSME Association/Govt Agency

3. Professional Design Project (individual/group of units) Budget Rs. 15,00,000/- to 25,00,000/-60% contribution by design clinic scheme 40% contribution by MSME Association/Govt

1. Introduction

Design Clinic Scheme

Design clinic workshop is the combination of presentation and workshop sessions based on interactive design study and need assessment survey. Design clinic workshop will create a platform where participants will be able to generate the holistic perspective for business scenario with the help of design expert/s guidance. The expert/s will also help the participants in identifying opportunity areas in their respective units and cluster with the help of interactive design study insights. The expert/s will also help in providing on the spot design solutions to problems taken up by participants from their respective backgrounds of product, process, communication and design strategy. In design clinic workshop, design expert/s will diagnose a solution for an existing design problem / opportunity and suggest on the spot remedial steps, during the workshop. The workshop will be organized in the area chosen by the organizers keeping in mind the convenience to participants and organizers.

Objective of DAP• Detailedreportonissuesandopportunityareasintheclusterandunits.• Identificationofclusterbasedissuesandopportunityareas.• Discussionofopportunityareaswithmembersandgovt.representativesas identified from interactive design research for design and other activities.• Workshoptounderstanddesignandbestdesignpracticespresentations.• Onthespotremedialsolutiontothedesignproblemstakenupbythe participants.

2. Design Awareness Programme (Need Assessment Survey and Design Clinic Workshop)

India is the fourth largest producer of natural rubber next to Thailand,Indonesia & Malaysia, second largest consumer of natural rubber next to China, fourth larg-est consumer of all rubber next to China, USA & Japan.

Indian rubber industry is divided in two major segments –

1. Tyre 2. Rest of the products.

Tyre industry’s total turnover is 25,000 crore and rest of the product have 17,000 crore turnover in the country. Total export is approx. 6,800 Rs. crore where other product contribution is approx. 3,150 crores.

Employment Generated - 4,75,000.

Total No. of Rubber product mfg. units in India - 4327

No. of Tyre Factories - 51Large/Medium Units - 501No of SSI/ Tiny Units - 3775

3. Rubber products and Industries in India:

Tyre Industry

Industrial product

Medical Products

Consumer product

1%

12%

87%

Rubber Industries in India

Tyre Factories

Large/Medium Units

Micro/Small Units

Other Industry

Industry level issuesNo differentiation and recognitions for industrial rubber products. No industry/academic body addressing issues related to technical, raw material, R&D, market, exports etc. issues. No dedicated industrial policies at central and state levels.

Raghudevpur is a Village in Uluberia-II Tehsil, Howrah District , West Bengal State . The village is situated approx 30 km from Howrah city on National Highway 6 and is located close to the Railway station Bauria at 4 Km distance. The nearest bus stop is Pan-chala Village.

As per 2001 census, Uluberia II block had a total population of 1,61,833, out of which 83,662 were males and 78,171 were females with a ratio of 1000:934. Uluberia II block reg-istered a population growth of 1.92 per cent during the 1991-2001 decade.

As per 2001 census, Uluberia II block had a total literacy of 68.60 per cent for the 6+ age group. While male literacy was 76.28 per cent female literacy was 60.38 per cent. Howrah district had a total literacy of 77.01 per cent, male literacy being 83.22 per cent and fe-male literacy being 70.11 per cent.

Schools near by Raghudevpur1 . BELKULAI C.K.A.C. VIDYAPITH 2 . UTTAR PIRPUR SUBHASBRATI PRY S

4.1 Raghudevpur Tehsil/Mandal - Uluberia-IIDistrict - Howrah, West Bengal

100% Sanitation target - Raghudevpur Panchayat has achieved 95% Sanitation facility at individual houses. Most of the households have basic sanitation facili-ties and toilets. Irrespective of existing road and accessibility issues the streets of villages are clean and filth free. Panchayat is aiming to achieve 100% mark by the end of current

Howrah District

Raghudevpur

West Bengal

financial year which shows the commitment and determination from the society and ad-ministration to achieve cleaner and healthier environment. .

4.2 History and Present status of rubber industriesin Raghudevpur cluster

History

The history of rubber industries establishment goes back to the pre- independence era when rubber product were required from domestic sources for heavy engineering industrial and locomotive manufacturing and maintenance.

The postindependence industrial structure grew stronger with more people starting to join the manufacturing business of rubber parts.

Due to the railway engine manufacturing and maintenance work, steel and heavy industries, power plants etc. the rubber industries in Raghudevpur slowly became the hub of rubber parts manufacturing in the country.

Presently the majority of manufacturers produce industrial rubber products like O’ring, oil seal, gaskets, washers, bellows, water valves, etc.. Apart from rubber products some of the manufacturers

produce plastic products which consists of industrial sealants, spacers, bushes etc. Some of the manufacturers also make consumer products like rubber bait, etc.

At present, there are more than 275 rubber manufacturing units working in Raghudevpur cluster. These units employ more than 3,025 people with cumulative turn over of Rs. 1,679 million as per the records of DIC Howrah.

List of villages under Raghudevpur rubber cluster

Raghudevpur Basudevpur Ghosalchak ShibramchakSantoshpur BalarampotaParamanandrachak

4.3 Products manufactured by Raghudevpur Rubber product Man-ufacturers

Bonded Seal,

Oil Seal,

Packing,

Chevron

O Ring,

Bush,

Cluster is known for the Industrial Rubber Components

Raghudevpur industries are famous for their range of products in the Industrial Segment.

The are supplying products to heavy industrial operation like hydraulics, pneumatics and bearings. The products are consumed by Railways, Power Plants, Water supply systems along with automotive, hydraulic machines etc.

The cluster has years old technique of product manufacturing which involves huge amount of human effort and traditional heating and moulding technology.

Issues with existing product range : 1. Majority of the products belong to the heavy engineering/automotive / industrial segment. 2. Competition with similar specification, mass produced, fully automatic-manufacturing processes made products. 3. Lack of innovation in the products, manufacturing process, materials, packaging etc. make the market more price and quality sensitive and create extensive pressure on sustenance of cluster units. 4. Lack of diversification from existing industrial products.

Diaphragms, V-Ring, V-Seal,

Bucket, Washer,

Quad Ring, Pads & Sheet,

Mats and Rubberised Cork Sheet.


Expansion Joints,

Air Release valves

Bellows,


Consumer products like sling, fishing bait etc.

Rubber manufacturing units in Raghudevpur are mostly very small setup with less then 10 employees in a unit on an average. Majority of them are established in household or in a small and dedicated manufacturing workplace. There are many manufacturers who

have inherited the business from their previous generations and have no other options but to remain in same business. Some of the manufacturers are those who have worked in the similar product manufacturing and have started the manufacturing as an entrepreneur. The major population of workforce is from cluster villages who have experience of decades and preferred to remain as work force, contributing to the need of rubber products manufacturing.

There is a very unique model of entrepreneurship visible in raghudevpur rubber products manufacturing. The relation between employer and employees is very much cordial and friendly. there is a huge sense of responsibility visible in most of the unit owners, providing livelihood to the workforce in their organizations. On an average each unit owner is providing financial assurance to more than 10 families or we may say 50 people at very nominal profit margins.

5. Structure of MSMEs in RMC :

Issues in existing scenario -Lack of growth opportunities for existing manufacturers.Increasing cost of labour, raw materials.Shrinking markets and profit margins.Majority of new generation entrepreneurs not interested in joining rubber business.

6.1 Market

Issue Faced by Manufacturers in terms of markets.

Not selling directly to OEMs. Lack of product quality. Lack of infrastructure and funds to meet OEM demand. No access to OEMs.Unorganised market place and dependence on agents.Lack of exposure to international markets.Lack of product quality, standardisation and consistency.Unpredictable profit margins

Rubber product manufactured from Raghudevpur are sold in following type of markets

1. OEMs - genuine products 2. Genuine products in open market3. Spurious products open market

The products are sold through following channels 1. Direct to OEMs2. To agents locally or spread across the country3. In retail through selected shops.

Types of product markets for manufacturers:

Common products - like oil seal, gaskets, etc. manufactured by majority of manufacturers- Highly competitive and low profit margin. Specialized products - complex products where manufacturer is specialized in manufacturing the products - Less competition.

Order based products - which are made as per the specification of customer and has no competition.

Tier 01 - Non Standard Parts in Retail

Tier 02 - Low cost parts for original

part replacement

Tier 03 - Supplying to OEM as Genuine Parts

Tier 04 - Specialized Parts -No competition manufacturers

6.2 Competition The industrial rubber product market is getting extremely competitive day by day. Change in market scenario and increased competition is happening. The broader reasons of competition are as per following:

New manufacturers.Higher product quality Standards.Advanced Technology. Improved raw materials. Open market place for international products.

There are three levels of competition faced by the cluster manufacturers

1. Local Products having common manufacturing process, processing similar raw materials, having similar amount of investments. This causes loss of profit margin, existing/prospective customer and market share.

2. Domestic products from other regions performing similar or advanced manufacturing process, posing great challenge due to priceand product quality competitiveness.

3. International products using advanced research and development capability for material and manufacturing process creating challenge for labour oriented, old technology-driven product manufacturers. Heavy automation, mass production and better product quality causing multiple damage to the existing market of Raghudevpeur industries.

CompetitionFactors and dominance levels Local

International

Domestic

Manufacturing Process

Clients

Material

Price

reginal market

Mass production

Automation

R&D and Technology advancement

7. Process of rubber product manufacturing

Raw Mateiral

Rubber milling

Prodcut Finishing

Rubber Moulding

Packaging and Distribution

Natural rubber and Chemical additives Procured from Local market

Semi processed rubber sheets made up of natural rubber and addetives

Pruchased in quantity as per ongoing orders

High pressure manual rubber mouldingLocally made MS moulds assembled for each piece

Coal/Electical heating process for rubber melting inside the mould Neatral colling and structure formation for rubber

Mould Flash removal using blades/sharpened tools

Poly Packaged for small orders in seperate sizes and combinationsCorrogate box pack for bulk ordersDispatched through couriers/surface transport

Raw material availability - In rubber cluster the natural rubber and various additives are pro-cured by the individual manufacturers from Howrah and Kolkata markets. The purchase is done as per the orders and future de-mands at the units and expected production plan.

Issues with raw material purchase For majority of units the purchase quantity of raw materials is small and doesn’t provide the bargain opportunity on each purchase.Fluctuating market prices- In general the price of rubber is con-trolled as commodity in domestic and international market. Ref 2. In retail the raw material market is dominated by few of traders in the region who control the market price. In comparison to international rubber price the domestic price of raw material has seen a drastic fluctuation which concerns the local manufacturers. In last 3 years the price of rubber raw material in local market has increased ex-ponentially for rubber manufacturers in comparison to the price of finished products. (Chart price rise). 3 years back the price of rubber used to be Rs. 90 Per kg which is currently at Rs 350 per kg. Manu-facturers are also forced to purchase the raw material in bulk quan-tity which causes unnecessary burden of inventory and compound-ing losses due to the damage.

8.1 Raw materials- 1. Natural rubber and additives

a. Nitrile Butadiene Rubber (NBR) b. Hydrogenated Nitrile Butadiene Rubber (HNBR)2. Semi processed rubber sheets.

Pricing and profit margin imbalance MSME in rubber industries are severally affected by factors like

raw material prices, production and market dynamics. The typical money flow cycle in SMEs is as per following...

Product purchase order is based on earlier negotiated prices which is highly competitive and rarely changes as per the raw material price. In contrast price of raw material depends on existing market supply and demand in regional market majorly dominated by the suppliers and de-cided irrespective of international prices. Small manufacturers are forced to purchase the raw materials at the price decided by the local suppliers due to absence of any controlling factor in the region.

Storage of Raw materials - There has been a common issue with stor-age of raw materials. There has been a prominent need of raw material storage system which requires- 1. Designated place for storage of various rubbers and chemicals. 2. Stock/Inventory status system for understanding the exiting/future requirements. 3. Raw material (specially chemicals) details on the container/box for easy identification and selection.

8.1 Raw material

Effect of Price Fluctuation

1. Affecting the profit margins2. Causing Uncertainty and unpredictably3. Loss of competitive advantage in the market

Rubber mixing machine ensures perfect and uniform blending of natu-ral and synthetic rubber with other raw materials. These machines mix all the raw materials to the desired specifications. The process of rubber mixing is carried out between two contrary rotated rotors. The wicks of both the rotors are parallel and have different tangential speed. The dis-tance between rotor surface is controlled by rotor regulator. Due to the difference in tangential speed and nip constriction, rubber compound will experience displacement and pressure energy during rubber mix-ing. Pressure energy will enlarge displacement energy, and displacement energy will break the rubber molecule bonding. The breakage of rubber molecules allow carbon and other chemicals to be mixed with rubber.

Semi-processed rubber sheets are manufactured by some of the MSME units who produce raw material for others and self consumption. Most of the small manufacturers are dependent on outsourced raw material processing and purchase the semi processed rubber sheet from local manufacturers. The life span of processed rubber is very less and need to consumed within few days times as per the composition of compound.

8.2 Rubber milling Mixing of Natural rubber and additives in the rotating mill at a very high pressure.

8.3 Possible Opportunity areas in the Raw materials

Raw Material

Cluster based Rubber Material bank -

Rubber material research cell

Record of existing materialDeveloping new materialsProtecting through IPRColloboration with R&D Centres

9.0 Rubber Moulding

Process

1. Mould opening

2. Raw material cutting and filling

3. Mould closure and Placement

4. Pressurizing and Heating

5. Moulded product extraction.

One of the type of coal based Manual Moulding Press

9.1 Process of rubber moulding - Experience and expertise of Rahudevpur cluster plays a vital role in sustenance of the industrial structure but gradual shift from manual to semi-automatic process definitely the call of moment to sustenance and growth of the industry.

9.0 Rubber Moulding

Coal based plate heating - Indirect heating

Direct coal based heating

All the manufacturers in Raghudevpur cluster are using manual moulding machines. These machines are locally made machines which highly relyies on manual operations . The moulding process have 3 major components of moulding -

1. Heating 2. Pressing 3. Rubber Moulds

1. Heating operation - 1.1. Coal Based heating - Coal heating is a conventional rubber moulding process which was employed during the early era of industrial process. the method is very old and conventional, requires the heating to be done under the moulds. There are two ways of mould heating using coal-1. Direct heating - coal is burnt under the mould support plates. 2. Indirect heating - Iron plates are heated separately and placed under the moulds for rubber heating.

1.2 Electrical Heating - the range of temperature requirement is between 180-240 Degree Centigrade for rubber product moulding. The electrical heating helps in maintaining the exact temperature for moulding operation with the help of sophisticated controls and mechanisms.

Raghudevpur cluster manufacturers are using the locally made electrical machines for moulding operations.

Electrical heating

Fully Electrical powered moulding machine

Leaver based Press

9.0 Rubber Moulding

2. Manual press with Electric heating

3. Hydraulic press Electrical heating

9.2. Moulding Press

Press is an essential part of moulding operation. Specified amount of pressure decides the shape, dentistry of rubber, molecular structure, desired properties, finish etc of product. The press operation is achieved by manual operations or machines in the moulding process. the tyeps of press used in rubber manufacturing in the cluster are as per following..

9.2.1. Manual press-Press operation for moulding is done

by manually pressing the mould. There are three major methods of pressurising the moulds.

i. Leaver based press. ii. Screw based press.iii. Manual hydraulic press

9.2.2. Electrical operated hydraulic press Few manufacturers are using hydraulic press with electrical heating system. This has a provision of manual placement of mould under the machine and rubber filling is done automatic by the hydraulic pressure.

1. Manual press with coal base moulding

Screw Jack Press

Hydraulic Press

9.3 Rubber moulding industries across the World -

Rubber moulding process across the world is majorly dependent on automatic moulding machines. These machines perform the mixing, heating and pressurising and moulding jobs in one machine. the machines are computer numerical controlled (CNC) machines which can handle the multiple cavity moulds and performs the higher productivity and quality operations. The fully automatic moulding machines are very costly but precise in operations.

None of the manufacturer has fully automatic moulding machines in the cluster. These machines pose great challenges to Raghudevpur industries in terms of mass productions and quality consistency but absolutely do not fit the model of Raghudevpur cluster which is mostly labour oriented and based on human intervention.

Fully automatic rubber injection moulding

9.0 Rubber Moulding

Meerut is one of the very similar cluster depends mostly on manual moulding process.

The reasons behind the nonexistence of automatic moulding machines in Raghudevpur cluster - • Higher Investment in terms of machine and Moulds• Lack of infrastructure • Lack of demand in terms of mass production • Customized products • Low volume demand • Lack of demand for high precision work• Exposure to sophisticated markets (in some products) Issues arising due to manual moulding process• Low volume production • Lack of automation • Dependency on trained man power • Poor quality and finish• Higher cost of production per piece• Heavy competition • Longer time to market cycle• Higher rate of rejection • Loss of opportunity in the international markets

9.0 Rubber Moulding

9.4 Moulds

Made up of Mild Steel plates/thick bars, machined in lathe. `The grove/cavity for rubber moulding made as per the specification. Majority of moulds are 2 piece cavities made for linear assembly method and joined by nut and bolts. Some of the moulds are placed under the press without fixing the mould plates with bolts and joining fixtures.

Core and Cavity

9.5 Mould tooling -

Machined Moulds- Majority of moulded rubber products are circular in shape. The moulds are manufactured using the lathe and milling operations. Most of the manufacturers are having lathe machines for making and modifying the moulds.

Fabricated moulds - are large size rubber products moulds which are made using the fabrication process with sheets and other product. Welding and machining of steel sheets, blocks and bars are mainly involved in the mould making process.

9.0 Rubber Moulding

be designed instead of “pre-filled and closed” moulds. Pre-filling process also causes defect formation due to trapped air or over density raw material formation.

4. Excessive flash formation-

Flash formation happens due to the gaps between the joining pieces of mould. Due to the high pressure and temperature, heated raw material flows inside the minute gaps and causes the excessive flash formation.

Flash formation also happens due to the excess material filled inside the cavity which flows out from the gaps and forms the flash.

Solution Possibility of flash free mould design.

Internationally the design of mould has helped tremendously for producing flash free moulded rubber products.

9.6 Issues with existing moulding system -

1. Multi Cavity Moulds-Majority of moulds are single product moulds making only one production in each cycle of moulding. In comparison, the best practices manufacturing processes involve production of multiple pieces in one operations. Possibility of multi-piece mould for higher production.

2. Assembly process of mould is time consuming and less productive. Bolt assembly method for small mould could be optimised for faster process.

Fit and go method could be designed for smaller moulds.

3. Material filling process for moulds is very long and based on approximation. The amount of material consumed is fixed for standard size of product in mass production and material cutting could be organized in the order. Pressurized material filling process could

There is a need of technical support on mould designs. Tool Rooms from Ministry of MSME could be collaborated to workout the mould design process meeting the cluster requirements. There may be possibility of joint R&D activity with tool rooms and cluster members to explore new designs of moulds, meeting manufacturers’ requirement.

Multi Cavity Mould

Rubber Flash

9.0 Rubber Moulding 9.6 Issues with existing moulding System-continued..

5. Environmental issues like air quality in the workplace, dust, heat and safety issues, etc. arises due to the coal burning.Coal based system’s accuracy is very low in terms of control over temperature.

External combustion process using Coal could be derived with the help of experts. This may provide more accuracy and control over the temperature. The method may work like a electrical heating system at a cheaper fuel cost and may not require major infra structural changes.

7. Manual press operation requires lot of human effort and space. Manual press operation need to be standardized from moulding pressure point of view. For better product quality and meeting specification, it need to be ascertained -

i. Amount of pressure required. ii. Pressure conversation ratio of machines.iii. Know the amount of human effort required to apply the pressure.

Heating unit(boiler)

Coal furnace

Moulding unit

External Coal Heating System

6. Product quality issues are higher in coal based heating. 3. Gradual shift towards the higher level manufacturing processes which may be in following orders..

1. Coal based heating to electrical heating 2. Human powered press to hydraulic press. 3. Manual systems to semiautomatic and fully automatic manufacturing process.

This may reduce the dependence on labour oriented work.Provide better quality products.More control over mass production.

10. Finishing of rubber productMoulding process at a very high pressure causes flash generation at the parting edge of products. Flash is excess rubber on a molded product. It results from cavity overflow and is common to most molding operations. Flash has two dimensions – extension and thickness. The flash needed to be removed after the end of moulding process. The finish is required to meet the quality parameters and product performance.

The flash removal process for all the rubber products is major part of product operations. It causes 10-20 of time consumption in prod-uct manufacturing and contributes for rejection of 2-5% of materi-als in the process.

The process of flash removal is done manually in majority of the rubber industries. The operation is done using the cutting tools, where raghudevpur industries are rellying mostly on sharpened metals and razor blades. Rubber flash

10. Finishing of rubber product

Issues with existing finishing process -

1. Flash removal a laborious job. 2. No automation available so far.3. Flash formation nonuniform in nature. 4. Excessive wastage of material5. Safety and ergonomic issues.

Possible areas of design intervention.

1. Better tooling design to minimize flash forming.2. Semi automation for flash cutting - designing of new machines which could reduce the labour dependence for flash removal. (Shot blasting machines are used in some cases for removal of flash)3. Use of proper cutting tools instead of razor blade and home made cutters 4. Development of new machines/technology with the help of Institutions. (Flash removing machine, Chryogenics flash removal process

Common deflashing methods include manual tear trimming, cryogenic processing, tumbling, and precision grinding.

11. Packaging and dispatch MSME units in Raghudevpur manufacture variety of products. For delivery of orders the finished rubber products are classified as per the specification and engineering pa-rameters. The packages are made according to following parameters.

1. Type of products.2. Order groups/combinations.3. Retails/Bulk batches. 4. Location and distances.5. Customers requirements.

In bulk quantity the single spec product are packed large quantity in polyethylene packs and corrugate sheets boxes. The bulk order rubber products also contains the product details on the top of the packaging and also contains the details on order/delivery forms. In case of multiple products or set of prod-ucts the listed products are grouped as per the desired order and packed in one poly-ethylene packs and the complete order in packed in box for final dispatch.

Logistics :Locally - Hand carried. Out of station - Couriers/Surface transports.

12. Wastes in manufacturing ProcessAreas identified during the Design Clinic workshop

Wastage Activities which doesn’t help in generating value in the manufacturing process are termed as waste. These elements need to be kept as minimum as possible. The best practice to reduce the waste in the systems is to first identify and define them and later derive the ways to reduce them to the minimum possible.

There are many levels of waste identified during the NAS and design clinic workshop involving the members of cluster in the detailed design research process.

The major areas of waste observed are Human effort, Materials , Semi and finished products, Machines, Market and competition etc.

One of the losses and wastage identification activity taken place during the workshop for rubber products. The amount of loss goes higher when it occurs at the higher level of product manu-facturing process. Also it is found that the loss carry forwarded from the initial stages amplify the damage if not sorted out at the stage of occurrence. Loss of Rubber material at various stages of production

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Status of infrastructure in Raghudevpur industries is very basic in nature. It matched closely with an rural infrastruc-ture instead of an industrial estate. The majority of units operating from domestic structures getting facilities for the standard of domestic living and do not get the infrastruc-ture required for the industrial operations. The requirements of rubber industries are different than other home based industries and deficiency causing huge losses in terms of product quality, position and profit mar-gins.

The major Infrastructure facilities required at the cluster level are as per following

1. Electrical Supply issue 2. Road infrastructure Issue 3. Lab, testing and certification 4. Common facilities - Training, Special purpose job work like mould making (CNC, special purpose machines), product display and exhibition, Packaging and logistics, etc.

13. Infrastructure - Status and Issues

The requirement of electricity is very much important to run the MSME units in any of the industrial setup similar to the Raghudevpur rubber industries. The rub-ber product manufacturing requires electrical opera-tions in following areas.

• Preparationofrawmaterial(15-20KVA)(approx10% manufacturers own the facility)

• Heatingandfurnaceoperations.• Runningofmachining/toolroomfunctions

(lathe, grinders, etc.)• Lighting,officeandworkplace

functions (Lighting, air circulation, etc.)

In existing scenario majority of units are purchas-ing the finished raw material from various local units who provide the raw sheet for product manufactur-ing. Some of the units who have higher raw material requirements are forced to procure it from local units becausetheydonothavesufficientelectricitysupplyfor processing raw material. The existing problem of short supply for electricity restricting may units to ex-pend in fullest of their capacity due to the basic power availability issue.

Even though the coal operated systems are almost equally costlier, electrical operations are preferred by allmembersduetoreasonslikequality,space,efficien-cy, control etc

13.1 Infrastructure- Electricity.

Availability of electricity in the majority of units and its demand.

Existing Supply of Electricity - 05 KVARequirement of Electricity - 20 KVA

Transformer Requested - 200 KVA Transformer Installed - 65 KVA

Urgent Govt Intervention required for getting Electrical supply

The electricity provides the control over the manufacturing process. This makes the product betterand competitive in the market. It helps improve the productivity due to more sophisticated and simplermanufacturing process.Many units are ready to upgrade to the modern technologies but lacks due to short electrical supply.There is a Heavy investment done by many MSME unit for electrical based manufacturing operationsand parked huge amount of money expecting a quality output from new setups. There has been noconnection of electricity for some units for last 3 years and are helplessly awaiting to get theelectricity connection to start the operation.

Electrical issue causing loss of motivation for investment and growth in the cluster.

13.1 Infrastructure- Electricity.

Coal based heating - There are many manufacturers (approximately 60%; based on discussion with members) are using coal based furnace for rubber heating and melting for final product processing. Majority of manufacturers are using coal based heating process duetounavailabilityofsufficientelectricity.Thecoalheatingiscumbersomeandtimeconsumingprocess.Italsoaffectsthequalityofproducts,efficiencyandproductivityofsystemresultinginunhealthyenvironmentalconditions. Despiteofhighwillingnesstoupgrade due to the lack of power availability at various unit locations many manufacturers are not in a position to upgrade to electrical heating systems.

Loss of quality due to coal based heating - Quality of product gets affected due to coal heating system. Usually in the process coal is burnt to heat up the iron plates which are placed with the dies for rubber moulding. Due to the conventional heating process at varying room temperature, the temperature of heated plates and the rubber raw material varies drastically causing different temperature zones and results in poor quality of rubber properties.

Loss of control over the temperature due to the coal based heating. In case of various type of raw materials the exact tempera-ture could not be achieved using coal heating where electrical furnaces provide the temperature accuracy of 1 degrees making the raw material process and finished goods quality very high.

Pollution and unhygienic environment due to coal burning. This causes clutter and uneasiness at workplace due to the smoke and coal dust in the environment. The temperature of work place is found to be more than the electrically operated moulding units. The other factors like cleanliness, space utilization, safety and fire hazard, etc. also arise due to the use of coal furnaces.

Coal related investment/storage/damage issues - Availability, purchase and storage of coal has to be done in advance and re-quires additional space and money in to be parked, which in case of electricity based operations is just opposite.

13.1 Infrastructure- Electricity and Issues arising due to coal based operations

Poor Roads connectivity with units - Majority of units are con-nected with only the walkway paths made years back for villag-ers’commute.Manyunitsfindtransportdifficultusingroadsasit is not suitable for even 3 wheelers to reach the unit. The road condition have been improved in last few years after laying-off of clay bricks but has eased only pedestrians and still do not support vehicular commuting. Better road would not only increase the accessibility for raw materials and finished good but will also help improving the images of manufacturing units when their existing and prospective customers visit the manu-facturing setup.

13.2 Infrastructure- Roads & Access to Unit

The nature of raw material and manufacturing process of rubber components creates range of properties for finished products. At times the values goes beyond the specification even though the standard procedure has been followed during manufacturing.

With the known properties of finished products, it makes manu-facturer more confident in the market place and provides as-surance of getting the product accepted. In some cases manu-facturers face loss of produce and investment due to rejection of complete lot because the raw material and product outcome specifications were not checked at the time of manufacturing and could not be corrected if anything was going incorrect at the time of manufacturing.

Having a laboratory facility at local place will not only reduce the burden of producing in approximation and assumption but will also boost the confidence to approach more tougher markets and customers in the national and international markets. The confi-dence will also bring more acceptances to newer challenges.

Having a lab facility at individual level of units is not possible at the present scenario. There is a possibility that a joint facility could be developed by the cluster which will facilitate the testing and inspection on the minimal payment criteria. The facility could be maintained by the joint committee / association members and may be part of special purpose vehicle mechanism of Ministry of MSME Govt of India.

13.3 Infrastructure- Lab and testing facility at Raghudevpur

Small Enterprises Cluster Development Programme(MSE-CDP)

Upto Rs 10 lakh per cluster for “soft activities” i.e. capacity building activities in the cluster where no fixed asset is acquiredUpto Rs. 10 Crore per cluster for Hard intervention i.e. CFC formation. GOI contribution for CFC varies from 30% to 80% depending on the nature of CFC and category of the units.

Benefits of common lab and testing facility

•Surety of raw material properties before manufacturing operation.

•Saving in terms of raw materials and production process.

•Reduction in rejection of finished good and orders due to improper material composition.

•Possibility of developing more advanced and competitive raw materials.

•Availability of certification for structured markets. •Competitive edge over the existing approximation

approach.

14 Status of Communication : Visuals

Visual communication at MSME level plays a very vital role in crea-tion of right image about the manufacturers.

Communication is conveyance of ideas and information in forms that can be read or looked upon.

Broadly two levels of visual communication works in MSME units:

1. Internal communication - Manufacturing process chartsMaterial and product InventoryBills, Challan and ReceiptsSafety Instructions

2. Outside communication - Catalogue, Brochure Product images, MSME Units Visual Identity, Logo, branding, promotional materials, catalogue, brochure, visit-ing cards, web site, exhibition materials, Packaging materials

In all the cases there in a need to give emphasis to manufacturers’ identity or brand logo on the product or on the cover of packaging. Most of the communication materials and symbols are designed as very basic and elementary type of medium and require a justified approach for visual identity and communication.

Product Catalogue

Visiting Cards

Safety Instructions

Process flow diagram

14 Status of Communication : Website

Websites are emerging as a strong platform for manufacturers and traders to interact with customers. With the emergence of online business the presence of manufacturers on webspace has gone many fold in last 5 years.

Web presence to provide information about product, business and customers is one of the easier ways to connect with prospective customers. It makes the job easier in terms of logistics of information sharing to your customers and prospective buyers.

Logistics of Information providing on web:• Easiest way to put information online • No need to send and distribute

brochure/visiting cards• Instant and complete information

available at any time • Some times helps in connecting direct

with customers and avoids middle man. • No other option otherwise to reach to a

person willing to buy your product. • Fast, easy and cost effective solution.

1.2 millionmanufacturers registerd

with Indiamart

Only in Indiamart6.5 million customer access information

for products

Own/trade Website a good platform for manufacutrers

Manufacturers can create own page on trade website - No need to have own website

More than 50% units have registerd with trade websites..But majority of them have very less information

about products, images, contacts details etc.

On an average only 1units from Howrah is found out of 20 in a pagewhen serched for rubber products like O’ring, Oilseal etc. in india

Most of the units are from Gujarat, Delhi, Tamilnadu etc.Majority of them are traders may be buying products from Raghudevpur

Only 4-5% units have their own website or page on trade portal

Ragh

udev

pur

15. Training and Skill up-gradation

Training is a continuous up-gradation process for human skills. The training activities helps in identification of possible areas of improvement and provides guidance on ways to develop. The training activities also helps in exchange of information and best practices which ultimately creates an environment of learning system.

There has been a lack of dedicated training activities for the owners and workforce of rubber industries in the cluster. The areas identified for training and skill up gradation for betterment of manufacturers and products of the cluster are as following:

1. Quality training Kaizen and 5 S training programme TQM training Lean Manufacturing etc.

2. Raw material and Rubber technology related training 3. Technology up gradation guidance. 4. IPR 5. Rubber industries best practices exposure and visits

Role of Cluster Association for Training programmes

Cluster representative association has shown constant interest on organizing various training programmes to benefit the members.

Cluster association has shown keen interest on conducting various activities like lean manufacturing, IPR, etc. schemes from Ministry of MSME Govt of India.

Many unit members have shown their interest to visit various rubber product clusters to understand the best practices in the industry.

Manufacturers of rubber product in Raghudevpur have decid-ed to form the cluster association in the name of Raghudevpur Rubber Industries Association (RRIA). The association will work as representative body of cluster members and will deal with daytodayissuesofmembersatvariouslevels.Issuesdifficultto deal with by MSME units due to the infrastructure, invest-ment, maintenance or convenience could be provided at the common facility centre. Member of association will be able to use the facility on minimum cost basis and will be able to im-prove the manufacturing output. The objective of this facility is to help members at no profit model.

The facilities could be covered under the association

1. Representation at levels where individual units could not voice out like Govt. policies and benefits2. Organizing awareness and interactive activities for ben-efits of members.3. Training and skill up-gradation activities4. Infrastructure for tool room, testing and inspection lab, certification centre etc. 5. Raw material bank to tackle the prices and availability issues.

16. Status of Cluster Association

Rubber board – body looking after the cultiva-tion and processing of rubber The Rubber Board is a statutory body constituted by the Government of India, under the Rubber Act 1947, for the overall development of the rub-ber industry in the country.

17. Rubber Industries bodies

All India Rubber Industries Association (AIRIA) The All India Rubber Industries Association (AIRIA) is not for profit making body serving the rubber industry and trade with the objectives of safeguarding and promoting interests of the industry.

The International Rubber Study Group (IRSG) is an inter-governmental organisation composed of rubber producing and consuming stakehold-ers. Located in Singapore, IRSG was established in 1944.In order to facilitate the interaction between the industry and the Group, a Panel of Associates with members of organisations involved in the rubber industry has been established.As of 1st June 2012, IRSG currently has 35 mem-ber countries and 120 industry members.

There has been a reorganization for rubber product cluster in Raghudevpur from Govt. of West Bengal, Directorate of Indus-tries. The initial survey of cluster is carried out by DIC Howrah earlier and has been listed as on of the prominent industrial cluster in the District of Howrah. Still manufacturers require much more support and facilities from state and Central Govt agencies. Formation of cluster as-sociation, support for creation of SPV and CFC for making the crucial facilities available to smallest manufacturer, training, education, and exposure to best practices etc. could be possi-ble through this initiative.

Financial Services, like loans for facility up-gradation, expan-sion, meeting higher orders etc. need more attention and transparency for convenience of manufacturers. During the interactionmanypeoplerevelledthecomplicationanddifficul-ties faced for taking such benefits which deters the progress of individuals and all.

18. Role of Government to Support Rubber Product Manufacturers

Awareness about new schemes, benefits, and procedure to avail must be provided through progressive agencies so that needy can come and discuss the possibilities of such initiatives. Very recent and impressive approach by design clinic scheme could be one of the way to connect with such members.

Infrastructures facilities like electricity, roads, etc. are major factors affecting the growth of Raghudevpur rubber industries. Lack of electrical supply has caused the issues like quality, slow production, scalability etc.

Road connectivity to the units causes inconvenience for con-nectivity to the rest of the world. Material transportation, man movement, visitors access etc are issues which arises due to the irregular connectivity.

19. SWOT Analysis

S – Strength

Low investment infrastructure.Oldest Industrial rubber cluster in the country Great Possibility of Process improvement. Years long experience of rubber productsAvailbility of trained man power.

W- Weaknesses

Raw material cost variation and availability.Exposure to export market.Lack of technology knowledge and collaborationLack of R&D activity Lower margins and higher competitionInfrastructure and Accessibility to unitsLack of automation and modernisationLack of govt support to promote the clusterLack of coordination btn units

T- Threats

Automation based rubber prodcuts.High volume production facilitiesNew and upgraded technology Other materials as a replacement to rubberIncreasing Labour costNew generations not interested in rubber business

S WO T

20. List of MSME units for Need Assessment Survey

Objective of Unit based Need Assessment Survey -The objective of unit based need assessment survey is to understand the need of individual units where design awareness programme is organized. The survey in a broader terms is a systems study to understand the inter-relation of various factors of any cluster which directly or indirectly affects the cluster and its units to perform at its fullest possible capabilities. In this approach the issues not related to units and not identified at there levels some times arise which could be handled at the cluster levels to solve the individual issues.

It is extremely difficult to reach to each unitin the cluster to understand the needs of any cluster therefore it has been worked out in a sample manner based on discussion with association/ representatives.Selection of certain number of units has an objective to generate information about the cluster based on some sample units who could in a broader terms represent the nature of products, processes, technology, market, competition, human factors, environment, policies, etc. of the cluster and its members.

Sr. Factory Name Owner Name Village

1 Essar Rubber Muddasar Ali Ghosalchak

2Purbasa Rubber Industries Amiruzzaman

MollickBalarampota

3 Amtone Rubber Industries Mosiar Laskar Raghudevpur(East)

4 Magnet Rubber Works . Mannan Laskar Raghudevpur (East)

5 Elate India Kazi Amirul Islam Raghudevpur (East)

6 Sitara Rubber Works Tojammel Laskar Raghudevpur (East)

7 Marshal Rubber Tech Sk Gulsan Ali Shibramchak

8 K B Rubber industries Sk Salam Ghosalchak

9 Rubber Tech India Sk Surat Ali · Ghosalchak

10 Pelican Rubber Industries Bina Roy Chowdhury Basudevpur

11 Ganga Rubber Moulded Nirod Banerjee Raghdevpur(East)

12 Winner Rubber S.K. Afsar GhosalChak

13 Eagle Rubber A.Rahman Shibramchak

14 SSR Rubber S Alom Raghudevpur

15 A.H. Rubber trading Jaharuddin Raghudevpur

16 Four Star Rubber company Parmanandchak

17 Russian Rubber Works Santu Kaji Balarampota

18 Asian Rubber Moulding Company M. Rahman Shibramchak

Unit 1 Pelican Rubber Industries Estd: 1962

Contact Person: Mr. B Banarjee

Address of Factory: Basudevpur Near Banda Rly Station (S E.Ry.)Bekuiai Howrah 711322

City/Trading Office26. Strand Road, Kolkata - 700001, Ph.:(033) 2231 5278 Telefax :(033) 2230 0213

Email address: [email protected] : palicanrubberindusitries.com

Trade portals and other web presence. -Yes

Registration status : DIC and NSIC

Certification:ISO 9001 - 2008

Employee Strength: 15-20 employees

Infrastructure set up: Electrical Heating - Manual rubber moulding press, Manual plastic moulding machines for Nylon, PVC etc materials. Lathe and other machines for moulds Product finishing and packaging setup

Market and Competition :

Sales and Distribution mode :

Trade portals and other web presence. - Listing with Trade portals- India Mart, Yel-low pages, Kolkata with detailed description.

Unit 1 Pelican Rubber Industries Product Manufactured: Specialist in : Seal Kit, Valve, Bucket, ‘0 Rings, Oil Seal, Washers, Strips etc

Polymer, Viz, Rubber, Neoprene, Nylon, PVC, Rubber Sheet, Cork Sheet. Tefflon Won. Ebonite BakeliteHylam Polyurethane & Leather Goods.

Bellows,

Diaphragms,

Oil Seal,

Packing,

O Ring,

Bucket, Washer,

Unit 1 Pelican rubber Work Environment : Pelican Rubber has one of the good infrastructure in terms of electrical machines, hydraulic and manual presses and better connectivity in the area. It poses the opportunity for improvement in the areas of internal setupandworkingconditionsforbetterproductivityandefficiency.

Areas of potential improvements. 1. Organized working space for movement and operations- could be improved following Japanese techniques of 5S. 2. Improvement in lightign may help improve productivity and precision. 3. Manual operations require more space than semi/automatic system. 4. Cleaner space around the machines would help improve safety and productive operation 5. Flatter and smoother floor could make safer and smoother movement of man, material and machines.

Hanging objects may be obstruction

Additional Space reqd. for manual operation

Unit 1 Pelican rubber Work Environment 1. Lighting - Light placement in work place improves the ef-ficiency of work.Less amount of natural/ Artificial lighting.Possibility of better placement of Lighting bulbs/Tubes.

2. New facility is well organized, same model could be incorporated in the old facility with time. 3. Organizing the work flow could result in higher efficiencyfortheunit.4. Ergonomic conditions for sitting and operation, movement and safety from machines, parts, process, etc. 5. Raw material cutting standards could be created to save time and material for standard products.

Appropriate Lighting for improving visibility

Appropriate Lighting for improving visibility

Raw Sheet cut and inserted in moulds

Mould Storage Moulds are stored as per the product size, seg-ment and frequency of use.

The MSME unit has got more than 250 different types of moulds.

Issues with mould storage:1. Standard procedure of storage and catagoriza-tion is not existing. 2. Identification is based on the sample attached 3. No record of available moulds (in most of the units_ 4.Selectionofdesiredmouldisverydifficultatthe time of urgency.5. Scattered mould occupying more space.

Possible solutions- 1. Identification system with dedicated training could be done.2. Space arrangement could be improved and vertical space could be used 3. Bar coding/number coding could be devel-oped to keep the record and identify the mould4. Procedural scrapping of mould could be planned for unused ones.

Bar Code system for mould identification

Unit 1 Pelican rubber

Product attached to mould for identification

Moulds stacked one above other for future

requirments

Storage - Raw Material storage

Storage of raw material could be better arranged.According to Type of raw materials, like - Natural Rubber, Various Additives and chemicals, Processed Rubber sheets and finally

Present Need - Designated storage space for materials

Benefits - Identification of raw material, selection of lot, quantity and inven-tory will be managed easily.


Natural rubber lump purchased from market

Processed Rubber for moulding

Natural rubber lump purchased from market

Process - Product finishing.

Removal of rubber flash from moulded rubber components. The flash forma-tion is non standard and uneven due to the joining gaps between the moulds.Manual operation involving high man-power.Tools like sharpened knife, razor blade etc used for finishing process In some cases (o-ring etc) cylindrical grinding stone is used

Issues with existing systemHighly lobour oriented jobtime consuming less precise and prone to defectspoor quality results

Possible solutions Semi automation could be explored keep-ing the need and limitations of existing units.Mould design may be worked out with the help of technical experts.Special tools may be designed catering to large volume products.


Grinding wheel used for flash removal

Flash in moulded product

Blade used for manual Flash removing

Communication:

Visual Communication

MSME unit identity - Helps in creating con-nections and association to Owner/s, Em-ployees, Customers and Competitors.

The unit may plan for creating logo and brand Identity. The same could be used in product catalog, brochures, letter head and visiting card

Language of communication - Dose not match with other materials Brochure/Letter heads/Visiting Card/Website presence could be designed in single visual language.

Web presence- The website content is not presenting the real work and image of the unit. More realistic image will help in attract-ing inquiries and business.

Possibility of more informative and user cen-tric website.


Website

Visiting card

Product Catalogue

Lack of common language among communication

materials

Unit 1 Pelican rubber Other areas of possible improvement -

Product Diversification - Present range for products at Pelican are seal Kit, Valve, Bucket, ‘0 Rings, Oil Seal, Washers, etc, which are mostly entry level very common products in the cluster..

Training and Skill up-gradation : Urgent need for train-ing for quality management, 5S, Lean manufacturing practices etc. along with employee skill upgradation.

R&D activities - Need for in-house R&D work for process innovation, standardization, cost reduction, wastage elimination etc.

Technology Upgradation/Modernization -

Packaging, Logistics and Distribution -

Market and competition related interventions - New means of product sale, promotions, e-presence, etc.

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9 10

8 10

5 10

7 10

7 10

Unit 2 Winner rubber industriesContact Person: Mr. S. Afsar

Address of Factory: Ghoshal chack, P.O. BalkhulaiDist. Howrah (W.B)

Mobile : 9830185442Email address: [email protected] : NoOther Web Presence - No

Registration status : DIC

Certification:ISO-9001-2008NSIC - participating in government supply

Employee Strength- 8-10 Person

Infrastructure set up- Rubber milling -Not availableRubber moulding - Hydraulic + Electrical Heating

Product Manufactured: All kind of rubber, ebonite, Bakelite and plastic material Seal kit, Valve, bucket, O'Ring, oil seal, washer, strips, etc.

Production Process: Raw material and Milling - Out sourced, Milling has been done from other units and raw material sheets are procured as per the requirement. Moulding- electrical heating and hydraulic machines are used for pressing the rubber material.

Bucket, Washer,

Oil Seal,

O Ring,

Bush,

Unit 2 Winner rubber industries

Workplace arrangement and Possible benefits. 1. 5S approach for better work and space management may be adopted 2. Sorting/ separating methods & stand-ardization may be adopted.3. Waste recycling or other creative value addition may be explored for better utili-zation in some other areas. 4. Possibility of better arrangement of workplace would help better human and machineefficiencyandmayimprovingproductivity.

Waste from Machining

Lathe machine workplace

Finished products

Unit 2 Winner rubber industriesStorage of Moulds

Each unit supplies various types of rubber components. the size and shapes of parts are as per the standard specifications and there fore need to be made through various types of moulds.

Once the products are manufactured the moulds remain unusable till the time next or-ders come for the new batch of production .To keep the mould available for future batch of production, all manufacturers keep the moulds in the store area so that they could be easily taken for the production.

The identification of mould - The rubber com-ponent manufactured using the mould is at-tached through the string for future reference.

Issues with mould storage:1. No standardization of mould storage.2. Identification is based on the sample at-tached .3. No record of available moulds.4.Selectionofdesiredmouldisverydifficult.5. Scattered mould occupying more space.

Possible solutions- Identification system and categorization could be done.Special training could be arranged for such technique.Space arrangement could be improved and vertical space could be used. Bar coding/number coding could be developed to identify the mould.Procedural scrapping of mould could be planned for unused ones.

Unorganized mould storage

Identification through part sample

Difficulttolocatethedesired mould

Unit 2 Winner rubber industriesStorage of finished products for stock

Existing status -Standardization for product storage Identification is based on the specification written. Products are stored as per the production schedule and desired quantity is taken as per the order.

Issue and solution- Stock and inventory details are not known from the boxes. Before the orders it need to be checked for available stock and produc-tion is planned.More sophisticated identification approach may be adopted for easy retrieval. Inventory details could be connected and maintained on computer for easy access.

Packaging-Packaging is done as per the order re-quirement

1. Packaged in bulk if same type of prod-ucts are ordered. 2. Sorting and grouping is done for com-bination of products. Packaged in single pack for one group.

Opportunities Possibility of Branding and company promotion- having the Manufacturer’s Symbol in the package.

Unique packaging solution instead of regular poly pack method.

Product sorting and identification sys-tem may be adopted to avoid mistakes in counting and making batches.


Packaging covers

Unsorted finished products

Product lot for dispatch

Communication:


Internal Communication

Possibility of following communications in the unit area. 1. Product Drawings 2. Process charts of manufacturing3. Safety Instructions .4. Equipment information, Machine details and maintenance History log.5. Order/Schedule/Dispatch/etc. information sheet.6. Organisational Structure Chart.

Out Side / Commercial Communication

MSME unit Visual Identity - Helps in creating connections and association to Owner/s, Employees, Customers and Com-petitors.

Communication Language - Brochure/Letter heads/Visiting Card/Website presence could to in single visual language.

Web presence- No web page available in any of the portal. Possibility of creating a page on own website(may not be required for all the Units) but atleast on Trade Sites like - India mart, YELLOW Page, GetIT etc.

The web page (trade site) could have basic information in fol-lowing order. About the UNIT Products Manufactured IMAGES of products. Contact Details for information/Order

Packaging Materials

Raghudevpur Howra

h W

inner Rubber Brand Identity possibility

Wimbledon Logo to create visual perception

Other areas of possible improvement -

Packaging, Logistics and Distribution -

Product Diversification -

Market and competition related interventions -

R&D activities -

Training and Skill up-gradation

Technology Up-gradation/Modernization -

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Unit 3 Essar Rubber Works Estd:1978

Employee Strength: 10 Skilled employees

Turnover : 1 CroreInfrastructure set up: Milling machine for rubber mixing Electrical Heating Manual rubber moulding press, Hydraulic Press Manual and ElectricalTreatment chamber and Testing facility

Market and Competition : Suppliers to OEMs in Indian Market. Essar rubber has developed some techniques of treatment post moulding process which improves the quality of rubber product. Domestic market and tough competition from China

Sales and Distribution mode : Direct to OEMs Transportation by Road and Air.

Web presence : No dedicated web presence available which could explain the products and business of Essar Rubber. The information on web-site like trade portals could help in improvement in business if provided as per the requirement of customers.

Contact Person: Mr. Muddasar Ali

(President - Raghudevpur Rubber Cluster)Address of Factory: Ghosal Chowk, P.O. Belkulai, Bauria Howrah - 711310, W.B. (India)

Contact : 90073 31300Email address: [email protected] : No .

Registration status : DIC, MSME and NSIC Certification:ISO 9001 - 2008Trade portals and other web presence. - No

Product Manufactured:

Oil Seal, Packing,

O Ring, Bucket, Washer,

Unit 3 Essar Rubber Works

Supplier to OEMsSpecialized product manu-facturing and processing system. Emphasis on R&D for high quality product.

Mixing Facility

1. Possibility of better lighting natural/artificial for easy and comfortable work environment. Incandescent lamps may be replaced with tube lights. More amount of light could be introduced.Wall finish and maintenance may im-prove the workplace condition, resulting inimprovementinworkefficiencyandhealthier environment.

2 Better air circulation needed keeping in mind the nature of rubber mixing and chemical processes involved.

3. Raw material selection and mixing could be made more standardized and simpler to avoid errors in calculations.


Unit 3 Essar Rubber Works Moulding machines

1. Existing machines are electrically oper-ated heating systems 2. Pressure press is operated by hydraulic machines

Possible areas of interventions - Mod-ern machines with more automation and sophisticated operations may be intro-duced.

Having in house testing facility and dedi-cated R&D activity is one of the advantage over the others in the cluster.

More exposure to best practices in simi-lar industries could help in expansion of business.

Urgent need for management training Possibility of collaboration with advanced institutions for exploring futuristic op-tions for better materials .

Unit 3 Essar Rubber Works Moulds and Machining Facility :

Moulds are crucial part of rubber product manufacturing and responsible for quality, finish, productivity, etc factors.

Major issues identified during the NAS across the cluster caused by moulds are -Mismatch between cavities, deformation of moulds due to high pressure, uneven parting line causing excessive flash, assembly, disassembly and cleaning time, etc.

Opportunity for new approach in mould making -

Selection of new materials for better mould life. Centralized facility for mould machining reducing the excessive burden of having individual machining facility. Innovative assembly process to reduce time and effort of assembling, errors and defects.


Lab testing facility - Essar Rubber Works has a dedicated lab and testing facility for raw material and finished product inspection.

R&D - Continuous R&D effort is taken by the owners to identify the new areas of product quality and process improvement.

Possible areas of improvement in R&D-

Efforts could be taken in the area of diversification through new range of products. Exploring new markets and clients through innovative marketing techniques like online presence, identifying new customers, collaboration, etc.

Very few units in the cluster have dedicated testing (limited) facility - Urgent need for common testing facility for cluster members ..Dedicated R&D investment and activity would be helpful in diversification

Product finishing related issues.

Issues with existing system-Manual finishing process causing lots of labour cost and consumption of time. Possibility of erros and rejection of mate-rial is very high.

Dependency on traditional process of finihhisng.


Product finishing - Possible solutions.

Adaptation of new methods of finishing of final products.

Local innovation of new techniques for better and fast finish.

Standardization of tools, processes and moulding techniques for better finishing of products.

Product Sorting and Counting

Issues in Existing system -

The present approach of counting of bulk number of finished products in manual and based on individual piece counting.

In some cases products are packaged in groups of similar natures of products which requires grouping of different specifications of products. This causes heavy consumption of time and possibil-ity of errors.

Possible solution -

Adaptation of sorting and counting tech-niques.Designing systems and machines for spe-cific job works. Simplification of work process to avoid certain steps of counting/sorting of mate-rials.


Visual identity and Communication:

VisuaL identity of Essar Rubber Works lacks in the areas of creating distinction through its logo, packaging labelling, in-ternal and outside communication mate-rials.

There is a huge amount of scope in creat-ing visual identity materials for the MSME unit.

1. Logo of enterprise - Creates an image of manufacturer.Best features of the company like quality, reliability, business relation, trust etc. gets established through the logo. Helps in connecting with customers and prospective customers. Logos creates a long lasting impression and recall as compared to name of the company. Creates uniqueness among the similar and other product manufacturers.

Unit 3 Essar Rubber Works 2. communication areas Internal communication like process charts, safety instructions, letter heads, envelops, bills and service manuals, etc. creates a deeper association among the internal systems of MSME units. It creates association and attachment with unit for employees and customers.similar type of identity helps in creating the same associaton in out side comuni-cations as well through brochure, website, user manuals, part catalog, service books etc.

3. long term benefits of good commu-nication system. A good visual communication system helps in establishing the image of a com-pany in a long term basis.Present and future.

Logo could be prominent and unique to the nature of product

Space for name of contact person could be well utilised

colour combinations of brochure, visiting cards, letter heads, packaging could be made common ...

website, trade portal, blog pages could help in getting more product/company information...single liner punch could be

utilized to explain the product domain..

HRD Policies -

Essar Rubber is one of the few units which keeps an interest in welfare and develop-ment of its employees.

In MSME sector it is very much important for employer to retain their employees, who have in depth knowledge of work-manship and skills. A loss of single em-ployee for any manufacturing unit some times becomes a loss of business. There has been a special attention on em-ployee facilities, welfare and development in Essar Rubber which included the long term benefits as well as day to day facil-ity during the working hours inside the premises of the unit.


Unit 4 Eagle Rubber Products Contact Person: Mr. A. RahamanEstd: 1980 Address of Factory: Vill. - Sibram Chowk, P.0.-Panchla, Dist - Howrah-711310 (W.B.)

City/Trading Office36, Starand Road (4th Floor, Room No. 35A), Kolkata - 700 001

Contact Number : 9330950322Email address: [email protected]@gmail.comeWebsite : www.eaglerubber.in

Registration status : SSI and NSIC


Trade portals and other web presence. - Yes


Turnover : NA Infrastructure set up: Electrical and Coal Heating. Manual rubber moulding process with high precision and rubber patch moulding ( Radial tyre type layering).Manual and hydraulic Press.Testing facility for joints with high pressure water testing.

Market : Water supply systems, Railways, Power Plants and other heavy Industries

Competition : International products like , Mass produced sophisticated mould products, Steel expension joints

Sales and Distribution mode : Through Govt . Tenders and Agents.

Unit 4 Eagle Rubber Products

Product Manufactured: Automotive Rubber Bellows.Expansion Joint.Rubber Expansion Joints.Assembly Expansion Joint.Fabric Expansion Joint.Metal Expansion Joint.Double Arch rubber Expansion Joints.Electrical Rubber Mat.Rubber Diaphragms.Rubber Gaskets.Rubber Grommet.Rubber Mounting.Rubber O-Rings.

Challenges to the MSME unit..Highly specialized products. Highly trained workforce requirement.Dependent on manual work.Low productivity due to lack of automation. Heavy competition from high quality imported products.

Tough competition from automation based products from China, Germany, etc. for bellows, compression joints etc. highly specialized Industrial products.


Manufacturing Process of expansion valve -Rubber layers are applied on fabric Fabric sheet are cut in various sizes and applied on mould for strengthening purpose.Rubber sheets are applied in between the fab-ric rolls. Moulding cavities are assembled and put un-der the stated pressure and heat. Moulds are dismantled and product is taken out.

Issues faced :Raw material availability - Rubberised Fabric Sheet (no manufacturer in Howrah)Time consuming manufacturing process.Lack of automation at various stages.Cumbersome assembly/disassembly process.

Possible areas of intervention Standardization of rubber sheet cutting.Semi automation for repeated and simpler processes.Innovative Assembly methods could be de-signed for less time consuming processes.

Slow mould assembly and preparation

Highly human oriented process - Time consuming

Raw material cutting and mould setting process`


Work space arrangement opportunities :

1. More organized workshops with dedicated workstationwouldhelpinimprovingefficiencyof workplace.2. Better arrangement for raw materials, in pro-cess products and finished products will help in bringing more clarity at workplace.3. Space arrangement according to flow of work could be done

Urgent need for 5S for workspace arrangemetn


Lab testing facility -

Eagle rubber products has a own lab facility for testing of rubber raw material and finished products.

In-house water pressure testing for expansion joints ensures meeting industry standards for products made by Eagle rubber products.

Possible Area of improvement Designated Testing area could be developed (instead of the existing workplace) to have a clutter free testing process and safety in case of high pressure tests.Simplified and safer operations possible through organized space and equipment.

Unit 5 Magnet Rubber Works Estd:

Contact Person: Mr. M. Laskar (Proprietor)

Address of Factory: Village and Post Raghudevpur,Dist. Howrah, West Bengal

City/Trading Office: Room No 33,4th Floor,36, Strand Road, Kolkata - 700 001

Contact Number : Email address: [email protected] : NARegistration status : SSI Registration

Employee Strength: employees: 8-10Turnover : Product manufactured: Manufacturer of float valve rubber moulded balls of various sizes and density, used in various types of valves like air release valves, stop valves, etc. Other products are - Rubber & ebonite coating wooden ball, rub-ber gasket, EPDM rubber channel, channel rubber for gate as per AWWA standard, rubber bellow, disbending join.

Infrastructure set up: Wood machining facility for making wooden balls.Coal based heating system, Manual press .

Market and Competition : Supplier to majority of water dis-tribution Govt and private agencies.

Sales and Distribution mode : Through participation in Govt tenders and Govt suppliers. Direct supplying to float valve manufacturing Companies and Western and northern India.

Trade portals and other web presence. - Yes - Trade india - India Mart - Getit.in

Unit 5 Magnet Rubber Works

Magnet rubber is manufacturer of rubber and vulcanite coated wooden Balls of different sizes as suite to different air Valve of various sizes. Manufacturer of different oil seal, O''Ring,Rubber Bellows, Expansion Jointing, Rubber Channel of AIWA Standard Gate. Tamper Proof Steel Ball for Tamper Proof Valve,Rubber Gasket, etc.

Air Release valves


Process of manufacturing wooden balls.1. Wood selection and turning.2. Rubber sheet application on wooden ball.3. Mould setting. 4. Heating and pressurizing.5. Finishing of rubber coated ball.

Issues faced in Manufacturing of wooden Balls.1. Dependence on Jungle Wood .2. Lengthy process of wood cutting and turning .3. Competition from emerging Stainless Steel and Plastic Balls. 4. Heating and pressurizing.5. Finishing of rubber coated ball.


Process of moulding of Rubber moulded Balls.1. Mould preparation.2. Rubber layering.3. Mould setting and Pressing.4. Coal Heating.

Issues and opportunities in Process

1. Rubber sheet cutting standardization. 2. Calculation of amount of rubber material utilized in each mould.3. Switching from Coal based operation with Electrical heating systems.


Finishing Process Removal of extra rubber and flash Surface finishing with filing tools. Semi-automation of finishing may be explored

Packaging Packaging in foam sheet envelope.Stacked in bulk stocks as per the requirement. Packaged products dosnt carry the manufacurers name or logo.

Possibility of product branding through packaging.

Finished rubber ball

Manual finishing process

Packaged final product

Unit 6 Raghudevpur Purbasa Rubber Industries Estd:

Contact Person: Mr. M.A. Mollick

Address of Factory: HeadOffice:Raghudevpur(E),Uluberia, Howrah-711322 (W.B.

Contact Number : 9432287539Email address: [email protected] Website : pRegistration status : DIC and NSIC



Turnover : 40-50 LakhInfrastructure set up: Own mixing mill setup. Electrical heating and manual pressing system.

Unique product - Cork mixed rubber sheets manu-facturer.Product used in electrical transformer for insulation. Supplying to majority of State electricity boards, electrical distribution PSUs and private companies.

Market and Competition : Very few competitors, dependency on imported cork material causing loss of margin.

Sales and Distribution mode :Govt tenders, direct supply to transformer manufac-turers and service companies.

Trade portals and other web presence. - Yes.

Unit 6 Purbasa Rubber Industries :

Material Storage :

1. Opportunity for better material storage in existing space. 2. Arrangement could be done as per classification of products. 3. Status of inventory could be better managed if organized storage procedure could be developed.4. Loss due to damage of material at storage could be reduced with the help of better management.


Liquid Chemicals stored in containers - Dedicated space could be specified considering the loss and safety from the material spillage.

Additives, agents and other materials, cork granules, chemicals etc. can be stored in one place.


Rubber milling and mixing

Selection of materials for mixing with rubber is crucial to decide the property of finished product.

Material measurement standardization, charts, measuring instruments, scales could be designed as per the requirement in day to day life.

Unit 7 Raghudevpur Amtone Rubber Industries Estd:Contact Person: Mr. M Laskar, Masum Laskar

Address of Factory: Work&Regd.Office,Vill & P.O. Raghudevpur (East), Howrah 711322.

Branch Office : 35, Upper Mohalla P. 0. Raipur Dehradun 248008 (Uttarakhand).

Contact Number : 9836750245Email address: [email protected]@gmail.com

Website : NA

Registration status : DIC and NSIC.

Certification:


Turnover Infrastructure set up: Electrical Heating - Manual rubber moulding press, Manual plastic moulding machines for Nylon, PVC etc materials. Lathe and other machines for moulds Product finishing and packaging setup.


Sales and Distribution mode :Specialized rubber, bacalite and other plastic products. Supplier part to Indian Army for various products.

Trade portals and other web presence. - Govt Tenders and direct supply.

Unit 7 Raghudevpur Amtone Rubber Industries Products manufactured:Amtone Rubber Industries is one of the very few product manufacturers who are listed supplier to Indian Army.There products are small components used in a wide range product applications.

Some of the parts are - 1. Binocular parts,2. Battle tank movement control lever cover,3. Rifle barrel top cover.

1. Binocular parts 1. Binocular parts

2. Battle tank movement control lever cover

3. Binocular cover

Unit 7 Raghudevpur Amtone Rubber Industries Opportunity for Process related interventions-

1. Electrical heating system for better control over the manufacturing process. 2. Simpler assembly methods to avoid mismatch and errors in assembly process. 3. Higher productivity through small change in fit and go type mould assemblies.4. Design of proper tools for operations like mould opening, cleaning and recharging etc.

Additional work of removal of residuals

Mould cleaning after disassembly

Coal heated machines and moulds

Unit 7 Raghudevpur Amtone Rubber Industries

Standardization of Manufacturing process.There are possibilities of standardization of processes in manufacturing area like rubber moulding.

Standardization of Raw material measurement.Assembly process of moulds.Cleaning of flash from finished products.

Balance type weighing scale is being used to measure the quantity of raw material- Scoop of equivalent mass could reduce the time and human error.

Unit 7 Raghudevpur Amtone Rubber Industries

Workplace Arrangement, orderliness of work space could be improved. Space management of different materials could be developed to improvetheefficiencyofwork.

Mould Storage system could be developed to reduce the space consumed in the units, quick selection of mould, etc.

Mould Storage

Unit 8 Marshal Rubber Tech (India)Contact Person: Mr.

Address of Factory: Marshal Rubber Tech (India) Works & Office: - Shibramchak, Panchla, Howrah-7 I 1322.

Contact : 9432235201Email address: [email protected] : - No.

Registration status : DIC

Certification:


Sales and Distribution mode :

Trade portals and other web presence. -

Employee Strength: 14 employees

Turnover Infrastructure set up: Coal based heating for moulding, Electrical heating for small products,Manual press .

Issues at Infrastructure Levels-

Product Manufactured: Various type of ‘O’ Ring, Oil Seal, Bucket, Seal kit. Make by-Viton, Silicon, EPDM, NBR, Neoprine, Butyle etc Specialist in: - Various type of Seal Kits, CB hose.

Oil Seal,

Packing,

O Ring,

Bucket, Washer,

Unit 8 Marshal Rubber Tech (India)

Expansion JointBellow

Work Environment

1. Dedicated workstations and proper arrangement of sitting and working plat-forms at machines at a primary level. 2. Work places are well lit through natural light in the day time. 3. Air circulation (natural/forced) designed properly.

Unit 8 Marshal Rubber Tech (India)Issues In the work environment

1. Coal based heating causing poor air quality and health hazard.2. More precise workplaces could be designedforhigherefficiencyandpro-ductivity like arrangement for keeping the raw materials, job work and finished product.

Storage : Possible solutions

1. Separate raw material, Finished goods storage space need to designed. 2. Inventory and stock data could be maintained for easier access and planning. 3. Vertical storage systems for different types of material can save space and time to access.


Mould Storage and Identification

Issues with existing system1. Large number of ongoing, previous moulds are stored. 2. Proper identification of moulds is not in place. 3. Status/inventory of moulds in stock is not maintained.4. Huge amount of space is occupied due to the moulds.

Possible solutions 1. Cluster level effort need to be taken to understand the issue of mould storage.2. Dedicated system need to developed for management of moulds.


Unit 9&10 Four Star Rubber Ind. &Russian Rubber works Contact Person: Mr.

Address of Factory: Vill.•Paramanandachowk,Santospur (S.E. Rly Bauria Station) Howrah•711310(W.B.)

Contact Number : 9830138047Email address:NARegistration status : DIC and NSIC Certification: ISO 9001 - 2008.

Employee Strength: 4-6 employeesInfrastructure set up: Coal Heating - Manual rubber moulding press, Manual plastic moulding machines for Nylon, PVC etc materials.

Contact Person: Mr. Mr. Santu Kazi, Aftar Kazi

Address of Factory: Vill Balarampota, P.O. PanchlaDist. : Howrah, Pin - 711322 (W.B)

Contact Number : 9331698651Email address: [email protected] status : DIC and NSIC Certification: NA

Employee Strength: 4-5 employeesInfrastructure set up: Coal Heating - Manual rubber moulding press, Manual plastic moulding machines for different natural rubber.

Unit 9&10 Four Star Rubber Ind. &Russian Rubber works

Products ManufacturedBellows, Packing, Orings, Oil Seals, packing, washers, diaphragms bellows Ebonite Bakelite, & Asbestos Gaskets OIL-Seals., ‘0’ Ring Hydraulic Seals Kits etc.


Oil Seal,

Packing,

O Ring,

Bucket, Washer,

Packing,

Unit 9&10 Four Star Rubber Ind. &Russian Rubber works Unit 9&10 Four Star Rubber Ind. &Russian Rubber works Work place ergonomics - Possible areas of intervention

1. Environmental conditions improvement - Coal heating causes air pollution, unhealthy environment, dust, smoke and untidy work space. 2. Comfortable and convenient workstations - better sitting arrangement and posture. 3. Appropriate lighting using natural and electrical lighting systems. amount of light required, distance etc. could be evaluated based on the nature of work.

Sitting posture may affecttheefficiency

Coal heating affecting the work environment

Scope for developing a mould storage and identification system

Mould storage and identification

1. Issue with storage - Occupying large space - approx 20% of workplace .

2. There may not by a need of some of the stored mould in its

whole life span - Better discard them.

3. Identifying a mould depends on the sample attached in a

lot of 50-500 moulds and memory of storing person .

Product finishing process causes huge amount consumption of time, material, labour and money in the complete product manufacturing process.

Losses due to the Flash formation and RemovalLoss of material in the form of waste.Loss of finished product due to the damage. Loss of time and Labour.

There are issues faced by all of MSME units in the cluster regarding the finishing of moulded products. . Lack of automation/semi automation in Flash Removal .. Variety of products range to develop a standard system. . Possibility of innovative flash removal process - deriving new techniques and customized machines.. Finishing, sorting and counting method could be developed.


Issue from Coal based heating operations - Environment, Safety, Work places requirement, etc.


Improved approach for Packaging of finished products.

Unit 11&12 Elate India & A M Rubber Contact Person: Mr. K. A. Islam

Address of Factory: Vill Raghudebpur (El IKazi Part) P.O. - Raghudebpur, Uluberia, Howrah - 711322 (W.B.). City/Trading OfficeShyamsundar Chawk , P.O. Santoshpur, Howrah-711310.Contact Number : 9339858299Email address: NARegistration status : SSI registered unit Certification: ISO 9001 - 2008.

Infrastructure set up: Coal Heating - Manual rubber moulding press, Manual plastic moulding machines for Nylon, PVC etc materials. Lathe and other machines for moulds Product finishing and packaging setup.

Contact Person: Mr. Azimudeen

Address of Factory: Vill Raghudebpur P.O. - Raghudebpur, Uluberia, Howrah - 711322 (W.B.)

Infrastructure set up: Coal Heating - Manual rubber moulding press, Manual plastic moulding machines for Nylon, PVC etc materials. Lathe and other machines for moulds Product finishing and packaging setup,

Product Manufactured: Elate India and A. M. Rubber manufactures all kinds of mechanical, Industrial Rubber & Plastic moulded goods in natural, Nitriler Neoprene Silicon, Viton, Nylon, Teflon, P.U., H.D.P., Bakelite, Hylume, Ebonite & Rubber lining etc. products.

Issues faced in the area of manufacturing : They are facing stiff competition in the area of quality of finished products. One of the major region of loss of quality is manufacturing using coal heating system. Coal heating causes loss of control over range of temperature which decides the quality of moulded rubber.This causes uneven molecular structure, reduced strength and life of finished goods.

Electricity connection and supply issue. In anticipation of getting electrical connection Elate India and similar MSME units have invested hugely in the electrical machines and infrastructure. Most of them are still waiting for the electricity supply and facing huge

O Ring,

Expansion Joints,

Bush

Unit 11&12 Elate India & A M Rubber

Unit 11&12 Elate India & A M Rubber Electricity issue and huge Investments done by Units

Elate India, A M Rubber and similar many industries have applied for electrical conneciton for better product manufacturing and productivity may year ago.

On assurance of electricity supply at their factroies they had made huge investments for building up the factory, purchase of machines and other faciliites.

It has turned a nightmare for them for a long time.

Issues relating to investment and electrical connec-tion unavailibility-

• Huge amout of money parked and lost in the investment.• To run the business dependence on Coal has increased and impacted double folded due to the un-certanity.• loss of optimism to run the rubber business.• Loss of business and customers in last couple of years.

Machine purchased long ago

Machine purchased long ago

Infrastructure ready for long time

Work process and Environment Ample work area - could be organized as per the work catagoryPlanning could be done for different moulding stations.

Issues : Environmental issues due to the coal operations.Production capacity is low due to slower operation.Electricity supply issue unresolved for last 3 years.Product quality is low due to the coal based infrastructure.

Unit 11&12 Elate India & A M Rubber

Product quality and productivity issue

Mould, Raw materials, finished Goods storage issues.

Reason : Heavy investment has been done in plant building and purchase of electrical ma-chines and other systems.

In anticipation of getting electrical connec-tion, MSME unit is not in a position to expand their work in any of the directions.

Possibility of good outcome from the unit when electrical supply is provided.

Unit 11&12 -Elate India & A M Rubber

Unit 13&14 - Sitara & Comp. S.S.R. RuberContact Person: Mr. Tozam Laskar Employee Strength: 10-15 employees

Address of Factory: Ghosal Chowk, P.O. Belkulai, Bauria Howrah - 711310, W.B.City/Trading Office :40/2, 1st Floor, Strand Road, Kolkata - 1.Contact Number : 90073 31300Email address: [email protected]

Certification: ISO 9001 - 2008Registration status : DIC and NSIC

Products manufactured:Quality Hydraulic & Pneumatic Sealing Systems.

Contact Person: Mr. S. Alom Employee Strength: 8-10 employees

Address of Factory: Vill & P.O.-Raghudevpur (East) , P S.-Ulubena, Howrah-711322Contact Number : 9874035464Email address: [email protected].

Certification: DICRegistration status : MSME registration, DIC.

Product Manufactured: Mfrs. Engineers & Exporters of Industrial Rubber, Ptfe, PVC & ABS Moulding Goods.

Unit 13&14 - Sitara & Comp. S.S.R. Ruber

Ergonomic and work environment issues..

Position of macine for human operation - 1. Distance from standing space should not be too far to opea-rate the machine.2. Hight of leaver and handle sould be appropriate to the stand-ard height of worker. Too short or too high (as shown in picture is notefficientforforceapplication.3. Sitting posture, place and Workbench could be designed bet-terforefficientwork.Saperateplacefokeepingrawmaterial,cutting and mould filling may help ease of operation and im-provement in comfort for workers.

Infrastructure set up: Manual Press with Coal based heating.

Discussion with Owners and Issues raised -

Issue of Electricity supply - Issue of shortage of electricity, coal based heating causing low quality products and polluting envi-ronment.Availability of electricity in various areas of cluster is different. Ghosalchak has a better availability of electricity as compared to Raghudevpur and other areas in cluster.

Location and Land Issue - Majority of MSME units are located in owned land by the proprietors. Govt. has suggested rubber manufacturers to shift to new places, rented or owned would not be commercially viable.

Taxations, Govt Licenses and approval - Units running the coal based furnaces are forced to update the fire licenses, etc. Taxation causes loss of profit to MSME running at a nominal mar-gins. MSME units are liable to make tax payment in 20 days of product sale where usual time for payments from customers are 90 days. Govt. related Issues link approval for licences, tax payment, infra-structure support, awareness about scheme etc. Financial issues like bank loan, credit facility etc.

Unit 13&14 - Sitara & Comp. S.S.R. Ruber

Lack of technology up gradation - Customers have start-ed demanding more high quality products and asking for lesser prices due to increasing competitions. Lack of tech-nology and quality sometimes results in compromising in profits or loss of orders.

Testing and certification issue- Testing and certification lab with NABL certification is in Kolkata. Units have huge incon-venience to do the testing and

Incentive to do business is less : Facing tough competi-tion from other regions, shrinking profit margins, reducing growth prospects etc. Raw material prices and procure-ment are constantly unpredictable. MSMEs are opting other options for new generations instead of keeping the busi-ness ongoing.

Unit 15 Asian Rubber ` Estd: 2004

Contact Person: Mr. M Rahman

Address of Factory: Vill. Shibram Chack,P.O. : Panchla Dist. : Howrah PIN : 711322 266/G/49 R/4.

Contact Number : 9339109511Email address: NAWebsite : NARegistration status : DIC

Certification: NA

Employee Strength: 08 employees.

Turnover : 3 Lakh

Infrastructure set up: 3 Coal heated moulding machinesManual press.

Market and Competition : Supplying to Jute mill spare parts.

Sales and Distribution mode : Sales through Agents or Direct to retailers.

Trade portals and other web presence. - No.

Product Manufactured: Manufacturers of all Kinds of Rubber, spe-cially Synthetic, Neoprene, Rubber Mould-ed Goods, Ebonite, Bakelite, Plastic, P.V.C., Hylam Moulded Goods, for Jute, Cotton, Sugar Mills, Tea Gardens, Engineering and Electrical Firms, Collieries etc.

Oil Seal,

Packing,

O Ring,

Bucket, Washer, Bonded Seal,

Unit 15 Asian Rubber ` Estd: 2004

Work Environment :

. Space utilization has been done nice to accommodate machines and moulding setup. . Orderliness could be improved using 5S techniques. . Coal generated gases affect the environ-mentandreducestheworkefficiency.. Up gradation to electrical system may help in product quality and production.

Unit 15 Asian Rubber Estd: 2004

Machining shop for moulds Moulding area - Coal furnaces

. Natural/Artificial lighting may help in better visibility and work comfort. . Improvement in sitting arrangement and posture would help in reduced fatigue. . Safety at the work place could be im-proved using better sitting chairs. Plastic chairs are not sturdy and safe as a struc-ture in the work place. . Electrical wiring would be made safer through proper distribution planning.

Unit 16 Ganga Rubber ` Estd: 2004

Contact Person: Mr. N. Banerjee

Address of Factory: P.O. Raghudevpur, Dist.: Howrah, W.BPIN : 711322 266/G/49 R/4.

Contact Number : 9331803932Email address: NAWebsite : NARegistration status : DIC

Certification: ISO-9001-2008


Turnover : 14 Lakh

Infrastructure set up: Coal heated moulding machines,Manual press,Rubber milling machines.

Market and Competition : Manufacturing rubber products like hand pump bush, Sales and Distribution mode :

Trade portals and other web presence. - NA

About the MSME unit - Ganga Rubber in one of the few MSME units who owns the Milling facility along with the moulding setup. The unit provides the milling services for rubber moulding units which helps in generating additional revenue to the unit.

In present scenario the unit is depending on coal based heating moulding process. The upgradation to electrical heating would help in improving quality of products and prospects of diversifi-cation.

Product Manufactured: All kind of rubber, ebonite, Bakelite and plastic material Seal kit, Valve, bucket, O’Ring, oil seal, washer, strips, etc.Mfgr of Bucket Bush “ O” ring, Gasket,Oil Seal,Washer.

Unit 16 Ganga Rubber `

Infrastructure and Environmental issues - Milling Machine for rubber mixing and raw material preparation Coal based mould heating system for rubber moulding .

Environmental issues due to coal burning. Safety hazard due to coal heating.Environment becomes smoky and suffocating due to coal burning. Less control over process. Time consuming and less productive process. Issue of coal purchase, storage, burning and dozing.

Unit 16 Ganga Rubber `

Product sorting and storage after moulding Finished product storage could be made. Counting and sorting system could be designed toDifficultyinunderstandingthenumberofpieces manufactured..

Raw material storage Better storage for raw materials, chemicals, etc could be designed. Raw material identification and selection could be made simpler. Measurement and carrying the material could be standardized.

Unit 17 Raghudevpur A. H. Rubber Mfg. & Trading Co Estd: Contact Person: Mr. SK.SAMSUDDIN

Address of Factory: Village and Post RaghudevpurDist- Howrah, W.B.

City/Trading Office20/1 A, Eden Hospital Road,Kolkata, W.B.700037.

Contact Number : (033) 2237 9089 Email address: [email protected] : NARegistration status : DIC and NSIC.

Certification: SSI and NSICNS-EN ISO 9001 - 2008


Turnover : Infrastructure set up: Coal and Electrical Heating - Manual rubber moulding press, Manual plastic moulding machines for Nylon, PVC etc materials. Lathe and other machines for moulds Product finishing and packaging setup.Products Mfg : Rubber Sheet and other products like-O Ring,Rubber Bucket and Canvas Bucket,Margan Seal,Gasket,Neeck Seal,Oil Seal.


Sales and Distribution mode :Rubber Bellows, Expansion Joint C.I. Fitting of Rubber, Vulcanite & Rubber Ball of All Type Rubber Moulding Jobs Rubber Bellows, Expansion Joint C.I. Fitting of Rubber, Vulcanite & Rubber Ball of All Type Rubber Moulding Jobs.

Trade portals and other web presence. - Yes - India Mart,Just Dial, infokhoj.in, Kolkata Yellow pages, etc..

A.H, Rubber producing wide range of Rubber Sheets and rubber coated fabrics, which come in different sizes, thickness and dimensions. Fabricated using flexible material, these sheets are extremely durable. These sheets are widely used in automobile, construction and many other industries. Our range of sheets is oil proof and can sustain high temperature.

Process of rubber sheets manufacturing Stretching of fabric in a open space.Applying the liquid rubber layer by layer.Drying of sheets in open area.Cutting and folding for dispatch.

Unit 17 Raghudevpur A. H. Rubber Mfg. & Trading Co Estd:

Process of Issues faced in manufacturing rubber sheets.

Space requirement for fabric stretching. Uneven application of layers of rubber.Open air natural drying causes issue in product quality due to the dust, rain, etc.

Unit 17 Raghudevpur A. H. Rubber Mfg. & Trading Co Other Areas of manufacturing

Machining shop making fabricated moulds.Coal based heating and moulding machine.Moulding press manual.

Unit 18 Ghosak Chowk Rubbertech India Estd: 1980 Contact Person: Mr. Sk. Surat Ali

Address of Factory: Factory & H.O. : Ghosal Chawk, P.O.•Belkulai,Howrah - 711322, W.B.

Contact Number : 9231444201Email address:

[email protected]@rediffmial.com

Website : http://www.rubbertechindia.com/

Registration status : DIC and NSIC Certification:ISO 9001 - 2008Employee Strength: 8-10 employees

Infrastructure set up: Manufacturing and supplying quality rubber products such as rubber moulded components , rubber hoses, rubber parts, rub-ber oil and more. Their precision engineered range is widely used in industries such as chemical, electrical and electronics and more. They have a state-of-the-art infrastructures facility that enables us in meeting the growing demands of these industries.

Trade portals and other web presence. - Listing with Trade portals- India Mart, Yellow pages, Kolkata with detailed descrip-tion

Opportunity to use Web based market - Websites and trade portals provide great opportunities to connect with prospective customers who want to explore trade possibilities with various customers whom they can not reach or meet physically.

In India online buyer seller platform for industrial products is see-ing a great amount of growth. Only at India Mart online website for traders, there are more than 12 Lakh seller are posted and more than 65 Lakh buyers putting there inquiries.

It has emerged as simplest solution to promote any product of company and to present the information a MSME unit is willing to provide to its customer for selling their product.

Unit 19 Ghosak Chowk K.B. Rubber Industries Comm. House Estd: 2000

Contact Person: Mr. Sk.J. Ali Address of Factory:Ghoshal chack, P.O. Balkhulai,Dist. Howrah, W.B.City/Trading Office135A, 1st Floor, B.R.B. Basu Road, Kolkata-700 001

Contact Number : -9432098441Email address: [email protected][email protected] : www.kbrubberind.comRegistration status : SSI registered Unit.Certification: NAEmployee Strength: 25-30 employeesTurnover - 1.5-2 Crores.

Market and Competition : Suppliers to PSUs and Private power plant establishments.

DirectsellingthroughTenders,HowrahOfficeandFewtraders.

Competition from local manufacturers and international part suppliers.

Products Manufactured - Manufacturer of all types of Rub-ber Components, Molded Rubber Products and Rubber Moulded Spares Of Neoprene, synthetic, silicon, nitrile, vi-ton, butyle, EPDM, PU, Teflon etc.

There products are used in majority of power plants like coal handling Plant, ontrol and Instrument, Merry-Go-Round, Ash Handling Plant, C. W. Plants.

Lab and Testing facility owned - KBR has a dedicated testing facility for testing of hose pipe for leakage, burst pressure test, proof pressure test, vacuum testing, tensile, strength elongation at break, bend Strength test, ageing test, heat & oil resistant test, hardness test, leakage test in tubber item & lining.

Issues and Opportunities identified at clusterRaw Material Availability of raw materials issue.Price fluctuation issue.Raw material - Chemical Mixing Issue.Lack of mixing facility .Rubber composition know how- Urgent.Excess production of Raw material.Lack of R&D work and collaboration. Possibility of Raw Material Bank - Urgent .

MouldsMould design issues - Urgent.Mould materials.Moulding Machines and process improvement - Most Urgent.Semi-automation for moulding systems. Mould assembly method redesign. Flash removal process development - Most Urgent.

Work space – Environment relate improvement. Workstation Improvements. Safety and health related areas. Improvement possibility for lighting, air circulation, cooling of workplace, etc.Layout and work place arrangement possibilities.

Product Quality of product improvement- Urgent.Storage of moulds. Removal of flash techniques could be developed in the cluster.Diversification scope for most of the manufacturers -Most Urgent.Tool design R&D could be developed at cluster level.

LabourAvailability of work force an issue.Retention issue Skilled labours.Training programme for skill upgradation.Scheme for labour welfare could be initiated .

Cluster Level Issues – IPR and privacy-common facility -Urgent.Electricity infrastructure development.Road development. Testing and Lab facility.Tool room Facility.

Training and Skill upgradation Quality related training - Most urgent. Time to time skill upgradation training IPR training - Most urgent.

Facility Up-gradation Manual – Electrical hydraulic press . Coal – Electrical mould heating.Single - Multi Cavity moulds.Manual - Semi - Fully Automatic moulding Production capacity up gradation - Most Urgent.

Marketing and Competition Management training and facility.Financial funding institution supportCompetition awareness - Urgent.Exposure to best practices visit in India and globally.

Govt. Issues – Recognitions to Cluster Association - Most Urgent.Special Schemes for Rubber product manufacturers - Urgent.Faster Payment of dues .Simpler Registration and Taxation- Registration Payment of taxes Excess amount of taxes No relaxation to MSME units.Financial assistance through Grants and easy credit scheme.

Project Opportunities emerging from cluster..Raw Materials Data Bank -UrgentRubber composition know how- Units have suggested to have a common raw material bank with the cluster under the CFC programme. There is a possibility of Joint Initiate with reputed institutions, like Dept. of Chemistry, Kolkata university, IIT Kharagpur, etc. to develop a culture of Industry based research and development programme to help Raghudevepur cluster grow.

Design of Moulds and moulding process - Huge potential for designing of moulds, moulding macines and semi automation in moulding process. Major areas are - New design of moulds for better product quality and productivty. Re design of manual moulding machines.Semi-automation for moulding systems for faster moulding process, assembly and dismantling etc. Flash removal process development.Organizations could be involved - CTTC Bhubeneshwar, IGTR Jamshedpur, CEPT, Bhubeneshwar, etc.

Work space and Workstation Improvements possibility with the help of Dept of Physiology, Kolkata University, NID, Ahmedabad. Storage of moulds could be developed in the cluster with the help of lean manufacturing consultants under the scheme from Ministry of MSME.

Product quality improvement Product quality improvement using various quality techniques - Could be arranged for cluster members on a regular basis under various schemes of Central and state Govt.DI-MSME and DIC, Howrah may be involved.

Product diversification Diversification scope for most of the manufacturers in the areas of consumer products and nonindustrial applications apart from industrial products. Self Initiative and design expert may be pooled in.

Training and Skill up gradation - Continuous requirement for improvement of cluster units. Quality related training.IPR training.Exposure to best practices in the similar product domain.

Facility Up-gradation Manual - Semi - fully automatic moulding process.Production capacity up gradation with the help of experts. DIC, Howrah has one initiative immediately after the workshop. More such initiative could be taken up.

End of Report

Thank you

Design Clinic Workshop Report

Raghudevpur Rubber Moulding Products Raghudevpur Gram PanchayatTaluka - Ulluberia Dist- Howrah, West Bengal

Report prepared by Jitendra Singh Rajput

Raghudevpur Rubber moulding Cluster

1 Objective-Design Clinic Workshop 2 5 Days Workshop Schedule 3 Day wise workshop activities4 Opportunity areas for future projects 5 Promotional materials

Contents

Objective of design clinic workshop is to create platform for design expertize and MSMEs to come togather for dialogue and exchange of information to solve the issues araising in MSME work scenario in day to day activities.

The workshop aimed to generate broader information of design, design process and its benefits in problme solving. The workshop discusses hwo design can be used by MSME members from owners to workman for identifying problems and their resolution in simplest and effective manner.

The workshop deals with issues which could be resolved with help of design ex-perts by providing on the spot remedial solutions. These solutions help in improv-ing outcome of resolved issues or opportunities in most simple, basic and contex-tual manner. The solutions most of the time are less resource consuming, quick and effective to see the immediate results.

Ultimate objective of design clinic workshop is to identify the poblem areas which could be taken up as long term projects and generate the idesas derive future solution with the help of expert designer(himself ) or others from different areas, expertize, background and institutions.

Objective-Design Clinic Workshop

Venue and Participants

Venue - S.S Institutional Hall, Shyam Sundar Chawk. Santoshpur, Howrah

Participants- Members of Raghudevpur Rubber mould-ing clusters participated in all the 5 days of workshop.

Apart from members of cluster, other par-ticipants were from DIC, Block office mem-ber and other local participation.

Shri Ashok SinhaRoy, General Manager, Disctrict industry Centre, Howrah was ea-ger to understand the issues and areas of future development, has been part of dis-cussion during one of the session.

Day 1. NAS report discussion with Association Members - 12.00 pm to 5.00 pm

Day 2. Inauguration of Design Clinic Workshop 10.00 am to 11.00 am Presentation on Understanding design Workshop on understanding design Process 11.00 am to 1.00 pm Strategy and its importance for growth of MSMEs 2.00pm to 4.00 pm

Day 3. Workshop on designing a new product.. 10.00 am to 11.30 pm Workshop on Product diversification for rubber cluster 11.0 pm to 12.30 pm Presentation to GM-DIC, Howrah Shri Ashok singha Roy 12.00 pm to 1.30 pm TQM and Design for continuous improvement 3.00 pm to 4.00 pm

Day 4. TQM and Design for continuous improvement 10.00 am to 11.00am Problem listing and definition in the cluster Design opportunities and project identification 11.00 am to 1.00 pm Design approach to creative problem solving on common cluster problem 2.00 pm to 4.00 pm

Day 5. Ergonomics in manufacturing – Prof. Somnath Ganguli, Dept of Ergonomics, Kolkata University 10.00 am to 1.00 pm Conclusion and Workshop outcome discussion and Concluding remarks.. 2.00 pm to 4.00 pm

Schedule 5 Days workshop

Date – 20th to 24th November 2012

Venue -

Design Experts Jitendra Singh RajputProf. Somnath Ganguli

Members-Design Clinic SchemeMr. Ashok MondalMr. Sudev Mondal

Number of participants - 40-45 members

Day 1 of workshop started with brief inroduction of Raghudevepur cluster and its role in betterment members of cluster. As part of design clinic scheme activity, the awareness programme is helpful in bringing members of the cluster together and create interest among the members for taking bigger steps towards betterment of manufactures.

Discussion on Objective of Design clinic scheme, Design Awareness Programme and its purpose in Rubber moulding cluster in Raghudevpur was presented by Shri Sudev Mondal.

NAS activity, the report, issues identified and possibility of using the report in ongoing workshop and future activities of cluster was discussed by Jitendra along with the schedule of design clinic workshop in coming days.

Workshop Day 1

Jitendra Singh Rajput-Design Expert along with Sudev Mondal, Design Associate, East Zone, Design Clinic Scheme

Shri. Mudassar Ali, President, Rubber mouling cluster, Raghudevpur along with Mr. M.A. Mollick, Secretary, cluster, and other members.

Members of Rubber mouling cluster, Raghudevpur ain the Day 1 of Design Clinic Workshop.

Workshop Day 2

Number of participants - 35-40 members

Inauguration of Design Clinic Workshop 10.00 am to 11.00 amPresentation on Understanding design Workshop on understanding design Process 11.00 am to 1.00 pm Strategy and its importance for growth of MSMEs 2.00pm to 4.00 pm

Inauguration programme :

Inauguration of Design Clinic scheme start-ed with information about the new formed Rubber moulding products cluster of Ra-ghudevpur.

The cluster comprising of more than 275 members, aims for improving product qual-ity, increasing its reach to more sectors and making the manufacturers and workforce of MSME units more efficient and profitable, as described by President, Mr. Ali and Secre-tory Mr. Mollic. Mr. Sudev Mondal, Representative, Design Clinic Scheme emphasised on role of de-sign in improving competitiveness.

Workshop Day 2Credit : http://blogs.bu.edu/

Post inauguration session focused on knowing design and its role in industrial scenario. what is design, how design works day to day activities as well as creation of break through solutions for any given situation. Design plays an important role in problem solving for manufacturing activities in MSME unit. Problem identification and its resolution in most simplest and creative manner was explained during the workshop session.

MSMEs Strategy - Session II in the second half focused towards strategy part of MSME business. The major focus was put on how different scenarios would be addressed through strategic approach. Strategy through Improvement, refinement, value creation, reorientation of offering, targeting new markets etc. explained during the session.

Flying Fish : Species of flying fish evolved thorough various attempts of evading predators, realizing that there is a space beyond the boundaries waters.(BBC : Challenges of Life)

Ever changing business scenarios force players to keep evaluating their existing scenario and identify new avenues, where their skills and experience could attract survival and profitability for its business. This is how some of the MSMEs derive strategies to exist and grow.

Workshop on designing a new product.. 10.00 am to 11.30 pmWorkshop on Product diversification for rubber cluster 11.0 pm to 12.30 pmPresentation to GM-DIC, Howrah Shri Ashok sinha Roy 12.00 pm to 1.30 pm

3.00 pm to 4.00 pm

Workshop Day 3

Day of design clinic workshop aimed for awareness about design process and its application in MSMEs activities in rubber product manufacturing.

The day started with brief presentation on Need assessment workshop to the honourable guest Mr. Ashok Sinha Roy, General Manager, District Industry Centre highlighting the issues identified in the cluster and possible areas of intervention for design and other activities. the presentation helped in opening up the discussion on what issues the cluster members facing at the individual and common levels where various agencies including DIC Howrah could become the pivotal in improving competitiveness of the cluster.

Mr Sinha emphasised on importance of self initiative and more importantly joint initiative in the form of cluster to fight external competition. He appreciated efforts of cluster to come forward to organize such activities and encouraged other members to participate in such events.

1. Workshop on design process understanding

1. Workshop scenario - To design products for hypothetical business scenario in a team exercise.2. Deriving creative solutions for changing scenarios in the market.3. Relating the design process to actual business scenario and understating possible solutions

Workshop Day 3

Team and discussion

Understanding the new scenario

Group Presentation on each creative solutions

2. Session - Diversification and its Importance for MSMEs 1. A detailed discussion on importance of diversification through case studies and examples presented. 2. Discussion initiated to understand, what all possibilities could emerge for rubber moudling products through diversification. 3. Some of the similar examples presented to understand the scope of diversification.

Workshop Day 3

Possible areas emerging through discussion - Consumer Items, Luxury goods, Jewellery etc.

First page result of Google Image with key word - Rubber Jewellery

TQM and Design for continuous improve-ment 10.00 am to 11.00am Problem identification and listing Design opportunities identification. 11.00 am to 1.00 pm Design approach to creative problem solving on common cluster problem 2.00 pm to 4.00 pm

Workshop Day 4

1. Session - Importance of TQM for MSMEs

1. Presentation on TQM techniques and its importance in general. 2. Role of TQM in improving competitiveness for Reguhdevpur rubber moulding MSMEs.

2. Session - Problem identification for the rubber products in the cluster.

A. The objective of this activity has been to identify the issues which directly relates to the improvement of process/products.

Participants of workshop were asked to pre-pare information about issues they feel that are important and need their solutions for improvement in productivity. They were suggested to write about their

plan, where they want to see their units in next 5 years.

The initial presentation and discussion were focused about issues we in face day to day activities and their resolution for improve-ment in our efficiency. Mr. Ashok Mondal helped in connecting with such situation in various industrial scenario and suggested the ways where design helps in bringing change.

Based on the issues listed by the participants a broader list of issues was prepared and dis-tributed according to the cluster based issues and individual issue.

In the second half of the workshop, one of the issue from the identified list and NAS report is chosen to understand the design process of problem solving. Wastage of material at various levels of man-ufacturing has been selected for futher study and discussion among the participating members of session and learned the basics of design process in problem identification and solving .

Waste issue in Rubber moulding ....

Workshop Day 4

Levels of defects and waste identified in the manufactur-ing process.1. Raw material wastage2. Processed raw material wastage 3. Mould Assembly process4. material damage5. Finishing Defect6. Material composition and test failure7. Finished product rejected by OEM9. Access material produced in anticipation of more orders. Various options were discussed and identified to

understand the nature of problem and their solutions

Ergonomics in manufacturing – Prof. Somnath Ganguly, Dept of Ergonomics,

10.00 am to 1.00 pm Conclusion and Workshop outcome discussion and Concluding remarks.. 2.00 pm to 4.00 pm

Prof Ganguly Associate Professor, Occupational Ergonomics Lab., Dept of PhysiologyUniversity of Calcutta started with basic introduction and need of Ergonomic in the manufacturing systems in most simplistic and acceptable manner.

He highlighted the areas where ergonomic practices could help MSMEs to improve the conditions of workplace for ease of workforce and in turn benefiting overall productivity.

Workshop Day 5

Workshop Day 5Concluding session..

Supports and Promotions

Raw Material Availability of raw materials issue.Price fluctuation issue.Raw material - Chemical Mixing Issue.Lack of mixing facility .Rubber composition know how- Urgent.Excess production of Raw material.Lack of R&D work and collaboration. Possibility of Raw Material Bank - Urgent .

MouldsMould design issues - Urgent.Mould materials.Moulding Machines and process improvement - Most Urgent.Semi-automation for moulding systems. Mould assembly method redesign. Flash removal process development - Most Urgent.

Work space – Environment relate improvement. Workstation Improvements. Safety and health related areas. Improvement possibility for lighting, air circulation, cooling of workplace, etc.Layout and work place arrangement possibilities.

Product Quality of product improvement- Urgent.Storage of moulds. Removal of flash techniques could be developed in the cluster.Diversification scope for most of the manufacturers -Most Urgent.Tool design R&D could be developed at cluster level.

LabourAvailability of work force an issue.Retention issue Skilled labours.Training programme for skill upgradation.Scheme for labour welfare could be initiated .

Cluster Level Issues – IPR and privacy-common facility -Urgent.Electricity infrastructure development.Road development. Testing and Lab facility.Tool room Facility.

Training and Skill upgradation Quality related training - Most urgent. Time to time skill upgradation training IPR training - Most urgent.

Facility Up-gradation Manual – Electrical hydraulic press . Coal – Electrical mould heating.Single - Multi Cavity moulds.Manual - Semi - Fully Automatic moulding Production capacity up gradation - Most Urgent.

Marketing and Competition Management training and facility.Financial funding institution supportCompetition awareness - Urgent.Exposure to best practices visit in India and globally.

Govt. Issues – Recognitions to Cluster Association - Most Urgent.Special Schemes for Rubber product manufacturers - Urgent.Faster Payment of dues .Simpler Registration and Taxation- Registration Payment of taxes Excess amount of taxes No relaxation to MSME units.Financial assistance through Grants and easy credit scheme.

Issues and Opportunities identified at cluster Promotional Materials

Raw Materials Data Bank -UrgentRubber composition know how- Units have suggested to have a common raw material bank with the cluster under the CFC programme. There is a possibility of Joint Initiate with reputed institutions, like Dept. of Chemistry, Kolkata university, IIT Kharagpur, etc. to develop a culture of Industry based research and development programme to help Raghudevepur cluster grow.

Design of Moulds and moulding process - Huge potential for designing of moulds, moulding macines and semi automation in moulding process. Major areas are - New design of moulds for better product quality and productivty. Re design of manual moulding machines.Semi-automation for moulding systems for faster moulding process, assembly and dismantling etc. Flash removal process development.Organizations could be involved - CTTC Bhubeneshwar, IGTR Jamshedpur, CEPT, Bhubeneshwar, etc.

Work space and Workstation Improvements possibility with the help of Dept of Physiology, Kolkata University, NID, Ahmedabad. Storage of moulds could be developed in the cluster with the help of lean manufacturing consultants under the scheme from Ministry of MSME.

Product quality improvement Product quality improvement using various quality techniques - Could be arranged for cluster members on a regular basis under various schemes of Central and state Govt.DI-MSME and DIC, Howrah may be involved.

Product diversification Diversification scope for most of the manufacturers in the areas of consumer products and nonindustrial applications apart from industrial products. Self Initiative and design expert may be pooled in.

Training and Skill up gradation - Continuous requirement for improvement of cluster units. Quality related training.IPR training.Exposure to best practices in the similar product domain.

Facility Up-gradation Manual - Semi - fully automatic moulding process.Production capacity up gradation with the help of experts. DIC, Howrah has one initiative immediately after the workshop. More such initiative could be taken up.

Project Opportunities emerging from cluster..

End of the Report Thanks

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