karanga knife cluster - design clinic...

KARANGA KNIFE

CLUSTER

Document Submitted by - EMOTOME

Year 2013

Karanga Knife Cluster : 1

Aknowledgement

Firstly, we would like to thank National Institute of Design (NID) and its following members of the North East zone Team of Design Clinic Scheme for MSMEs ,who gave us an opportunity to first of all select us as a consulting design resource to work with their es-teemed team of Design Clinic Scheme and then placing us to work with District Industries & Commerce Centre (D.I.C),jorhat. They played a great role in the successful completion of the Need Assessment survey report. Hence we would like to give my gratitude to Mr. Pradyumna Vyas (Director), Mr. Shashank Mehta (DCS for MSMEs, Head, NID), Mr. Ashok Mondal (East and North East Zone co-ordinator, DCS for MSMEs, NID), Mrs Sheikh Nilofar and the entire DCS for MSMEs team.

A special thanks to KARANGA KNIFE CLUSTER, for providing us the opportunity and platform to work with their highly qualified team. We would like to thank Mr. Rajan Chandra Hazarika, for supporting us throughout the need assessment survey and making the report. Also would like to thank Mr. Tarun Geore, Mr. Ratul Deori, Mr. Suren Saikia of DICC office by giving us knowledge about the particular field of Blacksmith Cluster and providing us with their valuable feedback which would be very useful in our near future and further inour life.

Thanks to the lovely people and artisans of KARANGA village, Jorhat, Assam


Chapter 1: Assam ... 04 Geography ... 05 Demographics ... 06 Economy ... 07 Language ... 08 Culture ... 09 Climate ...10 Traditional Crafts ... 11

Chapter 2: Blacksmithy : An overview ... 12 History ... 13 - 16

Chapter 3: Karanga ... 17 Cluster History ... 18 Objective of study ... 19 Scope of study ... 20 Demographic- distributioN of units ...21

Chapter 4: Tools & Techniques ... 22 - 27

Contents

Chapter 5: Processes ... 28 - 35 Chapter 6: Business Operations ... 36 - 46chapter 7: Products ... 47 - 53

Chapter 8: Unit wise Design audit ... 54 - 69

Chapter 9 : Intervention framework ... 70 - 90Chapter 10 : Windup ... 91

General Information

Unit wise Design audit

intervention frame work

Cluster wise design audit


General InformationAssamGeographyDemographicsEconomyLanguagesCultureClimateTraditional craftsBlack smithy : An overviewHistory


Assam


Geography

FACT FILE AREA - 78, 550 sq. km CAPITAL - Dispur ATTAINED STATEHOOD - August 15, 1947 POPULATION - (2011 census) 31,169,272DISTRICTS -27 LANGUAGES -Assamese, Bengali, Bodo, Hindi, English, etc. LEGISLATURE - Unicameral CLIMATE -Summer Maximum 38 degrees Celsius Minimum 20 degrees Celsius Winter Maximum 25 degrees Celsius Mini-mum 10 degrees Celsius

Brahmaputra, the life-line of Assam is an antecedent river, older than the Himalayas. The river with steep gorges and rapids in Arunachal Pradesh entering Assam, becomes a braided river with tributaries, creates a flood plain (Brahmaputra Valley: 50–60 mi/80–100 km wide, 600 mi/1000 km long). The hills of Karbi Anglong, North Cachar and those close to Guwahati (also Khasi-GaroHills) are originally parts of the South Indian Plateau system. In the south, the Barak originating in the Barail Range (Assam-Nagaland border) flows through the Cachardistrict with a 40–50 km wide valley and enters Bangladesh with the name Surma.

Assam is endowed with petroleum, natural gas, coal, limestone and other minor minerals such as magnetic quartizite, kaolin, sillimanites, clay and feldspar. Discovered in 1889, all the major petroleum-gas reserves are in Upper Assam. Located south of the

eastern Himalayas, Assam comprises the Brahmaputra & the Barak river valleys and the KarbiAnglong & the North Cachar Hills with an area of 30,285 Square miles (78,438 Square km).

Assam currently is almost equivalent to the size of Ireland or Austria. Assam is surrounded by the rest of

the Seven sisters state: Arunachal Pradesh, Nagaland, Manipur, Mizoram, Tripura and Meghalaya sharin International Border with Bhutan & Bangladesh. Assam is known for Assam tea, Petroleum, resources, Assam silk & for its rich biodiversity.


DEMOGRAPHICS

Assam’s population was estimated at 28.67 million in 2006 and at 30.57 million by 2011,34.18 million by 2021 and 35.60 million by 2026. Assam has many ethnic groups and the People of India project has studied 115 of these. Out of which 79(69%) identify them-selves Template: Explanation needed regionally, 22(19%) locally, and 3 transnationally.

The earliest settlers were Austro-Asi-atic, followed by Tibeto-Burman, Indo-Aryan speakers, and Tai-Kadai speakers. Forty-five languages are spoken by different communities, including three major language fami-lies: Austro-Asiatic, Sino-Tibetan and Indo-European. There are 23 notified Scheduled Tribes(ST) in Assam with the Bodos(40.9percent) making half of the total ST population (around 13 percent) of the state. The other STs (both plains and hills) in clude Miri, Karbi, Rabha, Kachari, Lalung, Barmanin Cachar, Borokachar, Deori, Hajai, Mech, Dimasa, Hajong, Sing-

hphho, Khampti and Garo, Chakma, Hmar, Khasi, Jaintia, Synteng, Pnar, War, Bhoi, Lyngngam, and Kuki.


Economy of Assam today represents a unique juxtaposition of backwardness amidst plenty. Despite its rich natural resources, and supplying of up to 25% of India’s petroleum needs, growth rate of Assam’s income has not kept pace with that of India’s; differences increased rapidly since 1970s.Agriculture: Assam’s biggest contri-bution to the world is tea. Assam is a major producer of crude oil and it ac-counts for about15% of India’s crudeoutput. Tourism: Assam is the cen-tral state in the North-East Region of India and serves as the gateway to the rest of the Seven Sister States. For the purposes of tourism there are wild life preserves like the Kaziranga National Park, Manas National-Park, Pobitora Sanctuary among others.

ECONOMY


LANGUAGES

Assamese and Bodo are the major languages spoken while Bengali holds official status inthe three districts in the BarakValley and is the second most widely spokenz language of the state (27%). Dimasaisa one of the oldest language spoken in North East India particularly in Assam. Other native languages of Tibeto- Burman origin and related to Bodo-Kachari are DEORIMising, Karbi, Rabha, Tiwa, etc. A total of six Tai language were spoken in Assam: Tai Phake,Tai Aiton, Khamti, Khamyang, Ahom, Turung. Bengali is the officiallanguage in Barak Valley and the widely spoken language there is Sylheti, adialect of Bengali.


Culture

Assamese culture is traditionally a hybrid one developed due to as simulation of ethno-cultural groups in the past. Various elements like Tamulpan (the areca nut and betel leaves), Sorai and Gamosa are being used to represent beliefs, feelings, pride, identity, etc. The major milestones in evolution of Assamese culture are:

1.As simulation in the Kamarupa Kingdom for almost 700 years (under the Varmans for 300 years, Salastambhas and Palas for each 200years).

2. Establishment of the Ahomdynasty in the 13th century A Dandas similation for next 600years.

3. Assimilation in the Koch Kingdom (15th–16thcentury AD) of western Assam and Kachari Kingdom (12th–18thcenturyAD) of central and southern Assam.

4. Vaishnava Movement led by Srimanta Shankardeva (Xonkordeu) in the 15th century and its contribution provided another dimension to Assamese culture. Of social institutions such as namghar and sattra (the Vaishnav Monasteries). Bihu (Rongali, Bohag, Kati) is the most important and common and celebrated all over Assam. Durga Puja is another festival celebrated with great enthusiasm. Muslims celebrate two Eids (Eidul-FitrandEidal-Adha)


Climate

With the “Tropical Monsoon Rain forest Climate”, Assam is temperate (summer max.at 95–100° For 35–38°C and winter min.at 43–46°For 6–8°C) and experiences heavy rain fall and high humidity. The climate is characterized by heavy monsoon down pours reducing summer temperatures and affecting foggy nights and mornings in winters. Thunder storms known as Bordoicila are frequent during the after noon’s. Spring (Mar–Apr) and Autumn (Sept–Oct) are usually pleasant with moderate rain fall and temperature.


Traditional crafts

Assam has arichtradition of crafts;presently,Caneand bamboo craft, bell metal and brass craft,silk and cotton weaving, jute products making craft toy and mask making, pottery and terracotta work, wood craft, jewellery making,musical instruments making, etc. remained as major traditions.

Historically, Assam also excelled in making boats, traditional guns and gunpowder, ivory crafts, colours and paints, articles of lac, agar wood products, traditional building materials, utilities from iron, etc. Utilities and symbolic articles such as Sorai and Bota made from bell metal and brass are found in every Assamese household. Hajo and Sarthebari are the most important centres of traditional bell metal and brass crafts. Assam is the home of several types of silks, the most prestigious are: Muga – the naturalgoldensilk, Pat – a creamy-bright-silver coloured silk and Eri

– a variety used for manufacturing warm clothes for winter. Assam possesses unique crafts of toy and mask making mostly concentrated in the Vaishnav Monasteries, pottery and terracottawork in lower Assam districts and wood craft,ironcraft, jewellery, etc. in many places acrossthe region.


Blacksmithy : An over view

A blacksmith is a person who creates objects from wrought iron or steel by forging the metal ; that is, by using tools to hammer , bend, and cut (compare to whitesmith).Blacksmiths produce objects such as gates, grilles, railings, lightfixtures, furniture,sculpture, tools, agricultural implements, decorative and religious items, cooking utensils, andweapons.

ORIGIN OF THE TERM :

The term “blacksmith” comes from the activity of “forging” iron or the“black” metal- so named due to the color of the metal after being heated (a key part of the blacksmithingprocess). The term “forging” means to shape metal by heating and hammering .” Smith” is from the Proto-German “smithaz” meaning “skilled worker.“ Blacksmiths work primarily with wrought iron and steel. The “black” in “blacksmith”

refers to the black fire scale, a layer of oxides that forms on the surface of the metal during heating. Theword “smith” derives from an old word, “smite” (to hit). Thus, a blacksmith is a person who hitsblack metal. Blacksmiths work by heating pieces of wrought iron or steel, until the metal becomessoft enough to be shaped with hand tools, such as a hammer, an viland chisel. Heating is accomplishedby the use of a forge fueled by propane, natural gas, coal, charcoal, coke or oil. The techniquesof smithing may be roughly divided into forging (sometimes called sculpting”), welding, heat treating,and finishing.


History

In hindumythology, Tvastar also known as Vishvakarma is the blacksmith of the devas. Hephaestus (Latin:Vulcan) was the blacksmith of the god sin Greekand Roman mythology. In Celticmythology, the role of Smith is held by eponymous (their names do mean ‘smith’ ) characters : Goibhniu (Irish myths of the Tuatha Dé Danann cycle) orGofannon (Welsh myths / the Mabinogion). The Aglo-Saxon Wayland Smith, known in Old NorseasVölundr, is a heroic blacksmith in Germanic mythology.

BEFORE IRON AGE.

During the Chalcolithic era and the Bronze Age, humans in the Mideast learned how to smelt, melt, cast, rivet, and (to a limited extent) forge copperand bronze. Bronze is sufficiently corrosion-resistant that artifacts of bronze may last thousands of years relatively unscathed. Accordingly, museums frequently preserve more

Before Iron age. During the Chalcolithic era and the Bronze Age, humans in the Mideast learned how to smelt, melt, cast, rivet, and (to a limited extent) forge copper and bronze. Bronze is sufficiently corrosion-resistant that artifacts of bronze may last thousands of years relatively unscathed. Accordingly, museums frequently preserve more examples of Bronze Age metal-work than examples of artifacts from the much younger Iron Age.

Medieval period.

In the medieval period, blacksmithing was considered part of the set of seven mechanical arts. Prior to the industrial revolution, a “villagesmithy” was a staple of every town. Factories and mass-production reduced the demand for blacksmith-made tools and hardware.

examples of Bronze Age metal-work than examples of artifacts from the much younger Iron Age.

Ironage

Concurrent with the advent of alphabetic characters in the Iron Age, humans became aware of the metal iron. In earlier ages, iron’s qualities, in contrast to those of bronze, were not generally understood though. Iron artifacts, composed of meteoric iron, have the chemical composition containing upto40% nickel. Despite being subject to rust, iron replaced bronze as soon as iron-wielding hordescould invade Bronze Age societies and literally slice through their obsolete bronze defenses. Iron is a stronger and tougher metal than bronze, and iron ores are found nearly everywhere. Copper and Tin deposits, by contrast, are scattered and few, and expensive to exploit.


During the 20th century various gases (natural gas, acetylene, etc.) have also come to be used as fuels for blacksmithing. While these are fine for blacksmithing iron, special care must be taken when using them to blacksmith steel. Each time a piece of steel is heated; there is a tendency for the carbon content to leave the steel (decarburization). A renewed interest in black smithing occurred as part of the trend in do-it-yourself and self-sufficiency” that occurred during the 1970s. Currently there are many books, organizations and individuals working to help educate the public about blacksmithing, including local groups of smiths who have formed clubs, with some of those smiths demonstrating at historical sites and living history events. Some modern blacksmiths who produce decorative metal work refer to themselves as artist-blacksmiths. While developed nations saw a decline and reawakening of interest in black smithing, in many developing nations

20th century

black smiths continued doing what blacksmiths have been doing for 3500 years: making and repairing iron and steel tools and hardware for people in their local area. For example artisans in a developing nation like India are still using Iron bouht from the wastes and left over from the Railway Industry an use them to make knives and other household utility items. Everything is done manually.

CLUSTERWISE DESIGN AUDIT


Cluster HistoryObjective of the studyScope of the studyDemographic distribution of unitsTools & TechniquesProcessesBusiness OperationsProducts


Karanga

Karanga, a small village of the Jorhat District, is renowned for smithery that successfully caters to the demand of neighbouring tea estates and natives.

Formation of SPV in the Cluster- An SPV by the name M/s Dakhin Jorhat Karanga Komar Shilpa Somobai Ltd. with 60 members was registered in the month of June2008.

Cluster Development Executive:-Shri T. Longcher, Asst. Director I/c, Br. MSME-DI, Diphu.Location:-Located 14 km away from Jorhat in 7/8 villages.No of Units:-Around 50 located within a radius of 5 km.Products Manufactured :-Agricultural Implements, Pruning Knives, Knives for domestic use.Employment:-1000 artisans.Turnover Before the Start of CDP:-Rs. 63 lakhs per year.Market:-Tea gardens, Farmers & domestic households in Assam.


History speaks of black smithy in Karanga . It is known that during rule of the Ahom King, Jorhat was protected with a fort from Jorhat to Rajabahar via Titabar from some mutinees like Moamoria and other attacks. To install Hillois and bortups ( Firing guns ) Black smiths were hired from gargaon under the leadership of Sarbanda Hazarika and he was settled at near by Karanga . In this area Hazarika started Black smithy activities with his skills along with his associates and the village was later known as Kamar Hazarika Gaon at Karanga which is 9 kms away to the south of Jorhat.

Since then, Karanga has become a place of traditional blacksmithy. Black smithy is a laborious trade. Different shapes of iron are heated and hammered to convert into products like Daw, Axe, Knife, Pen Knife , Kapi Daw, Sickle, Bothi and other tools used in ploughinglike Moi, Fal etc.

Cluster History

Through Karanga is pioneer in trade, there are some other areas also engaged in this trade in jorhat district . For example – Dhekargorah, charigaon, Hathigarh, Assoibari, Chenijan, Teok . Again there are some scattered black smithy units in some other places also. Ofcourse the interest amongst the new generation has significantly decreased as intense physical labour is required in this trade.

There are 28 nos of scale units are presently working in karanga area. Out of these most of the units do not work through out the year. It is worthly mention that due to the effort of few visionary people in 1954, “Karanga Kamar silpa samabai samity” was established. Initially the local artisians got immense practical help and guidance from the society with the help of modern and mechanized equipment’s.In addit on to this – The society trained the local entrepreneurs to

set up tiny industries as ell as in marketing of their products. Even Government assistance was arranged. But since the year 1964 there was a stalemate in functioning ofthis society . The area now witness the dilapidated and machineries of the society lying in 4 bighas of abandoned land. Scrap cast iron was produced from different departments and the coal was brough from Ledo during early sixties. The society collected products from the artisians for marketing and hence the whole process was cyclic. In the present scenario perhaps there is need for similar efforts tofirther strengthen such domestic micro enterprises .


Objective of the study

The Diagnostic study on the Blacksmith cluster at Karanga Gaon has been undertaken, Keeping in view about the following objectives .

• Identifying the socio-economy conditions of the cluster.• Outlining the present business environment of the cluster.• Identifying infrastructural and financial support required for the overall development of the cluster.

The present study has been carried out covering the entire Karanga Village in the Jorhat district of Assam. Based on the laid down objectives, both primary and secondary data have been used and analyzed in the study. The study has been divided the several stages.

1. In the first stage as per the requirement of the study, primary data has been collected using sampling through intensive interactions/ Interviews with

concerned cluster actors. For collecting the primary data, structureddiscussion formats has been devised for collecting the village level and artisan level information. Interviews have been carried out with the cluster units involved in manufacturing of products.

2. The secondary data have been gathered from the various government officials and the respective departments.

3. Analysis of data and information collected by applying various standards design tools. Studying the present scenario and identifying the problems and gaps in the existingbusiness operations.

4.In the final stage suitable interventions have been devised to bridge the identified critical gaps. Developing proper cluster vision and strategy formulation in the form of an action plan comprising both soft

and hard interventions. Considering the village population were chosen for detailed design research out of all the Karanga Village .


The study would will help to get basic information about the cluster including the exact location of the cluster, age of the cluster, cluster products, existing technology used, present workstation, number of micro and small units together along with the average investment, employment level, level of technology, turn-over, exports and institutional supports available in the cluster. The demography of the cluster will also be assessed. The proper intervention plan will be worked out in different areas like marketing, technology up gradation, credit, institutional capacity building etc. after making a need based analysis. It would also provide a means for assessing the feasibility of interventions, enhancing cooperation among the cluster actors and most importantly involve all the units irrespective of their size of business operation in the cluster development programme.

Scope of the Study

Total no. of working Units: 100+


Demographic Distribution of Units

Annual Production

As per need or order

Market

Trade FairsLocal Market

Raw Material Iron, Wood extracted from wood twigs of trees, Coal & Water.

Technology Used

Hand operated pump,Forging,Drawing,Bending,Upsetting,Punching,Combining,Welding,Finishing

Tools Used

Hand operated pump, Metal & Wooden Hammer, Chisel, Iron Tongs of various sizes and rounded mouth, File, Hand SawBhim(Anvil), Nieri( A ‘T’ shaped Iron object for hammering) Punching ToolSelf made cutter.

Products Produced

BarpetiaDau (Long straight cutting knife with flat nose), SeedhaDau(Long straight cutting knife), Deggar, Pati Bothi (Bird shaped peeling/cutting knife,)Katari(Knife), Jungar (A product with maningpointed mouths), Dighal Dau(Long cutting knife)

Type of Industry:Micro Scale Industry

Karanga Village

Total no. of working Units: 100+


Tools & techniques

There are various tools which a artisian use for making the products. Most of the tools are carrying the same earlier Design and process techniques.


Punching tools : Every unit has different marks of punch(by the name of unit).Hence there is frequent use of this tools so that they have welded it through Tongs.

Punching Tool

Punching Tool


Bending Tool

Bending Tool : Heated iron are hammered on it to give the shape.

Hammers : For the precesion and reduce effort there are variety of hammers having reason behind its design.

Iron base : It has the tempered shape at top which helps during the shaping of iron.


Seating : In local language it called “Pira” . it made of wood ( low seating ). Hand grinder Cutter : Use for cutting metal pipes


Electric Blower : Its a electric machine which blows air to the Fire chamber ( Bhhati ).

Water container : Heated and final products process here for tempering.


Electric Grinder :Finishing of products . A Electric Grinder which is used for Sharpening or Grinding the products.

File : Its a Manual tool , used for sharpening and grinding the products. Its requires more time and labor.


Processes

HEATING

FORGINGPunchingBending

Combining Process

WELDING

Sharpening & Grinding


Heating

Blacksmiths work by heating pieces of wrought iron or steel in a forge until the metal becomes soft enough to be shaped with tools such as a hammer. Heating is accomplished by the use of a forge fueled by propane, natural gas, coal, charcoal, or coke.Color is important for indicating the temperature and workability of the metal: As iron is heated to increasing temperatures, it first glows red, then orange, yellow, and finally white. Blacksmiths work in dim, low-light conditions because they have to see the color achieved at ideal heat for most forging, which is the bright yellow- orange color appropriately known as a “forging heat”.


Forging

A process in which metal is shaped by hammering. In this the iron is hammered into shape. Even punchingand cutting operations (except when trimming waste) by smiths will usually re-arrange metal around the hole, rather than drilling it out as swarf. There are seven basic operations or techniques employed in forging: drawing down, shrinking (a type of upsetting), bending, upsetting,swaging, punching and forge welding. These operations generally employ hammer and anvil at a minimum, butsmiths will also make use of other tools and techniques to accommodate odd- sized or repetitive jobs.


Bending

Heating iron to a “forging heat” allows bending as if it were a soft, ductile metal, like copper or silver. Bending can be done with the hammer over the horn or edge of the anvil or by inserting a bending work piece between the tines of the fork, and bending the material to the desired angle. Bends can be dressed and tightened, or widened, by hammering them over the appropriately shaped part of the anvil.


Punching

punching may be done to create a decorative patterns, or to make a hole. For example, In preparation for making a hammer head, a smith would punch a hole in a heavy bar or rod for the hammer handle. Punching is not limited to depressions and holes. It also includes cutting, sitting and drifting – all done with a chisel. In this process they use punching for marking the product as a brand.


Combining Process

The five basic forging processes are often combined to produce and refine the shapes necessary for finished products. For example, to fashion across-peen hammer head, a smith would start with a bar roughly the diameter of the hammer face: the handle hole would be punched and drifted (widened by inserting or passing a larger tool through it), the head would be cut(punched, but with a wedge), the peen would be drawn to a wedge, and the face would be dressed by upsetting.

As with making a chisel, since it is lengthened by drawing it would also tend to spread in width. A smith would therefore frequently turn the chisel-to-be on its side and hammer it back down—up setting it—to check the spread and keep the metal at the correct width.


Welding

Welding is the joining of the same or similar kind of metal. A modern blacksmith has arrange of options and tools to accomplish this. The basic types of welding commonly employed in a modern workshop include traditional forge welding as well as modern methods, including oxy acetylene and arc welding. In forge welding the pieces to be joined are heated to what is generally referred to as “welding heat”. For mild steel most smiths judge this temperature by color: the metal will glow an intense yellow or white. At this temperature the steel is near molten.

Any foreign material in the weld, such as the oxides or “scale” that typically form in the fire, can weaken it and potentially cause it to fail. He will first clean the parts to be joined with a wire brush, Then put them in the fire to heat. With a mix of drawing and upsetting the faces will be shaped so that when finally brought together the center of the weld will connect

first and the connection will spread out ward under the hammer blows, pushing the flux (if used) and foreign material out.


Depending on the intended use of the piece a blacksmith may finish it in a number of ways: A simple jig (a tool) that the smith might only use a few times in the shop may get the minimum of finishing : a rap on the anvil to break off scale and a brushing with a wire brush. Files can be employed to bring a piece to final shape, remove burrs and sharp edges, and smooth the surface. Heat treatment and case-hardening to achieve the desired hardness. The wire brush either as a hand tool or power tool can further smooth, brighten and polish surface. Grinding stones, abrasive paper, and emery wheels can further shape, smooth and polish the surface. There are a range of treatments and finishes to inhibit oxidation of the metal and enhance or change the appearance of the piece. An experienced smith selects the finish based on the metal and intended use of the item. Finishes include but are not limited to: paint, varnish, bluing, browning, oil, and wax.

Sharpening & Grinding


Business Operations

The working process has been described as per existing scenario in steps.


RAW MATERIALS

PR

OC

ES

S

FINAL OUTCOME

Describing the entire procedure of Karanga Blacksmith Cluster, wherein all the necessary steps are mentionedand described via the research and survey conducted among the cluster artisans. This would gives a proper idea that how and from where the raw materials are being bought and finally molded into a product.


Jorhat Metal / scraps

Metal / scraps

Karanga Village

Raw materials

Raw materials

Storage

Product Development

Wood

Wood

Jorhat local market Coal

Coal

CuttingHeatingForging

Drawing Cutting

Shaping

Finishing

Storage

Use as per required

Upsetting Combining Welding

FinishingBitting and shaping of rings to fit in knife handle.

Finished RingsCombining finished parts of wood and carbon steel.

Products Sold to VendorsLocal Jorhat market

Order based

Business structure


Step : 1 Raw material procurement

The knife handle made of wood which is made of sourced from Jorhat local market or made of sourced raw materialby artisans only.

Ultra high carbon Steel - Raw material brought from local market of jorhat. As per the order requirement articians keep the stock.

Coal is also a main part of their job. They keep the coal usually outside of the unit so in rainy season coal cansoak water, reason is when they burn it it produce less heat and remains for more duration.


Step : 2 Preparing Bhatti for heating the iron

This is a part of coal which makes the iron black and tendency to break product becomes higher. During the Heating process the artisan keep checking for thiscoal. this is a kind of lump which usually get stuck with rod and they take that off.

After making the bhatti the coal has been arranged and paper and plastic are used for light up. Instead of using flammable fuels the paper and plastic are used because it produces less smoke.

While preparing the Bhatti, The artisan put the layer of clay which blocks air from out side. It also helps blower to blow air directly at firing area.


Step : 3 Heating the metal and hammering methods

After preparing Bhatti, the metal objects are put on fire to heat. In every 5 minute of heating they take the object out and hammer or cut accordingly.

Bending and cutting is possible after heating the material. It can be done manually.

When material are heated it becomes easier to cut. The artisan hold the chisel and a helper help him for hammering


Step : 4 Hammering & Bending process

After heating, the forged part is beaten with great force with two black smiths on either side of the anvil. This process continues unless they get the desired shape.

The artisan plays a important role for making a product, He knows the art of shaping and molding the heated iron. The helper hammer as per need.

Heated iron getting shaped by hammering process.

While making a curve shape the artisan use the rounded metal object.


Step : 5

Upsetting Storage after shaping Grinding


Step : 6 Steel Rings

These Rings are cuted from pipes, came out of scrap materials. Rings are used for making handles.


Step : 7 Making Handles


Products


Rukani : Coconut cutter Bothi : Domestic use Fish and Meat cutter


Fish and Meat cutter Kalam Kotari Habi Kota : cut bushes


Chhuri Dab Kotari


Kassi : crops sutter Kopi Daw Naga Daw


Meat Cutter Nalia Kotari


Kothari Talwar

Unitwise Design Audit



People at Karanga Cluster

Sr. No. Name of Artisian Village

1 Ajit Dutta Karanga village

2 Dimbeshwar Kalita Karanga Village

3 Durlabh Borah Bhakatchauni gaon,Karanga

4 Jibon Borah Bhakatchauni gaon,Karanga

5 Khogen Dutta Karanga Village

6 Mintu Dutta Karanga Village

7 Rajeev Neog Karanga Village

8 Sanjib Neog Karanga Village

9 Devojit Dutta Karanga Village

10 Munin Kalita Karanga Village

11 Suresh Borah Karanga Village

12 Ajit kalita Karanga Village

13 Kashab kalita Karanga Village

14 Suren Borah Karanga Village

15 Bhaiti Kalita Karanga Village


S.D PratishthanDevojit Dutta [Proprighter ]

Mr. Devojit Dutta, citizen of karanga village. A ITI graduate from Jorhat Assam. He is in blacksmithy profes-sion since child-hood. The product they make are not different from the way of other people are doing.

At his workshop there are 4 helper working with him on daily basis. They work on order based which makes a limit for his income of source, where the Black smithy is the main source of income. As a prop righter of the unit he take care of the production and business operations. where he pays 250 rs/ day to the skilled helpers and 200 rs/ day to the unskilled helpers.

He do take initiative to exhibit their products in exhibitions which makes profit for him in respect to take orders from more clients and from different places.

Name of unitType of unitNumber of people work at unitType of products they makeBusiness ClientsPer month IncomeTechnology StatusUnit status

S.D PratishthanMicro level 6Domestic toolsOrder based15 - 20 thousandTraditional and very basicRegular basis

Design Intervention suggested.

1. Workshop Need rearrangement.2. Use Power Hammer to increase productiv-ity.3. Storage area should be moisture free.4. For Economic help frequently ask for gov. schemes.

The workshop setup. The products made at s.d pratishthan Power hammer installed at unit but rarelly they make use of it.


M.D enterprises

Mintu Dutta [Proprighter ]



1. The Products should modify in terms of design.2. Workshop Need rearrangement for tools.3. Buffing machine can be used for better finish.4. Always look for exhibition or events as marketing purpose.

M.D EnterprisesMicro level 4Domestic toolsOrder based20 - 25 thousandTraditional and very basicRegular basis

Mintu Dutta a prop righter of M.D Enterprises. The blacksmithy is his genera-tic gift to him, With a good courage and potential he take care of unit. His chosen this business as his main source of income. During the audit it has been observed he has made the different experimentation with the product in terms of design and marketing by exploring the exhi-bitions, But still that based on order.The products made at unit has the similar story as other units compare to process and finish.


A.D EnterprisesAjit Dutta [Proprighter ]

Mr. Ajit Dutta, citizen of karanga vil-lage. He is in black smithy profession since 20 years after his studies. The product they make are not different from the way of other people are doing.

At his workshop there are 2 helper working with him on daily basis. They work on order based which makes a limit for his income of source, where the Blacksmithy is the main source of income. As a prop righter of the unit he take care of the production and business operations. where he pays 250 rs/ day to the skilled helpers and 200 rs/ day to the unskilled helpers.



A.D EnterprisesMicro level 3Domestic toolsOrder based15 - 20 thousandTraditional and very basicRegular basis

The workshop setup. Tools and Hardware at unit Punching tools : Each unit has differ-ent punch which is used as branding.


1. Grinder machine need to place at proper height for good working posture.2. Workshop needs rearrangement.3. Through improving in design the material cost can be maximize.4. Ask for gov. available schemes.


Mr. Sanjib Neog

Mr. Sanjib Neog a blacksmithy arti-san at koranga village,Assam. Farming and blacksmithy are his pro-fession. His unit are more of depend-ed on order based projects on tem-porary basis. The more informations about the unit is not mentioned here due to closing of the unit.


K.N EnterprisesMicro level 2Domestic toolsOrder based10 - 15 thousandTraditional and very basicTemporary basis

K.N Enterprises


1. This is true people are moving for anoth-er business because of not enough income source.2. During the interview it has been observed, having the same facility and process his pro-duction is less than others, reason work on temporary basis, Some times the order is good enough for a month of work but due to no stability in working patterns they has to refuse the project.

3. Its has been found during interview and observations, who ever artisan having agri-culture and black smithy work they usually found no where. Most of the time they spend it in just roaming around, which leads them to poverty issues.


Dimbeswar Kalita (babu) [Proprighter ]

Mr. Dimbeswar Kalita, citizen of karanga village. He is in black smithy profession Child-hood. At his unit He work with his own brother Jibon kalita.At his workshop there are 2 helper working with him on daily basis. Since they work on order based which makes a limit for his income of source, where the Black smithy is the main source of income. As a prop righter of the unit he take care of the production and business operations.

During the personal interview with them it has been observed tha lack of system knowledge. Just like the other artisan he is just aware of black smithy, not the market trends or re-quirement.


A.D EnterprisesMicro level 3Domestic toolsOrder based15 - 20 thousandTraditional and very basicRegular basis

The workshop setup. Its covered by tin ( metal shad ) which produces more heat compared to bamboo.

Dimbeswar kalita working at his own unit

Making daw.


1. Workshop need rearrangement.2. Having few helpers can help to increase productivity.3. Few Electric/ Power tools required.


Bhaiti Kalita

Mr Bhaiti Kalita is one of the senior artisan at this village, age 52.

At his workshop there are 2 helper works. They work on order based which makes a limit for his income of source, Agriculture is the another source of income for him. He source the materials from Rupohiali (Jorhat)The products and processes are same as other artisan do. He only take orders from client when he get free from farming.


B.K EnterprisesMicro level 2Domestic toolsOrder based10 - 12 thousandTraditional and very basicContemporary basis

B.K Enterprises


1. This is true people are moving for anoth-er business because of not enough income source.2. During the interview it has been observed, having the same facility and process his pro-duction is less than others, reason work on temporary basis, Some times the order is good enough for a month of work but due to no stability in working patterns they has to refuse the project.

3. Its has been found during interview and observations, who ever artisan having agri-culture and black smithy work they usually found no where. Most of the time they spend it in just roaming around, which leads them to poverty issues.


J.B EnterprisesJibon Borah [Proprighter ]

Mr. Jibon Borah, age 42 years. citi-zen of karanga bhakatcheuni village. He is in black smithy profession since 35 years.

At his workshop there are 2 helper working with him on daily basis. They work on order based which makes a limit for his income of source, where the Black smithy is the main source of income. As per the market need he is unable to provide the products due to finan-cial situations. His workshop contains very basic tools and stock of materi-als.


J.B EnterprisesMicro level 3Domestic toolsOrder based15 - 20 thousandTraditional and very basicRegular basis

The workshop setup. At work. Making products at workshop.


1. Workshop need rearrangement.2. Having few helpers can help to increase productivity.3. Few Electic/ Power tools required.


Mr. Durlabh Baruah

Mr durlabh baruah is one of the se-nior artisan at this village, age 58.

At his workshop there are 2 helper working with him on daily basis. They work on order based which makes a limit for his income of source, where the Black smithy is the main source of income. He unit is based at a DRDA work-shop building, which is sponsored by district rural development agency ( DRDA). This workshop has few new technology equipped with power tools & it has been made for all the artisans at karanga village. Unfortu-nately no artisans are interested to work at this place. Lack of electricity and machineries handling is one of the reason.


D.B. Black smithyMicro level 3Domestic toolsOrder based15 - 20 thousandTraditional and very basicRegular basis

The workshop setup.

Artisan working on Grinder machine

Electric Bhatti which is no more in use

D.B. Blacksmithy


1. DRDA provided workshop can be used in good ways.2. The machineries will be benefited if used.3. While using the power tools safety concerns should not ignore.4. For more production invite another unit artisan to work on order based.


Rajeev Neog[Proprighter ]

Mr. Rajeev Neog, citizen of karanga village. He is in black smithy pro-fession since childhood. Apart from the Black smithy he has agricultural business. As per requirement he work on order based.

At his workshop there are 2 helper working with him on daily basis. They work on order based which makes a limit for his income of source, where the Black smithy is the main source of income. As a prop righter of the unit he take care of the production and business operations. where he pays 250 rs/ day to the skilled helpers and 200 rs/ day to the unskilled helpers.



Not Registered Micro level 3Domestic toolsOrder based15 - 20 thousandTraditional and very basicSeasonal basis

The workshop setup. Unit from outside. Products they usually make as per order.


1. Electronic tools should implement.2. Workshop needs rearrangement.3. The helpers should work on permanent basis.4. Ask to avail gov. available schemes.


M.D Enterprises (Mridul Dutta)




1. Filing can be done by power tools.2. To use different grades of file for finishing.3. Use of C- clamps for filing & finishing.4. Tools need to be placed at standard table height.


Khogen Dutta




1. Filing can be done by power tools.2. To use different grades of files for finishing.3. Use of C- clamps for filing & finishing.4. Tools need to be placed at standard table height.

Mr. Khogen dutta a senior artisian having a small unit at karanga village. His expertise are making handles and give the finish to the products. Usual-ly he works with the other unit.

The working posture and ergonomic issues are the main concern which came out during the audit.




S.K Enterprises (Munin Kalita)




Jibon Kalita




kHOGEN dUTTA


intervention framework


Description of Ergonomic & environment factors.

Design opportunities in workstation & tools.

Existing products, Redesign, New product development & product diversification.

Existing status & opportunities for visual identity, Branding & communica-tion design.

Scope for research & development directions for future initiatives.

Scope for technology, modernization & design collaborations.

Packaging & logistics related design opportunities.


Description of ergonomic and environment factors

Through out the observation of cluster units, It has beenfound “ The whole system has need to be redesign” in terms of workspace, Machineries, Techniques & othereffecting factors.

Ergonomics - Ergonomics is the term which defined as the science of fitting the work to the user instead of forcing the user to fit to the work. At cluster there are people who going through the daily work tasks which need focus of Ergonomics.For a good postural comfort and enhance the user productivity as well as safety its necessary to design spaceergonomically . But there is a large variability in size of people in the work force population,their culture, Education, Skill’s, Attitude, Physical and mental capabilities which challenge us to make a workspace which should be compatible for all. The current scenario at cluster and the problem they facing day to day life.

Hot metal bruises due to hammering & shaping the knife

Hot metal bruises on feet.

Hand: while heating and hammering iron the small particles used to hit the body parts.

Foot : It is important to them to take care of possible incidents, but still they do face problems.


1. Traditionally blacksmith is having sitting workstation for their work which is ergonomically very poor design.2. Time taken for movement of hands from furnace to quench basin is also more that is why they have to do more hammering and repeatit again and again until the shape will be made. 3. Productivity and efficiency is less due to poor design as far as ergonom-ics is concerned, they have muscular problems. 4. No proper place to keep the tools at place.5. The semi-finished products, fin-ished products, tools and raw materi-als, everything lie one above the other with any proper systematic arrange-ments under the shed.

Issue and concerns : Solution/opportunities:

Human factor integration and Ar-rangement of the workplace.

1. Workstation design in terms of physical dimension, including seating can solve lots of problem of end user.

2. The aim should be to minimize the risk of operator discomfort and relat-ed muscular-skeletal problems such as back and shoulder complaints.

3. Workstation layout, should such that specifically the positioning of equipment on and around the work-station to ensure that it is visible and within easy reach of the operators who will use it.

4. Rhythm is essential to the smooth and automatic performance of a re-petitive operation. The work should

be arranged to permit easy and natu-ral rhythm whenever possible.

5. Work should be arranged so that eye movements are confined to a com-fortable area, without the need for frequent changes of focus.

6. Tools and materials should be pre-positioned to reduce searching.

7. “Drop deliveries” or ejectors should be used wherever possible, so that the operative does not have to use his or her hands to dispose of the finished work.

8. Provisions should be made for ade-quate lighting and a chair of the type and height to permit good posture should be provided. The height of the workplace and seat should be ar-ranged to allow alternate attending

and sitting.


The working posture

Key words

Low seat heightShoulder & back painHard impression on palmPain in FeetFrequent Interval of breaksLess productivity


Safety tools are avoided while using machineries.


Work place


The workplace is not well organized as per requirement. There is other effecting factors which causes the work productivity, and ergonomics factors.

The Water tub which artisans use it for tempering the metal products. As per Design audit the place and size need to rethink as per standards.

A simple bamboo structure, use to keep tools.


low height seating Hand grinder cutter machine: Use it for cutting rods and pipes, But for this purpose there is not such space alloted. Usually they cut the piece of metals on the floor only.

After the initial precesses done they keep the products on one corner of floor. There is no such take care of rusting metals. Every time they clean and file the knives which take more time { cause of less productivity }.


Solution/opportunities:

Design of tools and equipment

1. The hand should be relieved of all work of “holding” the work piece where this can be done by a jig, fix-ture or foot operated device.

2. Two or more tools should be com-bined wherever possible.

3. Handles should be so designed that as much surface of the hand as pos-sible can come into contact with the handle. This is especially necessary when considerable forces have to be used on the handle.


Design opportunity in workstation and Tools.

1. There is no proper lighting system for working in night hours,rely gener-ally on natural light.

2. There are no such modern tools used in the cluster.

3. The artisans sit in inappropriate and tire some working positions to make the positions

4. There is no place to work as a group,every one works individually as per the need of the market.

5. In case of no electricity arti-sans work in candle light for long hours,which can be painful for eyes and leading to eyesight problems .Its a major area of concern in the cluster.

6. The amount of heat and dust pro-duced during the entire procedure of knife making is very harmful for the artisans as they do not were any kind of safety equipments or devices in order to save themselves from inhal-

ing harmful gases of coal and burning there hands during the process of making the products.

7. There is high amount of risk for the artisans to get hurt by the process of cutting,beating,forging etc processes without using any kind of precaution.

8. Very less artisans can afford work-ing inside with decent facility,but maximum artisans work in sheds outside inhaling fumes.

9. The products are kept with no proper arrangement or storage,leads to damage.

10. The work process is really slow due to hand made nature of the pro-cess.


The Workshop is very dark and artisans have to work in such a dark place that threats there eyesight.

cluttered and unorganized Work shed.The work shed is made up of bamboo and hay, and it is difficult to protect the inner materials and be-longings from rain and sunlight.


1.Few unit has some power tools like power hammer but due to lack of proper training and maintenance it has been out of use.

2.The new tools for cutting, finish-ing, polishing etc or other treatment agents etc. can be introduced at com-mon facilitation centre.

3.Introduction to proper machineries and tools etc could improve produc-tivity.

4.Organized work stations at CFC.5.Solar lights can be introduced so that they could work in the evening hours.

6.Proper gloves, eye protection glass-es, helmet to wear during the dyeing process, treatment processes.

7.Seating need to be improved along with tables to work upon in the CFC.

Solutions and opportunities :


Existing Products, redesign, new product development and product diversification :

1. Since there is a good demand for sustainable products all over the world, but the designs, particularly in the cluster till now, has not went beyond what has been developed since ages and are of very limited variety.

2. National - international market linkages are not yet developed and strengthened sufficiently to get continuous order and better remuneration.

3. The existing products consist of only few repetitive designs and with no contemporary or new colours or designs.

4. On orders the artisans can’t afford buying raw materials and only procure them after receiving any kind of less cash advance.5. The products are of the same quality even if the traders/customers are different.

6. Some products, made by the artisans are inspired randomly or from existing products made in other parts of Assam, and other states.

7. Most of the existing products does not have such good finishing which decreases the life cycle of the products.

8.Except one or two artisans almost all the artisans in the cluster make similar products on order basis only.

9. Very Poor Raw material quality.

10. The finishing in the products is not up to the mark.

11. There is no product diversification at all in terms of aesthetics and quality

12. No body anatomy is considered while designing products.

13. No inspirational engravings or

other things are being practiced till now in the cluster.

14. The product made are not in much demand as similar kinds of products are being made in other part of Assam also. 15. The lack of Quality Certification makes it very difficult for the artisans/agents to win trust of customers, especially outside the state.

16. When the products get wet,they are easily attacked by rust. There has not been any such step taken forward to protect the products from outer damage, i.e. no treatment process has been developed yet.

17. The deformity in the handles and poorly finished knives are easily visible on the product which make its less attractive and not for international market.

Issues & Concerns



1. The Raw materials procured can be of better quality to improve per-ceptual quality of existing product by proper linkage via the organization handling the cluster.

2. Possibility of another range of product in cutting tools itself, so that the basic idea of knife makers are not gone from the cluster. Other new age products like with the help of proper technology and machineries, can be easily developed and would bring in much higher remuneration to the makers. The products can then cater to the needs of a different target group who are more design and are quality conscious.

3. The existing products can be made more contemporary and relevant, less labor intensive.

4. The elements from the existing tra-ditional designs of assam, eg. : designs

in traditional Assamese dress, nature inspired designs etc. can be used and engraved in new product develop-ment and diversification and to give the products a local identity of itself.

5. Local craft can be combined with the Blacksmith products to get di-versified products, like combining bamboo for making handles instead of wooden,

6. Increasing the life span of the metal by treating with various agents or by using better steel.

7. The elements from existing tradi-tional products can be used to intro-duce lifestyle products such as fold able knife, cutlery, and other nick knacks for contemporary homes lead-ing to scope of wider customers.



Existing status and opportunity for visual identity, branding and communication design

Issue and concerns :

1. The artisans mostly does not have any pictures of their creations in any kind of format be it photographs or other.

2. There is a punch as visual identity for the clusters as they rarely sell the products directly to the final consum-ers.

3. There is no proper documentation/ catalogue of the traditional products made in karanga Blacksmith cluster.

4. The products till date has never been advertised, hence people indif-ferent cities and places of India and around the world are unaware of the craft.

5. Mostly the people in the cluster are unaware of the latest trends, also they work individually and make the designs which has been taught

to them by someone else, therefore they don’t get much opportunity to share ideas of how to promote their products to reach out to maximum consumers.

6. Even while selling them off to the consumers, the products are not prop-erly packed and labelled.



1. The idea of having a common visual identity and branding for the cluster was well accepted. However it was felt that it should go in sync with initiatives like Online selling portal/website, advertisement, packaging design, branding etc.

2. There is a big scope in developing visual identity for the cluster units, branding and communication design to connect them to the market directly and get them more exposure.

3. Along with product diversification, a product catalogue is a must and also presence of products online will be of great help to reach larger audience.

4. A comprehensive documentation of Karanga Blacksmith cluster along with the catalogue will be a great source of information for the people outside Assam and to understand benefits of completely hand made products.

5. The concept of common brand building like will help them to create an identity for themselves.


Scope for research and development direction for future initiatives :

1. There is no as such hardcore technology used in the making Blacksmith products by the artisans and the process to make it are also outdated and quiet time consuming.

2. The artisans and other cluster people also don’t have enough resources as well as funds to get introduced to new technology.

3. They do not have enough funds, time and expertise to carry out research and development on a regular basis to find out the market trends in national or international market.

4. The quality of products is compromised due to insufficient delivery time and lack of man power and technology which would have facilitated and increased the speed of work without compromising on quality.

5. They are not geared to thinking in terms of conducting research and development in this area which is seen more as a local prevalent traditional craft.

6. The cluster does not have a proper schedule of work or time and each unit works individually though being in a group, therefore there are no separate departments to handle specific job.

Issues & Concerns


1.The Raw materials procured can be of better quality to improve perceptual quality of existing product by proper linkage via the organization handling the cluster.

2. Possibility of another range of product in cutting tools itself, so that the basic idea of knife makers are not gone from the cluster. Other new age products like with the help of proper technology and machineries can be easily developed and would bring in much higher remuneration to the makers. The products can then cater to the needs of a different target group who are more design and are quality conscious.

3.The existing products can be made more contemporary and relevant, less labor intensive.

4.The elements from the existing traditional designs of assam, eg. : designs in traditional assamese dress,

For the finishing of the product cluster need to introduced with new technologies.

The Techniques & equipments are more of “Jugaad”. They arrange it themselves as per resources availability.

Lack of technology and working-shed makes it difficult for the artisans to work single handedly and need accompany always.

The workspace need to Design in a proper way which take care of productivity, Health issues, Safety.

nature inspired designs etc. can be used and engraved in new product development and diversification and to give the products a local identity of itself.

5.Local craft can be combined with the Blacksmith products to get diversified products, like combining bamboo for making handles instead of wooden,

6.Increasing the life span of the metal by treating with various agents or by using better steel.

7.The elements from existing traditional products can be used to introduce lifestyle products such as fold able knife, cutlery, and other nick knacks for contemporary homes leading to scope of wider customers.



Scope for technology, modernization and design collaborations.

1. The disadvantages of the products include poor raw material quality, poor finishing and knives when subjected to water gets rusted.

2. Due to lack of technology, products can not be finished properly.

3. The tools used by the artisans are either outdated with no real modern technology available to them.

4. There is no automatic facility of cutting the metal, any beating technology, or automatic finishing technology/tools/machineries like buffering etc in the cluster, and artisans have to do it all by hand.

5. Even in case of bulk orders for the same products, its made by hand, which leaves them with no time to experiment and create new designs.

6. There is a reluctance and resistance to modernization and adoption of new designs on the produced products.

7. The products get destroyed during the storage of the semi-finished or finished products.

8. The amount of waste generated is not utilized in any way.

9. The kind of knives the artisans haven been making tends to break on the joinery part mostly the wooden handles breaks and people have to make the handles again.

10.Very difficult for the artisans to work in summers due to the fact that the open furnace gets too heated up.

11. Since the furnace os open most of the heat escapes into the air giving less than half of the heat produced out of burning coal for the production of the knives.


Technology:

1. Improvisation in machinery, tooling, process through R&D activities.

2. Investigating the properties of Metal in order to make the best use of the same while developing products.

3. A Common Facility Centre (CFC) can be set up with modern technology.

4. Exchange of technology ideas can be initiated through CFC.

5. Research in the area of proper furnace, working table to cut the products, proper heighted Anvil etc.

Marketing:

1.Research in terms of consumer trends and competition in the local,

National and international market.

2. Creating an online portal or website to sell the products to the unreachable.



Packaging and logistics related design opportunities

Issue and concerns :

1. There is no real concept of pack-aging at the cluster level.

2. No unique identity for the Karan-ga Blacksmith products, packaging for products from all clusters is the same.

3. Products are kept either in a shed, or kept in a plastic bags or mostly openly outside, leads to breakage and wear and tear of the surface of the finished or semi-finished products.

4. There is also chances of theft during commuting from city to other.

5. No insurance cover.

Solution/opportunities:

1. New packaging design can be introduced such as pouches or knife carriers using and blending tradition-al Assamese textiles with Jute, silk or leather type material to pack the products.

2. These packaging solutions will give a visual and unique identity to the products made in Assam.

3. Packaging can be taken care of in terms of moisture content even in extreme cases when the products are shipped while exporting.

4. To make the artisans aware of the packaging process by training ses-sions and teach them how cushioning and proper packaging could save the products and avoid damage while the shipping process.

5. New and cost effective form of packaging needs to be introduced.

6. If packaging is improved, it would create a good presence and in turn will boost the business and help in competing.

7. Proper Bar coding on the packag-ing.


Workspace Need to Design Need to introduce with Technology : Purpose & benefits

In the village there are few tools but again people don’t know the good use of it.

At work the safety requires proper attention The finished product : which still requires finishing work for good value.

Windup

During the Research & analysis of the cluster survey at Karanga its has been found the cluster has been carried in same methodology. The artisans are skilled and have a potential to make products but they lack of new technologies, and that is also the one reason for their financial situation.Here in this report we would like to introduce you with some facts of Cluster which they are going through and need to take good care of it.

1. Since the cluster tradition is following from the long years ago, Non of the design or processes has been changed.

2. The new generation dint have interest to continue with cluster works. Feel shy and people are moving to bigger cities for occupation.

3. There are few families who are in this business, The income is not enough for survival because of that

7. The product they make need lots of effort and attention, but the finishing need to demons trait with different options.

8. The value of the products can be raise if they market their business in proper & possible ways.

they keep alternatives for it.

4. The work and effort, non of these get exposure through out the world, which is also one of the reason for gradually decreasing the number of units per year.

5. The Government schemes are available but not easily accessible for them. which put him in financial trouble.

6. Very few people are graduate or completed their basic education, which limits their knowledge within their work and resources .

9. Their workspace or unit need redesigning for well ergonomic and productive.

10. The new Technology need to introduced to them for making the work & process easier. i.e. Buffing tool, C clamps, different grades of sand papers and its benefits.

Karanga Blacksmith Cluster

Design Clinic Workshop || Band 524/12/2013 - 29/12/2013

Submited by - Govind KrishnaEmotomes

Workshop Schedule

SL.No 9:15 AM Session (10:00 am to 1:00 pm) Session (10:00 am to 1:00 pm)

Day 1 Registration

With Attendance

Session 1: Inauguration, felicitation of the Chief guest BREAK Session 2 : Presentation by Govind Krishna on

showcasing the blacksmith products made

throughout the world

Day 2 Attendance Session 1 : Tools and Technology usage and

implementation and Finishing Methods/technologies :by

Govind Krishna

BREAK Session 2 : Quality assesment and finishing

workshop : govind krishna

Day 3 Attendance Session 1 : Product Diversification and making process with

addition of new materials and design: by Govind Krishna

BREAK Session 2 : Product diversification workshop

Day 4 Attendance Session1 : Involvement of new technology

intervention in Blacksmith Industry: Govind Krishna

BREAK Session 2 : Hands on workshop on use of power

tools for process improvement

Day 5 Attendance Session 1 : Concept of Packaging and Branding for

sustainable marketing : By Govind Krishna

BREAK Session 2 : End of the program with remedial

solutions, Evaluation and Conclusion Ceremony

/Feed Back Form

•Presentation by Ankit agrawak on Showcasing the blacksmith products made through out the world .

•Tools & technology usages and Implementation & finishing methods/ Technologies.

•Metal Carving Workshop.

•Involvement of new technology intervention in Blacksmith Industry.

•Product Diversification and making process with addition of new materials and Design.

•Wood Carving and finishing Workshop.

•Concept of Packaging and Branding for sustainable marketing.

Topics covered during 5 days Workshop

Registration with attendence

Day 1: Session 1: Inaguration, felicitation of the chief guest: speech by DIC officials

Day 2: Session 2: Presentation by Arpit Agrawal on showcasing blacksmith products made through out the world.

Different Blacksmith knives made throughout the world.

Day 3:session 1: Tools & Technology usages and Implementation & Finishing process.

Bench Grinder Buffing machine

Drill machine C Clamp

Tools & Techonology

• Most of the existing products does not have such good finishing which decreases the life cycle of the products. • The deformity in the handles and poorly finished knives are easily visible on the product which make its less attractive and not for • international market. • There is no automatic facility of cutting the metal, any beating technology, or automatic finishing technology/tools/machineries like buffering etc in the cluster, and artisans have to do it all by hand. • Even in case of bulk orders for the same products, its made by hand, which leaves them with no time to experiment and create new designs.• The products get destroyed during the storage of the semi-finished or finished products. • The tools used by the artisans are either outdated with no real modern technology available to them. • No safety precaution being taken while the process of making the products.

1. It is a high time to introduce them to processes and agents for treating the raw materials so that the life cycle of the products increases and the consumer does not have any issues related to Jute products.2. Buying good quality raw materials via proper dealers through financial help would definitely raise up the cluster above its present status. 3. The introduction to the CFC will give them an opportunity to explore beyond the traditional technique of polishing or weaving. They can be introduced to which can increase speed of work by many folds especially for bulk order. 4. A few changes in machineries and mechanisms, won’t change the concept of the ‘100% HANDCRAFTED’.5. Separate units of Cutting, heating, forging, drawing, bending, upsetting, combining, welding and finishing can be set up in the common facilitation centre.

Observation :

Solutions:

Finishing Techniques

Nickel Finish

Brush Finish

Engraving

Industrial Machineries Introduction

Brushing machine Bench grinder

Bench Grinder cum brushing machine

Bench Grinder cum brushing machine

Buffing Process

Buff Polishing : Creates a smooth, non-textured finish. Buff polishing machine uses a cloth wheel to buff the product’s surface, resulting in a high, glossy sheen. The process is often used for decorative products that benefit from lustre and smoothness.A great way to buff any metallic, painted, or varnished surface. Buffing uses a buffer that is powered by an electric motor, making the job far more effortless and time consuming that buffing by hand

Day 3: Session 2: Quality assesment & finishing workshop.

Earlier handles Handle Design explored in workshop

Day 4 :Session 1: Product Diversification and makiing process with addition of new materials .Designs explored by artisans in workshop

Day 4: Session 2 : Product diversification& making process with addition of new materials.Metal carving workshop (Developed a design made in workshop)

Knife made with proper measurement in Workshop.

Material Optimization

Observations

Solutions

•Very poor raw material quality.•The lack of Quality Certification makes it very difficult for the artisans/agents to win trust of customers, especially outside the state. •When the products get wet,they are easily attacked by rust. •There has not been any such step taken forward to protect the products from outer damage, i.e. no treatment process has been developed yet.

1. The Raw materials procured can be of better quality to improve perceptual quality of existing product by proper linkage via the organisation handling the cluster. 2. Increasing the life span of the metal by treating with various agents or by using bettersteel. 3. Quality Certification will makes it easy for the artisans/agents to win trust of customers, especially outside the state.4. It is a high time to introduce them to processes and agents for treating the raw materials so that the life cycle of the products increases and the consumer does not have any issues related to Jute products. 5. Buying good quality raw materialsvia proper dealers through financial help would definitely raise up the clusterabove its present status.

SCOPE OF DEVELOPMENT

Observations • Karanga is quite a remote village of Assam where the clusters only produce knives and few other products. •The artisans and other cluster people also don’t have enough resources as well as funds to get introduced to the new technology.•The cluster does not have a proper schedule of work or time and each unit works individually though being in a group, therefore there are no separate departments to handle specific job. •They are not geared to thinking in terms of conducting research and development in this area which is seen more as a local prevalent traditional craft.

1. Improvisation in machinery, tooling, process through R&D activities. 2. Investigating the properties of Jute in order to make the best use of the same while developing products. 3. A Common Facility Centre (CFC) can be set up with modern technology. 4. Exchange of technology ideas can be initiated through CFC. 5. Research in the area of proper furnace, working table to cut the products, proper heighted Anvil etc.

Marketing:

1. Research in terms of consumer trends and competition in the local, National and international market. 2. Creating an online portal or website to sell the products to the unreachable. Sukanya Bor

Solutions

Day 4 : Session 1: Hand on tools.

Day 4 : Session 2: Discussion on made products during workshop by artisans for better understanding

PRODUCT DEVELOPMENT

Observations • The existing products consist of only few repetitive designs and with no contemporary or new colours or designs. • Some products, made by the artisans are inspired randomly or from existing products made in other parts of Assam, and other states. > The artisans in the cluster make similar products on order basis only. • No inspirational engravings or other things are being practiced till now in the cluster. • No body anatomy is considered while designing products. • There is no product diversification at all in terms of aesthetics and quality.• The deformity in the handles and poorly finished knives are easily visible on the product which make its less attractive and not forinternational market.

1. Possibility of another range of product in cutting tools itself, so that the basic idea of knife makers are not gone from the cluster. Other new age products like with the help of proper technology and machineries, can be easily developed and would bring in much higher remuner-ation to the makers. The products can then cater to the needs of a different target group who are more design and are quality conscious. 2. The existing products can be made more contemporary and relevant, less labour intensive by inclusion of machineries in the cluster.3. The elements from the existing traditional designs of assam, eg. : designs in traditional as-samese dress, nature inspired designs etc. can be used and engraved in new product develop-ment and diversification and to give the products a local identity of itself. 4. Local craft can be combined with the Blacksmith products to get diversified products, like combining bamboo for making handles instead of wooden. 5. The elements from existing traditional products can be used to introduce lifestyle products such as foldable knife, cutlery, and other nick knacks for contemporary homes leading to scope of wider customers.

Solutions

Day 5 : Session 1 : Concept of Packaging and Branding for sustainable marketing.1

Packaging

karanga kni e

Name :

Productcode :

Material:

Mrp :

Jorhat knife cluster

karanga kni eJorhat knife cluster

Product Tag & Visiting card made for Artisans.

Day 5 : Session 2 : End of the programe with remedial solutions, Evaluation and ConclusionCeremony /Feed Back Form

PROJECT OPPORTUNITIES

WORKPLACE LAYOUT AND SIMPLIFICATION OF MOVEMENTS

ARRANGEMENT OF WORKPLACE

1.If similar work is being done by each hand, there should be a separate supply of materials or parts for each hand.2.If the eyes are used to select material, as far as possible the material should be kept in an area where the eyes can locate it without there being any need to turn the head.3.Use semi-circular arrangements.4.Design the workplace using ergonomic principles.5.The nature and the shape of the material influence its position in the layout.6.Hand tools should be picked up with the least possible disturbance to the rhythm and symmetry of movements. As far as possible the operator should be able to pick up or put down a tool as the hand moves from one part of the work to the n4ext, without making a special journey. Natural movements are curved, not straight: tools should be placed on the arc of movements of any material which has to be slid along the surface of the bench.

1.Definite and fixed stations should be provided for all tools and materials to permit habit formations.2.Tools and materials should be pre-positioned to reduce searching.3.Gravity feed, bins and containers should be used to deliver the materials as close to the point of use as possible.4.Tools, materials and controls should be located within the maximum working area and as near to the worker as possible.5.Materials and tools should be arranged to permit the best sequence of motions.6.“Drop deliveries” or ejectors should be used wherever possible, so that the operative does not have to use7.his or her hands to dispose of the finished work.8.Provisions should be made for adequate lighting and a chair of the type and height to permit good posture should be provided. The height of the workplace and seat should be arranged to allow alternate attending and sitting.

PRODUCTS MADE DURING THE FIVE DAY WORKSHOP

Sword Handle Knives Knife handle

Mobile : +91 8758615965 / 9507629936email : [email protected] : Shivpuri campus, Main road Garhwa, Jharkhand,

822114 .

karanga knife cluster - design clinic...

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