need assessment survey of howrah rolling mill cluster ...designclinicsmsme.org/design awareness...

Need Assessment Survey of Howrah Rolling Mill Cluster under the

Design Clinic Scheme for MSMEs supported by Ministry of MSME, Govt.

of India

Survey Team

Dr. Somnath Gangopadhyay, PhD, FABMS

Associate Professor,

Occupational Ergonomics Laboratory,

Department of Physiology

University of Calcutta

Krishnendu Sarkar, M.Sc.

Research Scholar,


Department of Physiology University of Calcutta

Sujaffar Hosain Mollah, M.Sc.

Research Assistant,


Department of Physiology

University of Calcutta

Acknowledgement

Mr. Shashank Mehta, Project Head, Design Clinic Scheme, National Institute of Design

Mr. Ashok Mandal, Coordinator, Eastern zone, National Institute of Design

Mr. Sudeb Mandal, Designer, National Institute of Design

Mr. Sankar Sanyal, President, Howrah Chamber of Commerce and Industries

Mr. Ramaswami, Howrah Chamber of Commerce and Industries

Mr. Pradip Chakraborty, Howrah Chamber of Commerce and Industries

Mr. Upaddhyay, Howrah Chamber of Commerce and Industries

Owners and workers of the different Rolling Mills studied

Table of contents

Introduction ....................................................................................... 1

Geographical Location: .................................................................. 2

Rolling Mill- History and present scenario ..................................... 3

Rolling Process ................................................................................... 5

Materials and method ....................................................................... 7

Questionnaire ................................................................................ 8

Ergonomics Checklist ..................................................................... 8

General Interview .......................................................................... 8

Study Units ..................................................................................... 8

Descriptive Study: Cluster Level ......................................................... 9

SWOT Analysis: ............................................................................ 10

Other Observations ...................................................................... 11

Development of Musculoskeletal Disorders ................................ 11

Poor Workplace ........................................................................... 11

Descriptive Study: Unit Level ........................................................... 12

1. AJAY INDUSTRIES ..................................................................... 13

2. HARYANA STEEL INDUSTRIES ................................................... 14

3. ALLOY STEEL ROLLING MILLS ................................................... 16

4. BHARAT STEEL INDUSTRIES ...................................................... 18

5. GOYAL ISPAT UDYOG ............................................................... 20

6. KK STEEL ................................................................................... 21

7. CROWN METAL INDUSTRIES .................................................... 22

8. DADA BHOMIA ISPAT Pvt. Ltd. ................................................. 24

9. POONAM ALUMINIUM METAL ................................................ 25

10. KULHARIA STTEELS Pvt. Ltd. ................................................... 27

11. KWALITY STEEL PROCESSORS ................................................. 28

12. SIDHI VINAYAK ALLOYS Ltd. ................................................... 29

13. SKG IRON & STEEL Co. ............................................................ 31

14. SUJATA STEEL INDUSTRIES ..................................................... 32

15. SHREE VIJAY LAXMII ROLLING MILLS Pvt. Ltd. ....................... 34

16. GADIA ALUMINIUM Pvt. Ltd................................................... 35

Design Possibilities (Cluster wise) .................................................... 37

Workplace Layout ........................................................................ 38

General Recommendations ......................................................... 39

Design Possibilities: Unit wise .......................................................... 40

Scope for research and development direction for future

initiatives ...................................................................................... 49

Design Clinic Workshop ................................................................... 50

List of figures

Figure 1: Map of Howrah ................................................................... 2

Figure 3: Flow diagram of rolling process .......................................... 6

Figure 2: Rolling process (Schematic) ................................................ 6

Figure 4: Existing workplace layout ................................................. 38

Figure 5: Proposed modified layout ................................................. 38

Figure 6: Bending posture and position of man cooler fan ............. 41

Figure 7: Low level of Illumination ................................................... 41

Figure 8: Poor working posture ....................................................... 42

Figure 9: Self made leg protecting guard ......................................... 42

Figure 10: Final products hinder normal movements ..................... 43

Figure 11: Poor work posture of the wrist ....................................... 43

Figure 12: Lack of proper safety shoe .............................................. 44

Figure 13: Worker at the face of the furnace works at very high

temperature ..................................................................................... 44

Figure 14: Workers using local goggles as protective equipment ... 45

Figure 15: Workers working with awkward posture ....................... 45

Figure 16: Unsafe work condition .................................................... 46

Figure 17: Handling of the big forcep .............................................. 46

Figure 18: Working at the furnace ................................................... 47

Figure 19: Bad layout ....................................................................... 47

Figure 20: Hazardous job at the face of the furnace ....................... 48

Figure 21: Existing working condition .............................................. 48

Figure 22: Proposed Design solution ............................................... 48

Figure 23: Dignitaries in the dais...................................................... 51

Figure 24: Dr. Gangopadhyay delivering his talk ............................. 51

Figure 25: Dr. Banerjee giving his talk.............................................. 51

Figure 26: Owners of different rolling mills ..................................... 51

Figure 27: Dr. Gangopadhyay discussing about Ergonomics ........... 51

Figure 28: Mr. Sankar Sanyal, President, HCCI ................................. 51

Figure 29: All the participants of the workshop .............................. 51

Figure 30: Need assessment survey presentation ........................... 51

Figure 31: Discussion with the owners ............................................ 51

Figure 32:Interactive session ........................................................... 51

Figure 33:Dr. Gangopadhyay discussing with the workers .............. 51

Figure 34:Improper safety shoes ..................................................... 51

Figure 35:All the participants of Day 2 ............................................. 51

Figure 36: Presentation on Need Assessment Survey ..................... 51

Figure 37: Discussion with the owners ............................................ 51

Figure 38: Dr. Gangopadhyay interacting with the workers ............ 51

Figure 39: Participants of day 3 ....................................................... 51


Figure 41:Proper storage of raw materials ...................................... 51

Figure 42: Interaction with the owners ........................................... 51

Figure 43: All Participants of Day 4 .................................................. 51


Figure 45: Interaction with workers ................................................. 51

Figure 46: Worker at the face of the furnace .................................. 51

Figure 47: Talking about the big forcep ........................................... 51

Figure 48: interactive session .......................................................... 51

Figure 49: Discussion with workers.................................................. 51

Figure 50: Safety shoe not proper ................................................... 51

Figure 51: All participants of day 5 .................................................. 51

1

Introduction

Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta

2 Geographical Location:

The Howrah district lies between 22°48′ N and 22°12′

N latitudes and between 88°23′ E and 87°50′ E longitudes. The

district is bounded by the Hooghly River and the North 24

Parganas and South 24 Parganas districts on the east, on the

north by the Hooghly district, and on the south by Midnapore

East district. On the west Howrah district is bordered by the

Ghatal sub-division of Midnapore West district, and partly by

the Arambagh sub-division of Hooghly district to the north-

west, and the Tamluk sub-division of Midnapore East district

to the south-west.

Boundaries of the district are naturally determined by

Rupnarayan River on west and south-west, and by Bhagirathi-

Hooghly River on east and south-east side. On north side, the

boundary is an artificial one except for Bally Canal on north-

east and Damodar River on north-west.

Annual normal rainfall is 1461 millimeter per year.

Annual maximum temperature varies between 32-39°C,

whereas minimum temperature varies between 8-10°C.

Figure 1: Map of Howrah

http://en.wikipedia.org/wiki/Hooghly_%28district%29


3 Rolling Mill- History and present scenario

The rolling mill was started in India in 18th

century.

Later on with the development of electricity re-rolling mill

started first at Howrah, West Bengal and gradually to other

parts of the country.

In 1966 there were about 400 re-rolling mills in India,

whose number increased to 1133 in 1980 and in 1986 increased

to over 1600 units. It is seen that Punjab is the highest number

of re-rolling mills. The second position goes to West Bengal.

Now re-rolling mills in India is about 2500 and in West Bengal

it is more than 300. The main concentration of re-rolling mill is

at Howrah Industrial Belt. The special advantages of Howrah

are the Ganges, National Highway, Largest Railway station,

Calcutta Port and other Engineering Industries.

After 1975, setting up of new re-rolling industry and

expansion of existing unit was declared ban by the Government

of India. Even then a few small scale units come up at Howrah

without government assistance and therefore they are not

allowed registration. These types of units, uses only scrap as a

raw materials and the investment is low. Later on Government

of India lifted ban due to imposition of liberalized industrial

policy.

The small scale industries play a pivotal role in our economic

development with particular advantages of low investment,

high potential for employment generation in rural and

backward area.

In the developed countries, the usage of steel is

phenomenal. In some of the developing countries too, there has

been substantial growth in steel consumption over the last few

years. This is largely attributable to the fact that in the recent

past there has been a tremendous change in construction

technology. Moreover the pre-engineering concept for

residential and office building based on steel framed

construction has become popular.

Today steel re-rolling is an important industry in the

country. The large scale units like Steel Authority of India

(SAIL), Tata Iron & Steel Company Ltd. etc which produce

steel, do not normally manufacture smaller sizes of sections

required for construction and structural work. Rolling smaller

section is done primarily in the small scale sector. Generally

there is no product specification in small scale re-rolling units


4 for producing particular sections and sizes. The product is

decided by the customer.

This survey aimed at detailed study of the existing re-

rolling mills that are located around Howrah, West Bengal. The

focus of the study was to generate detailed information about

the existing condition and to identify the need or area for

improvement of these rolling mills

5

Rolling Process


6 In metalworking, rolling is a metal forming process in which

metal stock is passed through a pair of rolls. Rolling is

classified according to the temperature of the metal rolled. If

the temperature of the metal is above its recrystallization

temperature, then the process is termed as hot rolling. If the

temperature of the metal is

below its recrystallization

temperature, the process is

termed as cold rolling.

Rolling is one of the

principal methods of plastic

working of metals employed to

manufacture a great amount of

square, round, angles, beams,

sheets etc. Rolling consists essentially in passing the metal

between revolving rolls.

Rolling is a continuous and regular process,

characteristic of which is an uninterrupted motion of the

worked metal through the zone of deformation. Continuous

process yield products of uniform structure and properties, as

the conditions of working of the metal are the same throughout

the length of the product.

In hot rolling process the raw materials (Iron scraps) are

heated in furnace to a temperature between 1120 0C to 1300

0 C.

The heating process ensures high plasticity and reduces the

resistance of flow. Flow diagram of rolling process

Figure 3: Flow diagram of rolling process

Raw Material Shearing

Heating in Furnace

Rought Rolling Finished RollingEnd Cutting (Twisting if necessary)

Finished Product

Figure 2: Rolling process (Schematic)

7

Materials and method


8

The Need Assessment Survey (NAS) of the rolling mills of

Howrah was carried out during the first week of August, 2012.

The survey team visited the different rolling mills for five days

and carried out the survey.

Following methods were followed to complete the study:

Questionnaire A short questionnaire on musculoskeletal disorder was

developed for the study purpose. The questionnaire consists of

two parts. 1st part contains the general information about the

workers and the 2nd

part contains questions regarding the

development of musculoskeletal disorders (MSD). This

questionnaire was performed among the randomly selected

workers of the rolling mills.

Ergonomics Checklist Ergonomics checklist is an observational method. Here,

researcher observes the workplace condition (both working and

physical) and accordingly makes entries in the checklist. The

checklist contains information like housekeeping, illumination

etc. of the work place. The checklist was used in all enlisted the

rolling mills of the cluster.

General Interview Finally the Owners of each rolling mill were

interviewed individually to get the information about the

rolling process in detail. The aim of this interview was to know

about the type and procurement of raw materials, technical

details about the process, the market need and customer base.

Study Units The study was carried out on the following units of the re-

rolling mills cluster.

Sl. No. Name rolling mill

1. Ajay Industries

2. Hariana Steels Re-Rolling Mills

3. Alloy Steel Rolling Mills

4. Bharat Steel Industries

5. Goyal Ispat Udyog

6. KK Steel

7. Crown Metal Industries

8. Dada Bhomia Ispat Pvt.Ltd

9. Poonam Metal

10. Kulharia Steels (Pvt.) Ltd.

11. Kwality Steel Processors

12. Sidhi Vinayak Alloys Ltd.

13. SKG Iron & Steel Co.

14. Sujata Steel Industries

15. Shree Vijay Laxmii Rolling Mills Pvt. Ltd

16. Gadia Aluminium Pvt. Ltd.

9

Descriptive Study: Cluster Level


10 SWOT Analysis:

Strength

Raw materials are procured from the local market

which is nearby.

The acceptability of the finished goods in the market is

good.

Weakness

Condition of the road is very poor leading to problems

in transportation.

There is no quality check of the raw materials, as a

result different types of raw material are used to make

same product.

There is no variety of the product.

There is no ergonomics and safety training for the

workers.

Opportunity

There is scope for the production of different varieties

of product.

Development of a Common Facility Centre (CFC) – the

units can buy the raw materials directly from CFC

Threats

Competition among the rolling mills – every mill tries

to sell their product leading to low profit margins. Units

with fewer sales become the sufferer.

Steep increase in the price of the fuel.

Road condition is one of the main threats. The trucks

loaded with finished goods are kept waiting for hours

for roads to clear. This adds to the cost of production.

The prices of the product have increased but the tax

exemption limit for this company has remained same as

before. Therefore, selling the same product (now at

higher price than before), the factory has to pay taxes

(as the limit remained same) for which they were

exempted before.


11 Other Observations

The re-rolling mills fall under the category of Micro Small and

Medium Enterprises (MSME). Like all other MSMEs, the

working of these units is mostly labor intensive. Although the

re-rolling of the iron scraps is done by the installed rollers, the

workers are the mainstay of the whole process. The jobs of the

workers include

Carrying the raw materials to the furnace

Pulling out the melted iron and placing them in the

roller

Pulling out the rolled iron from a roller and

subsequently putting it into the next roller

Pulling out the finished product from the final roller

Carrying the finished product.

Development of Musculoskeletal Disorders

During the whole process there are lots of repetitive

movements of the body along with twisting and bending of the

body. All these factors may lead to the development of

musculoskeletal disorder.

The short musculoskeletal disorder questionnaire

(mentioned in methods) was applied on the randomly selected

workers. On analysis of the questionnaire it was found that the

prevalence of the musculoskeletal disorder was high (80%)

among the workers. Most affected body parts was lower back

(75%) followed by the shoulders (50%) and wrists (50%).

Poor Workplace

Many of the units had pedestals (Man coolers)

installed in different places to dissipate the heat generated by

the rolling process. But most of the units didn’t place the man

coolers in proper position and some of the units have no such

facilities.

The noise level is high in these units. The mean

noise level around 99.5 dBA.

Housekeeping is very poor that adds ineffective

time in total manufacturing process.

12

Descriptive Study: Unit Level


13 1. AJAY INDUSTRIES

1.1 Raw Materials: Iron scraps are used as raw material. Iron

scraps from the Railway discarded coaches are also used

as the raw materials. This unit buys these raw materials

from the nearby local market.

1.1.1 Problem areas:

There is no quality management system for these

iron scraps. Therefore, different qualities of iron

scraps are used to make the product.

The sellers of the local market buy the raw material

from the railway in auction. After buying it from

railways, they process it before selling it to the

units. Thus the cost of the raw materials increases

for the unit and which ultimately increases the cost

of the final product.

1.1.2 Recommendations:

Setting up of a Common Facility Centre, from

where the unit will be able to buy the raw materials

directly.

A quality testing and certifying center can be setup

to screen the iron scraps separately.

1.2 Processing and product: The iron scraps are melted in

a furnace (~ 1100°C) and re-rolled until the desired

product is obtained. The main products of this unit are

Iron plates and squares.

1.2.1 Problem Areas:

Like raw materials, there is no quality check for the

final products.


Screening the final products according to their

quality will help in better marketing of the goods.

1.3 Storage: The production of this unit is around 1 tonne

per hour. There is fixed storage space for the raw

materials and the final product.

1.4 Logistics:


The condition of the approach road to the unit is

very poor.

The roads are too narrow; this also hampers the

movement of the trucks to and from the unit.


Improvement in the condition of the roads.

Improvement in the condition of the traffic.


14 1.5 Ergonomics and Safety:


The workers work without any proper personal

protective equipment.

There are repetitive movements of the body of the

workers along with twisting movements.

The workers at the furnace work at very high

temperature and sound.


Proper personal protective equipment should be

provided to the workers.

Work rest schedule for the workers should be

introduced.

Proper ventilation should be implemented by

increasing the height of the units.

1.6 Marketing: The finished products are sold at the local

market.


There is no variety of products.

The customer base is limited and fixed.

Road condition is one of the main threats. The

trucks loaded with finished goods are kept waiting

for hours for roads to clear. This adds to the cost of

production.

The prices of the product have increased but the tax

exemption limit for this company has remained

same as before. Therefore, selling the same product

(now at higher price than before), the unit has to

pay taxes (as the limit remained same) for which

they were exempted before.


Variety of product should be explored.

Other customer pool should be explored to increase

the customer base.

2. HARYANA STEEL INDUSTRIES

2.1 Raw Materials: Iron scraps are used as raw material.

Iron scraps from the Railway discarded coaches are

used as the raw materials. The unit buys these raw

materials from the nearby local market.


Due to the absence of quality management system

for these iron scraps different qualities of iron

scraps are used together to make the product.


15 The sellers of the local market buy the raw

material from the railway in auction. After buying

it from railways, they process it among

themselves before selling it to the units. Thus the

cost of the raw materials increases for the units

and which ultimately increases the cost of the

final product.



where the unit will be able to buy the raw

materials directly.

A quality testing and certifying center can be

setup to screen the iron scraps separately.


a furnace and rolled and re-rolled until the desired


the TMT bars and other rounds of different diameters.

The daily production is around 6-7 tonnes


Like raw materials, there is no quality check for

the final products.




2.3 Storage:


There is no fixed storage space for the raw


The lack of fixed storage adds ineffective time to

the production time.


Proper storage of raw materials and the final

product will reduce the ineffective time and

increase the productivity.

2.4 Logistics:



very poor.







16 2.5 Ergonomics and safety:

2.5.1 Problem Areas

There are repetitive and twisting movements of

the body of the workers.



The workers at the furnace have to work at very

high temperature and sound

2.5.2 Recommendation


introduced such that no workers work for more

than one hour continuously.




increasing the height of roofs of units

2.6 Marketing: The finished products, i.e. the TMT bars,

are then sold at the local market.


Problems in transport (delay in the movement of

the trucks) adds to the cost of production.


The customer base is limited and fixed for the

unit.



Other customer pool should be explored to

increase the customer base.

3. ALLOY STEEL ROLLING MILLS

3.1 Raw Materials: Like all other units of the rolling mill

cluster, this unit also uses iron scraps as raw material.

These iron scraps are procured from the local market

and railways.


There is no quality management system for the

procurement of iron scraps. Therefore, different

qualities of iron scraps are used for making the

final product. This may lower the quality of the

final product.

Railway auctions their waste wagons etc. The

sellers of the local market buy the raw material

from these auctions. After buying, they process it


17 among themselves before selling it to the units.

The cost of the raw materials thus increases.

Ultimately units have to purchase them at higher

prices.


A quality testing and certifying center may be

established for the selection of iron scraps


where the unit will be able to purchase the raw

materials in fixed price.


a furnace (~11000 C) and rolled until the desired




There is no quality checkup of the final product.


Setting up of a quality check setup for the final

product will help in grouping them according to

their qualities.

3.3 Storage:


There is no fixed and separate storage space for

the raw materials and the final product. The lack

of fixed storage adds ineffective time to the

production time.



product will reduce the ineffective time and

increase the productivity.

3.4 Logistics:


The physical condition of the approach road to the

unit is very poor.

The roads are too narrow and congested this also

reduces the movement of the trucks with raw

materials and finished products.





18 3.5 Ergonomics and safety






The workers at the furnace have to work at very

high temperature and sound.








increasing the height of roofs of units.


market and to specific customers.


There are no design variations in products.

The customers are limited and fixed.



for hours for roads to clear. This adds to the cost

of production.


Variety in product design should be explored.



4. BHARAT STEEL INDUSTRIES

4.1 Raw Materials: The unit buys raw materials from the

nearby local market.


The sellers of the local market buy the raw

material from the railways in auction. Thus the

cost of the raw materials increases for the owners

of the units




materials directly.


19 4.2 Processing and product: The iron scraps are melted in



Iron plates.



the final products.




4.3 Storage:






product will reduce the production time.

4.4 Logistics:



very poor.

The roads are too congested for movements of the

trucks.



4.5 Ergonomics and safety



workers.

There are also twisting movements.






market.






of production.


20 4.6.2 Recommendations:

New customers’ needs should be explored

5. GOYAL ISPAT UDYOG

5.1 Raw Materials: Iron scraps are raw materials. The unit

buys these raw materials from the nearby local market.


The sellers of the local market purchase the raw

materials from railways through auction. Thus the

cost of the raw materials becomes high for the

unit owners.




materials directly and in cheap rate.

5.2 Processing and product: After melting in furnace, the

melted scraps are re-rolled until the desired product is

obtained. The main products of this unit are iron wires,

plates and squares.


Unsafe working area

No quality check for the final products.


Working conditions must be improved.

5.3 Storage:


No fixed and demarcated storage space for the

raw materials and the final products.


Demarcated storage spaces are highly

recommended.

5.4 Logistics:


The roads are narrow, full of pot holes which

causes the slow movement of the transport

vehicles


Immediate improvement of roads.


21 5.5 Ergonomics and Safety


Improper work methods due to unsafe working

conditions may decrease productivity.


Application of proper interventions through

improvement of work method will decrease the

ineffective time.

5.6 Marketing: The finished products are sold to fixed

customers.



No need to create variations in product design.


To identify the need of customer a specific need

assessment protocol should be implemented by

which new customers may be identified.

6. KK STEEL

6.1 Raw Material: Iron scraps from the Railway discarded

coaches are used as the raw materials. The unit

purchases these raw materials from the nearby local

market.


Different qualities of iron scraps are used in

making a single product as there is no quality

checkup test for these raw materials.



where the unit will be able to buy the raw materials

directly.

A quality testing center can be setup to screen the

iron scraps separately.


a furnace and re-rolled until the desired product is

obtained. The main products of this unit are the TMT

bars and other rounds having diameter 5 – 6 mm.



the final products



quality will help in better marketing of the goods


22 6.3 Storage: There is fixed and designated storage space

for the raw materials and the final product

6.4 Logistics:



very poor

The roads are too narrow; this hampers the

movement of the trucks



6.5 Ergonomics and Safety:


Improper work methods due to unsafe working

conditions may decrease productivity


Application of proper interventions through

improvement of work method will decrease the

ineffective time


market.




for hours for roads to clear. This adds to the cost of

production.


The customer base is limited and fixed for the unit.





7. CROWN METAL INDUSTRIES


Iron scraps from the Railway discarded coaches are also

used as the raw materials. The unit buys these raw



23 7.1.1 Problem areas:

Lack of quality management system for the raw

materials. Therefore, different qualities of iron



A quality testing and certifying center can be setup

to screen the iron scraps separately.

7.2 Processing and product: The iron scraps are melted in a

furnace and re-rolled until the desired product is obtained.

The main products of this unit are Iron plates and rods.



the final products




7.3 Storage:






product will increase the productivity.

7.4 Logistics:


The roads are too narrow and very congested.

Condition of these roads damages the movement

of the trucks with raw materials and finished

products.


Condition of the roads must be improved.









The finished products are kept in such a way that

it creates problem in the general movement of the

workers.





Work schedule for the workers should be



The place where the finished goods are coming

out should be arranged in such a way that it does

not hamper the general movements.


increasing the height of the roofs.


market.




unit.




of production.





8. DADA BHOMIA ISPAT Pvt. Ltd.


The unit buys these raw materials from the nearby local

market.






A quality testing center can be established to

screen the iron scraps.

8.2 Processing and product: The iron scraps are melted

and re-rolled until the desired product is obtained. The

main products of this unit are Iron squares.


25 8.2.1 Problem Areas:


the final products.




8.3 Storage: There is fixed storage space for the raw


8.4 Logistics:


The roads are too narrow; this also slow down the



Immediate improvement of the approach roads.






Proper ventilation should be implemented


market.




Variety of product should be explored through

market research.

9. POONAM ALUMINIUM METAL

9.1 Raw Materials: Broken utensils are used as raw

materials for the rolling mills. The unit buys these raw



There is no quality management system.

Therefore, different qualities of raw materials are

used to make the product.



screen the raw materials.

9.2 Processing and product: The aluminium scraps are

melted in a furnace and then casted into different

shapes. These casted structures are then rolled until the


26 desired thickness of the product is obtained. The main

products of this unit are fan blades of different sizes.


There is no quality check for the final products.




9.3 Storage:


There is fixed storage space for the raw materials

and the final product.



product will increase the productivity.

9.4 Logistics:


The approach road to the unit is full of pot holes.


Condition of the roads should be improved.






workers.


temperature.




Proper rest should be given to workers to decrease

the heat stress.


increasing the roof height of the unit.

9.6 Marketing: The finished products are then sold at the

local market.




unit.






10. KULHARIA STTEELS Pvt. Ltd.



There is no quality management process for these

iron scraps.


A quality testing center may be setup in locality






Use of old machine with minimum maintenance

cause occasional problems in manufacturing

process.


Periodical maintenance is required

10.3 Storage:


The lack of ill-defined storage adds ineffective

time in total production process.


Proper storage of raw materials and final products

10.4 Logistics:


The approach road to the unit is full of pot holes.


Roads should be properly repaired






the body of the workers during work





28 Proper rest pauses required


market and fixed customers








11. KWALITY STEEL PROCESSORS

11.1 Raw Materials: The unit buys iron scraps as raw




iron scraps.







Iron plates.



the final products.




11.3 Storage:





Proper storage spaces are required to avoid

production loss.

11.4 Logistics:


The roads are congested; this hampers the easy

movement of the trucks with raw materials and

finished products.









temperature and noise.


No workers should work for more than one hour

continuously.


market.






of production.




12. SIDHI VINAYAK ALLOYS Ltd.

12.1 Raw Materials: Iron scraps from the Railway

discarded coaches are used as raw materials. The unit

purchases these raw materials from the nearby local

market.









a furnace and re-rolled until the desired product is

obtained. The main products of this unit are plates and

squares.





A quality checking center can be established. This

will help in screening the final products according

to different qualities.

12.3 Storage:


Lack of well-defined space for storage of raw

materials and final product.


Proper areas should be allocated for storing the

raw materials and the final products. This will

improve the productivity by reducing the

ineffective time.

12.4 Logistics:


The condition of road is very poor.

The roads are too narrow and highly congested.









temperature.




Ventilation should be improved by increasing the

roof height of the unit


market.


Lack of variety of products


Variety of product can be explored.


31 13. SKG IRON & STEEL Co.








screen the iron scraps.


a furnace and rolled until the desired product is

obtained. The main products of this unit are Iron plates

and squares.






13.3 Storage:






raw materials and the final product. This will


ineffective time.

13.4 Logistics:



The movements of the trucks are hampered as the

roads too narrow.









32 There are repetitive movements of the body of the

workers.













market.






of production.



14. SUJATA STEEL INDUSTRIES

14.1 Raw Materials: Iron scraps from the Railway

discarded coaches are used as the raw materials.










materials directly.


a furnace and re rolled until the desired product is

obtained. The main products of this unit are Iron rods.






quality.

14.3 Storage:






raw materials and the final product. This will


ineffective time.

14.4 Logistics:



very poor.











workers.













market.





34 Road condition is one of the main threats. The



of production.





15. SHREE VIJAY LAXMII ROLLING MILLS Pvt. Ltd.




iron scraps.





a furnace and rolled until the desired product is

obtained. The main products of this unit are Iron rod.



the final products.




15.3 Storage: There is fixed storage space for the raw


15.4 Logistics:













workers.


35 There are also twisting movements.












market.







of production.





16. GADIA ALUMINIUM Pvt. Ltd.

16.1 Raw Materials: Broken aluminium utensils are used as

raw materials for the rolling mills.



raw materials.




16.2 Processing and product: The utensils (raw materials)

are melted and the molten aluminium is then poured

into different casts to produce the desired product.



the final products.





36 16.3 Storage: There is fixed storage space for the raw


16.4 Logistics:













workers.











market.







of production.





37

Design Possibilities (Cluster wise)


38

FURNACE

FURNACE

Workplace Layout

The current layout of the rolling mill is shown in figure

20. In this layout, the individual rollers are arranged side by

side. The movement of the melted iron is shown by the arrow

heads. In this present layout there is lot of ineffective time in

pulling out the rolled iron and putting it into the next roller.

This layout also requires lots of bending and twisting

movement of the workers.

A proposed modified layout of the workplace is shown in

figure 21. In this proposed modified layout, the roller will be

arranged one after the other. The melted and rolled iron will

move from one roller to the next roller in a continuous process.

This layout will reduce the frequent bending and twisting

movements.

Figure 4: Existing workplace layout

Figure 5: Proposed modified layout


39 General Recommendations

There is continuous use of water to cool the rolled iron.

This water is drained out of the factory. A suitable

drainage system may be installed to recycle this water.

This will reduce the wastage of water in the process.

The workers, who work at the face of the furnace, work

at a very high temperature. Suitable personal protective

equipment like thermal suite, hand gloves, safety

goggles and safety shoes should be provided to shield

them from high temperature.

Pedestals may be installed at the back the workers to

dissipate the heat generated by the whole rolling

process.

40

Design Possibilities: Unit wise


41

The worker bends repeatedly while working. Also the

position of the man cooler fan is not correct

Recommendations

The height of the platform of the rolling machines may be made adjustable.

The direction of the man-cooler fan should be such that the workers feel

the affect of it.

1. Ajay Industries

2. Poonam Aluminium Metals

Level of illumination in the workplace is low. Working in this

low illumination workplace is very risky.

Recommendations

The level of the illumination of the workplace can be improved by the

installation of the natural skylights. This will help in illuminating the

workplace with natural lights.

.

Figure 6: Bending posture and position of man cooler fan

Figure 7: Low level of Illumination


42 3. Haryana Steel Industries

4. Alloy Steel Rolling Mill

There are continuous repetitive movements and twisting

movements of the body during the work process. This will

lead to the development of the musculoskeletal disorder.

Recommendations

Ergonomics modification of the workplace can aid in reducing the chances of

developing Musculoskeletal disorder.

The worker use jute made leg guard. This guard is not

proper and can be less effective in protecting the

workers from the injury.

Recommendations

Safety shoes can be designed to suite the context of the workers. The

shoe should provide necessary protection to the workers.

.

Figure 8: Poor working posture

Figure 9: Self made leg protecting guard


43 5. Goyal Ispat Udyog

6. Crown Industries

The finished products are kept in such a way that

they hinder the normal movements.

Recommendations

Designing of proper storage area will help in sorting out this problem

Workers work with poor working postures

that include frequent bending and twisting of

the body.

Recommendations

The handle of the forcep can be made adjustable so

that the bending can be eliminated

Figure 10: Final products hinder normal movements

Figure 11: Poor work posture of the wrist


44 7. Bharat Steel Industries

8. Dada Bhomia Ispat Pvt. Ltd.

Working without proper safety shoes can lead to

serious injuries

Recommendations

Proper safety shoes should be provided to the workers so that he

can be protected from the injuries.

Worker at the face of the furnace works at

very high temperature

Recommendations

Heat resistant shield can be installed between the worker and the

furnace to screen the workers from the high heat

Figure 12: Lack of proper safety shoe

Figure 13: Worker at the face of the furnace works at very high temperature


45 9. Shree Vijay Laxmii Rolling Mill Pvt. Ltd.

10. Kulharia Steels Pvt. Ltd.

Workers using local goggles as protective

equipment

Recommendations

Proper ergonomically designed safety goggles should be provided

in place of the local goggles

Workers working with awkward posture

Recommendations

The height of platform of the rolling machines can be made

adjustable. This will help in reducing the awkward posture

Figure 14: Workers using local goggles as protective equipment

Figure 15: Workers working with awkward posture


46

The transference of the hot molten iron

from a roller to the next roller is very

unsafe

Recommendations

Protective barriers can be provided to shield the feet of the

workers

There is awkward posture of the wrist

during the handling of the big forcep

Recommendations

The modification of the design and increase in awareness

about good handling technique will help in reducing the

awkward postures of the wrist. Further the upper part of the

forcep should be made of non-heat conducting material

11. SKG Iron and Steel Co.

12. Sujata Steel Industry

Figure 16: Unsafe work condition

Figure 17: Handling of the big forcep


47 13. Kwality Steel processor

14. Gadia Aluminium Pvt. Ltd.

Workers working at very high

temperature at the face of the

furnace

Recommendations

Proper heat shields can be placed between the worker and the

furnace. This will help in screening the worker from the heat.

There is repetitive movement of the

body along with twisting

movements.

Recommendations

The layout is such that the worker needs to move

continuously from right side to left side in order to transfer

the rolled aluminium to the next level. The successive

levels of operation can be arranged in a straight line. This

will reduce the repetitive movements.

Figure 18: Working at the furnace

Figure 19: Bad layout


48

Recommendations

Figure 21 shows the existing condition,

which is very unsafe as there is risk of

getting injured. The proposed design

solution for this problem is shown in

figure 22. The exit point of the molten

iron and its entry into the next roller will

be covered by the structure as shown in

the figure. This will help will reducing

the risk of injury.

15. Sidhi Vinayak Alloys Ltd.

16. KK Steel

Workers working at very high

temperature at the face of the

furnace

Recommendations

Proper heat shields can be placed between the worker and

the furnace. This will help in screening the worker from

the heat.

Figure 20: Hazardous job at the face of the furnace

Figure 21: Existing working condition Figure 22: Proposed Design solution


49 Scope for research and development direction for future initiatives

Process Immediate Intervention Mid-term Intervention Long-term Intervention

Raw Materials

Heating in Furnace

Rolling

Finished Product

Designing proper storage area Setting up of quality testing

center

Setting up of Common Facility

center

Providing workers with proper

heat resisting clothing

Installation of heat shield between

worker and the furnace

Exploration of new latest

technology in heating the iron in

furnace

Rotation of the working shifts of

the worker such that no worker

works at a stretch

Ergonomic modification of the

layout of the workplace

Designing of the sliding structure

to aid the workers

Exploration of new technologies

and machineries

Proper storage area can be

designed

Setting up of quality testing

center

The opportunity to develop new

and different varieties of product

should be explored

Design Clinic Workshop

September - October 2013


51

Howrah Rolling Mill Design Clinic Workshop (Day One)

Venue: Fortune Park Panchiwati, Howrah

Date: 28th

September 2013

Schedule

1. Inauguration

2. Inaugural speech

3. Need assessment of rolling mills – Dr. Somnath Gangopadhyay

4. Tea Break

5. Rolling - a technical perspective- Dr. Debamalya Banerjee

6. Ergonomics in rolling Mill– Dr. Somnath Gangopadhyay

7. Interactive session and conclusion

8. Lunch


52

he five day Design Clinic Workshop of the Howrah re-rolling mills was inaugurated on 28th

September 2013. Many distinguished dignitaries attended the program. Mr. Sankar Sanyal,

President, Howrah Chamber of Commerce and Industries (HCCI) presided over the ceremony.

Many other members of the HCCI were also present. Dr. Somnath Gangopadhyay, Associate

Professor, Occupational Ergonomics Unit, Department of Physiology, Calcutta University and Dr.

Debamalya Banejee, Associate Professor, Production Engg. Department, Jadavpur University

were the invited speakers in the program. The inaugural session was attended by the owners of

different rolling mills of Howrah.

The inaugural speech was delivered by Mr. Sankar Sanyal wherein he introduced and welcomed

the dignitaries to the dais. Then he briefed about the importance of Need Assessment Survey for

the rolling mills which was done previously by Dr. Somnath Gangopadhyay. He also discussed

about the fruitful association between National Institute of Design (NID) and HCCI for the

improvement of productivity in different rolling mills.

Mr. Sanyal’s speech was followed by an informative talk from Dr. Gangopadhyay. His

deliberation emphasized on the Need Assessment Survey that was carried out by him in the rolling

mills. Starting with the meaning of Need Assessment Survey, his lecture encompassed regarding

the procedures he followed, the results derived from the survey and the suggestions put forward to

improve the conditions of the rolling mills.

After the tea break, Dr. Banerjee delivered his lecture. His talk entailed the current global

procedures practiced in rolling mills and the ways to improve it.

T

Figure 23: Dignitaries in the dais.

Figure 24: Dr. Gangopadhyay delivering his talk


53 Dr. Gangopadhyay gave his second deliberation on Introduction to Ergonomics and its application in rolling mills. This was followed

by an interactive session.

Finally Mr. Sanyal concluded the program by summarizing the day’s events.

Figure 26: Owners of different rolling mills Figure 25: Dr. Banerjee giving his talk

Figure 27: Dr. Gangopadhyay discussing about Ergonomics

Figure 28: Mr. Sankar Sanyal, President, HCCI


54

Figure 29: All the participants of the workshop


55

Howrah Rolling Mill Design Clinic Workshop (Day Two)

Venue: Rolling Mill, Belgachia, Howrah

Date:29.09.2013

Schedule

1. Presentation on Need Assessment Survey Dr. Somnath Gangopadhyay

2. Discussion with the owners Dr. Somnath Gangopadhyay

3. Interaction with the workers Dr. Somnath Gangopadhyay


56

he second day of the Design Clinic Workshop was continued on 29th

September,

2013 at a rolling mill in Belgachia, Howrah. The focus of this day was to have a

one to one discussion with the owners as well as with the workers. Dr. Gangopadhyay

began the workshop by giving a detailed presentation on the Need Assessment Survey

of the rolling mills. This was followed by a discussion with the owners of the mills

regarding the survey, the outcome of the survey and the proposed suggestions. This

discussion was followed by another discussion with the workforce of the factory. This

was an interactive session where the factory owners as well as the workers participated

graciously.

Highlights of the workshop

Proper work rest cycle is being implemented in the factory.

Workers use safety shoes but that are not proper.

Suggestion of common facility centre was welcomed.

Workers were advised and made aware about working with good posture

T

Figure 30: Need assessment survey presentation

Figure 31: Discussion with the owners


57

Figure 34:Improper safety shoes Figure 33:Dr. Gangopadhyay discussing with the workers

Figure 32:Interactive session Figure 35:All the participants of Day 2


58 Howrah Rolling Mill Design Clinic Workshop (Day Three)

Venue: Rolling Mill, Dharmatala Road, Howrah

Date:30.09.2013

Schedule



3. Interactive session with workers and owners Dr. Somnath Gangopadhyay


59

he third day of the Design Clinic Workshop was continued on 30th

September, 2013 at a rolling mill in Dharmatala road, Howrah.

This day also focused on one to one discussion with the owners and

workers.

Presentation on the Need Assessment survey was followed by

interactive session with the workers.


Workers were advised and made aware about working with

good posture

Job rotation for the workers was proposed

Proper personal protective equipment is required for the workers

working immediately in front of the furnace.



T

Figure 36: Presentation on Need Assessment Survey

Figure 37: Discussion with the owners


60

Figure 38: Dr. Gangopadhyay interacting with the workers

Figure 39: Participants of day 3


61 Howrah Rolling Mill Design Clinic Workshop (Day Four)

Venue: Rolling Mill, Ghusuri, Howrah

Date:03.10.2013

Schedule





62

he fourth day of the Design Clinic Workshop was continued on 3rd October,

2013 at a rolling mill in Ghusuri, Howrah. This day also focused on one to

one discussion with the owners and workers.

Dr. Gangopadhyay started the day with the presentation on Need Assessment

Survey of the rolling mills. This was followed by discussion with the owners and



Proper storage space for raw materials were identified

Workers were advised and made aware about working with good posture

Proper personal protective equipment was advised for the workers working immediately in front of the furnace

Production of different variety of products was discussed

Use of overhead cranes for moving materials was encouraged



T



63

Figure 42: Interaction with the owners Figure 41:Proper storage of raw materials

Figure 43: All Participants of Day 4


64 Howrah Rolling Mill Design Clinic Workshop (Day Five)

Venue: Rolling Mill, Dharmatala road, Howrah

Date:04.10.2013

Schedule





65

he fifth and the last day of the Design Clinic Workshop was continued on

4th October, 2013 at a rolling mill in Dharmatola road, Howrah. This day

also focused on one to one discussion with the owners and workers.

Dr. Gangopadhyay started the day with the presentation on Need Assessment

Survey of the rolling mills. This was followed by discussion with the owners and



Workers were advised and made aware about working with good

posture

Safety shoes are being used but that are not proper



Proper storage space for raw materials was identified

T


Figure 45: Interaction with workers


66

Figure 47: Talking about the big forcep Figure 46: Worker at the face of the furnace

Figure 48: interactive session


67

Figure 50: Safety shoe not proper Figure 49: Discussion with workers

Figure 51: All participants of day 5

need assessment survey of howrah rolling mill cluster ...designclinicsmsme.org/design awareness...

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