need assessment survey report 2013 -...

Need Assessment Survey Report 2013

Steel Engineering Clusterat

Mangaldoi, Darrang, Assam

Jointly Organised byMicro & Small Scale Enterprises Mangaldoi, Govt. of

Assam&

Design Clinic, MSME, National Institute of Design Ahmadabad

byPrathap Raj Sekar

Moris Industrial Consultancy - Chennai

NEEDS ASSESMENT SURVEY/ENGINEERING CLUSTER/DARRANG DIVISION/MANGALDOI/ASSAM/MSME 2013


ACKNOWLEDGEMENT

I would like to thanks Steel and Fabrication Department of Industry andcommerce (DIC), Darrang, Assam and entire team for showing immense interest,support and organizing the ‘Design Clinic Scheme for MSMEs’ and showing metheir work also letting me be part of visiting their individual plants /work life toaccomplish the program of Need Assessment Survey.

I would also like to thank General Manager and Design Awareness Programmecoordinator Nilufar for organizing the ‘Design Awareness Programme. for givingme the opportunity towards the successful extensive visit of the Engineeringwork Industry and to prepare an intensive report after realizing my strength andpast experience on understanding the potential of the same industry.

I would like to thank “Design Clinic Scheme; National Institute of Design”, whohas given me an opportunities to accumulate an intensive report. My specialthanks to each individual unit member of this cluster’s who has given me theirgreat support during the design audit without their kind involvement &assistance I would have not been able to understand cluster background & theirpresent status.

My special thanks to each individual unit member of Engineering Units who hasgiven me their great support during the survey /audit. I would have not been ableto understand cluster background & their present status without their kindinvolvement /assistance /support. Thus I come up with such informative,structural, analytical and design intervention opportunities.


PREFACE

Engineering and Steel Fabrication Cluster plays a significant role in building the economy mostly in the area of construction, home safety and many ,more from 1 inch tool to 1000 inch flying plane. This cluster is mainly focused on to understand and know the need of MSME’s current trend and uncovering the hidden needs and proposing a market trend demand for future better business.

I have visited 40 units at Mangaldoi in Assam. All they have created employment opportunity for their village people and while in field study its clear understood every small scale unit thriving hard to build and scale up their business. The importance of the cluster lies mainly in its good employment potential, lower capital investment and higher value addition in the success of Engineering and steel Fabrication.

Moreover, this cluster provides good employment to the persons mostly in the rural areas and comparatively with lower educational background.

There are many small enterprises /units, which are employing the similar process of Steel Fabrication. This report is a cluster level report of Interactive Study of around 40 units in the Engineering and Steel Fabrication Clusters using the platform of DIC Assam, under the premise of National Institute of Design MSME scheme.NEEDS


TABLE OF CONTENTS

CONTENT Page No. Cover Page Acknowledgement .................................................................................................... 03 Preface ..................................................................................................................... 04 Need Assessment Survey ...........................................................................................05 (Objective /Methodology, Expected Deliverable, Duration)

Chapter-1 Introduction ……………………………………………………………………………………..…………..06Assam Historical Back Ground ………………………………………………………………..……………………..07Prehistory/Ancient/Geo-Graphic of AssamHistory of Mangaldoi……………………………………………………………………………..……………………….08Climate of Assam / Industry/Festival in Assam/Tea History

Chapter-2…………………………………………………………………………………………………………………….…10Cluster level informationGeneral Information……………………………………………………………………………………………………….11Cluster product typeSteel raw materials…………………………………………………………………………………………………….….17List of tools and equipment……………………………………………………………………………………………19Tools measuring instrument and general shop out fit…………………………………………………….20General machinery …………………………………………………………………………………………………….….21Fabrication unit specialist……………………………………………………………………………………………….22Metal fabrication process……………………………………………………………………………………………….23Sequence of activities in fabrication unit………………………………………………………………………..24Work station design factor…………………………………………………………………………………….…….…25Housekeeping factor in units……………………………………………………………………………….…………26Lighting factor in units……………………………………………………………………………………….…………..27Temperature of workplace………………………………………………………………………………….………….28Hand and Tools…………………………………………………………………………………………………….………..29Strategic goals………………………………………………………………………………………………………………..30Physical work place risk factor………………………………………………………………………………………..31Ergonomic in the welding environment………………………………………………………………………….32Opportunity mapping…………………………………………………………………………………………..………..38

Chapter- 3Design audit unit wise…………………………………………………………………………………………………….41Unit – 1 to Unit – 23………………………………………………………………………..………………………62 -221A) Detail Information About UnitB) Opportunity Areas for Design InterventionC) Problem Identification in unit wise and Scope for InterventionD) Scope for Research and Development Direction for Future InitiativesE) Analysis and ObservationF) Man Handling Analysis in the UnitG) Hand Tool Usage Analysis in the unitH) Environment Analysis in the Unit


TABLE OF CONTENTS

CONTENT Page No.

Machinery Recommendation for Advanced Design………………………………………..……………..217Safety Needs………………………………………………………………………………………………………………….224An Analysis of other minerals…………………………………………………………………………………..……225An Analysis of Current Market Trend……………………………………………………………………………..226SWOT Analysis……………………………………………………………………………………………………………….229Unit with Unit Owners…………………………………………………………………………………………………..231Conclusion………………………………………………………................................................................232


NEED OF ASSESSMENT SURVEY

Objective:The objective of this need assessment survey is focussed to identify the need, to explore design intervention opportunity and detailed refractory cluster information to understand the core issues related to ;Supply, availability of Raw Materials- Infrastructure setup- Practices and design techniques- Product type, shape and usage- Tools and technology in use- Capability of manufacturing unit- Scope of skill up gradation- Present Market status- Customer expectation and behaviour- Market Competitiveness /scenario- Packaging, logistics and storage-Exhibition, display and merchandising

Methodology:- Visit to individual units /plants- Questionnaire survey of the units.- Discussion with unit owner /partner /stake holder(s).- Techniques /Process observation.- Identifying tools and equipment.- Meeting and collecting feedbacks from different categories of workers-Self observation and analysis.

Expected Deliverable :This design research /intervention program is intended to provide qualitative anddetail data of around 40 units in the Engineering and Steel fabrication cluster to develop insights about this industry/entrepreneurs, which would help to address the existing problems for their growth /survival and future opportunity area or scopes which can be further workout and can be taken up during the design clinic workshop and areas be taken up as design /research projects in an interactive mode with the adjacent Academia.

Duration :Present Need Assessment Survey(NAS) is based on extensive visits made to the Individual Plants /unit for 10 days in different areas.


CHAPTER-1I N T R O D U C T I O N


Assam- Historical Background

Pre-historyAssam state and adjoining regions have evidences of human settlements from all the periods of the Stone ages, but there are no archeological evidence of bronze-or iron-age culture. The hills at the height of 1,500–2,000 feet (460 to 615 m) were popular habitats probably due to availability of exposed doleritic basalt useful for tool-making. According to a late text, KalikaPurana (c.7th–8th AD), the earliest ruler of Assam was MahirangaDanav of the Danava dynasty, which was removed by Naraka who established his theNaraka dynasty. The last of these rulers, also Naraka, was slain by Krishna. Naraka’s son Bhagadatta became the king, who, it is mentioned in the Mahabharata, fought for the Kauravas in the battle of Kurukshetra with an army of kiratas, chinas and dwellers of the eastern coast.

AncientThe historical account begins with Samudragupta’s 4th century Allahabad inscription that mentions Kamarupa and Davaka as frontier kingdoms of the Gupta Empire. Davaka was soon absorbed by Kamarupa kingdom which grew into large kingdom that spanned from Karatoyariver to Sadiya and covered the entire Brahmaputra valley and, at times, North Bengal and Northern Bangladesh.Ruled by three dynasties Varmanas (c.350–650 CE), Mlechchhadynasty (c.655–900 CE) and Kamarupa-Palas (c.900–1100 CE) from their capitals in present-day Guwahati (Pragjyotishpura), Tezpur (Haruppeswara) and Durjayarespectively, it was 10,000 li in circuit and capital city Pragjyotishpura was about 30 li. Kamrupi kings claims their descent from Narakasura, an immigrant from Aryavarta. In the reign of the Varman king, BhaskarVarman(c. 600–650 AD), the Chinese traveler XuanZang visited the region and recorded his travels. Later, after weakening and disintegration (after the Kamarupa-Palas), the Kamarupa tradition was somewhat extended till c. 1255 AD by the Lunar I (c. 1120–1185 AD) and Lunar II (c. 1155–1255 AD) dynasties.

Geography of AssamThe state of Assam can be divided into 3 principal geographical regions: 1. The Barail ranges and the low hilly terrains of Mizo hills in the south2. The Alluvial valley of Brahmaputra, Dhansiri and the Barak river in the north.3. The lower and central Assam hills, known as the Shillong PlateauThe Brahmaputra Valley is a dominant physical feature of the northern part of Assam. The Brahmaputra river along with its tributaries and its alluvial soil rich flood plains forms the life line of Assam. The height of the Shillong plateau ranges between 3000 feet and 6000 feet. Frequent mild earth quakes and annual floods are common phenomenon in Assam. Assam is rich in biodiversity and is home to numerous endangered species of flora and fauna.


History of Mangaldoi

Climate of AssamAssam has a tropical monsoon rainforest climate. Assam receives heavy monsoon rains and does not have the hot, dry season experienced by other parts of India. The climate of Assam can broadly be divided into Cold Season and Rainy Season - October to February being the cold season and the rest of the year being rainy season with heavy or scanty rain. An uncomfortably humid climate is the speciality of Assam. Assam has a moderate temperature.

Mangaldoi (Pron:ˈmæŋgəlˌdɔɪ) (also spelt as Mangaldai) is a town and a municipal board in Darrang district in the Indian state of Assam. It was named after “Mangaldahi” who was the daughter of the *Raja+ of Darrang and who was married to the Ahom King [PratapSingha]. Mangaldoi is the headquarters of the Darrangdistrict.Its population ranges between 20000-50000 according to 2011 census. It is an important trading centre for all agricultural products.

IndustryIndustrial scenario has undergone a vast change in Assam. Apart from tea, petroleum and petrochemicals, other industries in various sectors like paper, fertilizer, cement, coke, lime, sugar, engineering, plastic, steel, printing, cosmetics, poultry & dairy products along with handloom and handicraft have thrived in the state. Moreover, with its rich flora and fauna, breathtaking natural beauty, age-old temples and monuments, Assam offers a unique potential for tourism industries for both domestic and foreign market. Assam’s proximity to SAARC countries like Bangladesh, Nepal and Bhutan gives it the investment potential considering the advantage of border trade with theses countries. Border Trade Centre at Sutarkandi in Karimganj district and Mankachar in Dhubridistrict have been developed to facilitate border trade with Bangladesh. The Govt. of India has identified some thrust areas for industrial development of Assam, which are

Petroleum and natural gas based industriesIndustries based on locally available minerals

Processing of plantation cropsFood processing industriesAgri-Horticulture products

Herbal productsBiotech productsPharmaceuticals

Chemical and Plastic based industriesExport oriented industries

Electronic and IT base industries including services sectorTextiles and sericultureEngineering industries

Cane and bamboo based industries


Assam- Historical Background

Festivals in AssamPeople of Assam celebrate several traditional festivals. Bihu and Durga Puja are two festivals celebrated in Assam with great enthusiasm. Bihu is the national festival of Assam and since it is connected with agricultural the festival is celebrated by all the people of Assam irrespective of religion or caste. Apart from these, there are cultural events and festival like Elephant Festival, Brahmaputra Festival, Tea Festival etc...

Tea historyAfter discovery of Camellia sinensis (1834) in Assam followed by its tests in 1836–37 in London, the British allowed companies to rent land since 1839. Thereafter tea plantations mushroomed in Eastern Assam, where the soil and the climate were most suitable. Problems with the imported labourers from China and hostilities of native Assamese resulted into migration of forced labourers from central-eastern parts of India. After initial trial and error with planting the Chinese and the Assamese-Chinese hybrid varieties, the planters later accepted the local Camellia assamica as the most suitable one for Assam. By 1850s, the industry started seeing some profits. Industry saw initial growth, when in 1861, investors were allowed to own land in Assam and it saw substantial progress with invention of new technologies and machinery for preparing processed tea during 1870s. The cost of Assam tea was lowered down many folds and became more competitive than its Chinese variant.

Despite the commercial success, tea labourers continued to be exploited, working and living under poor conditions. Fearful of greater government interference, the tea growers formed the Indian Tea Association in 1888 to lobby to retain the status quo. The organization was very successful in this, and even after India’s independence, conditions of the labourers have improved very little.


CHAPTER-2CLUSTER LEVEL INFORMATION


General Level Information

s.no Name of the Unit Contact Person Contact Details

1 Hazarika engineering works Mr.Mridul Hazarika I/E MangoldoiDhurba Enterprise ward No-2,Mangoldoi9854583761

2 J P Engineering Mr.jayin Hazarika Bagaverghat . Mangoldoi986433007

3 Baba Trinath works Mr,Ganesh Pd Gupta Ward -5 LNB Road MangoldoiMobile: 9435087230

4 Modern Engineering Mr.Adul Hussain Dumuni Chowki9854314734

5 Das Steel Fabrication Mr.Kamal Das Ward no-6. Kahirabari Bus Stand 9854392632

6 kangkana Engineering Mr.Chitta Kunta Ward 9, Mangoldoi9951387403

7 S K Engineering Mr. S N Konowar Block Chowk, Mangoldoi9851110837

8 Shiva Steel Industries Mr.Nabin Kalita I/E Mangoldoi9707281123

9 Sharma Steel Engineering Mr.Debajit Sharma Islampur, Ward NO-8,Mangoldio

10 Rajamahal Fabrication Mr.Sanjay Mandal. 9854141212

11 Rodall Engineering Mr.n Haque Karim Chowk, Mangoldoi9854144272

12 J B Engineering Works Mr.Ahmed 9854547166

13 Pankaj Steel Industries Mr.Pankaj Das Ward no 89854238833

14 J B Steel Enterprises Mr. Jyotish Kr Baruah Kpnowar para, Mangaldoiu9864190674




15 Hazarika engineering works Mr.Mridul Hazarika I/E MangoldoiDhurba Enterprise ward No-2,Mangoldoi9854583761

16 Maa Steel Furniture Mr.Nur Hussain NO 1 Khanapara Ganeshkuwari

17 K N Steel Industries Mr. K k Nath Aulachowka, Mangaldoi9859054123

18 Das Engineering Mr.Putul Das Upahupara9854258129

19 B A Steel fabrication Mr.Babul Ali Ganesh kuwari

20 Bright Steel Fabrication Mr.Azarudhin Ahmaed 9864838855

21 Mayur Steel Furniture Mr.Ripul Deka Bhebarghat wrad no 10Mangodio989192215

22 Mayur Steel Engineering Works

Mr.Rajul haque Dumuni Chowki Darrang9859801062

23 Deka Fabrication Works Mr.Depak Deka Mena Para7399621016

24 Freya Steel Fabricaton Mr.Aftav Uddin Ahmed Saikia Dalagon985912457




25 P K Engineering Mangoldio9854406746

26 Mousumi Engineering works

Kahrupetia. Nageswar Darrang9954793325

27 Mehjubin Stell Industries Kahrupetia Darrang9135087898

28 Baba lokenath Grill Industries

Kahrupetia Darrang9508806324

29 Narajan Steel Work shop Begamukh Mongodio7896549733

30 Jakin Bibha Steel Fabrication

Kharupteia Darrang9577921649

31 Maa Steel Fabrication 9613084764

32 Ata Kata SHA Dhula Chowk98445010111

33 Omarnath Welding Kahurpetia, Darrang9954051557

34 B E Steel Engeineering Lengri Para, Mangoldoi9207144132

35 Jyod Steel Engeineerings Kahropetia, Darrang9613086423

36 Baba Lokenath Steel Products

Dalgaen, Darrang99570158320

37 Dilip Grill Works Kahurpetia Nageswar9854165008


Cluster Product (Types)

1. Grill Design2. Gate3. Railing4. Trusses5. Shutters6. Bus Body

7. Furniture Industries8. Roofing Structure9. Mild Steel Steps10. Window Grill11. Round Raling12. Locker


Cluster Product (Types)


Steel Raw Materials

Generally there are two types of steel bars (“Sariya” in hindi) available in the market.

1. Mild steel barsMild steel bars (as per IS: 432, part-I -1982)

Mild steel bars are used for tensile stress of RCC (Reinforced cement concrete) slab beams etc. In reinforced cement concrete work. These steel bars are plain in surface and are round sections of diameter from 6 to 50 mm. These rods are manufactured in long lengths and can be cut quickly and be bent easily without damage.


Steel Raw Materials

2. Deformed steel bars

Deformed steel bars (as per IS: 1786-1985)As deformed bars are rods of steels provided with lugs, ribs or deformation on the surface of bar, these bars minimize slippage in concrete and increases the bond between the two materials. Deformed bars have more tensile stresses than that of mild steel plain bars. These bars can be used without end hooks. The deformation should be spaced along the bar at substantially uniform distances. To limit cracks that may develop in reinforced concrete around mild steel bars due to stretching of bars and some lose of bond under load it is common to use deformed bars that have projecting ribs or are twisted to improve the bond with concrete. These bars are produced in sections from 6 mm to 50 mm dia.In addition the strength of bonds of deformed bars calculated should be 40 to 80 % higher than that of plain round bars of same nominal size. And it has more tensile stress than that of plain round bars of same nominal size.Cold twisted deformed (Ribbed or Tor Steel Bars) bars are recommended as best quality steel bars for construction work by structural Engineer.


List of Tools and Equipment

Hand gloves (leather)

Apron (leather)

Welding hand shield

Auto darkening welding helmet

Gas welding goggle (spectacle type)

Plain goggle for chipping (spectacle type)

Hammer (chipping) 250 grams with handle

Chisel flat (cold) 6”

Centre punch 9mmx127mm

Divider 20cm

Stainless steel rule 30cm

Stainless steel wire brush 5 rows

Stainless steel wire brush 3 rows

Spark lighter

Safety boots for welders

Scriber double ended 15cm

Steel tongs flat 14”

Hammer ball peen 1kg. with handle

Try square 6”

File flat 30 cm rough

File half round bastard 30 cm

Hand hacksaw frame

Leather sleeves


TOOLS, MEASURING INSTRUMENTS AND GENERAL SHOP OUT FIT

Hammer sledge 4 Kg with Handle

Screw driver 25 & 20cm

Number punch 6mm.

Letter punch 6mm

Hammering blocks 5cm thick 60cm sq.

Magnifying glass 15 cm

Weld measuring gauge fillet and butt weld

Spanner 12 mm and 15 mm Double Ended

Spanner D.E 6 mm to 15 mm

C – Clamp 10 Cm, 15 Cm, 20 Cm and 30 cm

Pipe Wrench 25 Cm And 35 Cm

Steel Tape 5 mtr Flexible In Case

Welding torches high pressure with ten nozzles 2 to 13

Pipe cutter capacity 50 mm diameter

Cutting torch oxy – acetylene with cutting nozzle 3/64

Electrode holder 400 amperes

Welding rubber hose, oxygen and acetylene ID 8 mm

Hose clips

Spindle keys (for opening cylinder valve)

Pressure regulator oxygen double stage

pressure regulator acetylene double stage

Tip cleaner

Arc welding coloured glass 108 x 82 x 3 mm DIN 11 A 13 A

Glass plain 108 x 82 mm


GENERAL MACHINERY

A.C. Arc Welding transformer with all accessories (30 - 300 amps

capacity with 60% duty cycle

D.C. Arc welding rectifier/Inverter set 30 to 400 Amps continuous Welding

current with all accessories

Welding D.C. Motor generator set 300 amps capacity with all accessories Dye

penetrant testing kit

Oxygen and Acetylene gas manifold system (Working provision for at least six

trainees)

Empty Oxygen cylinder 7 cubic meter capacity

Empty Oxygen cylinder 7 cubic meter capacity

Hand shearing machine 6mm capacity (sheet & flat)

Power shearing machine 4mm capacity on M.S. and 3mm capacity on S.S.

D.E grinding machine 30 cm wheel motorized pedestal type

Trolley for cylinders (HP unit)

Portable drilling machine 12 mm capacity

Electrode drying oven thermostatically controlled - temperature 0 – 250° C,

10 Kg capacity

Power hacksaw (1 HP) 24”

Fire extinguishers Foam type and CO2 type

Bench vice 4”

Swage block

Arc welding table all metal with welding positioner 80 x 65 x 65 cm (three

side covered)

Gas welding table fire bricks on stand with welding positioner 100 x 49 x 37 cm

Anvil 12” sq. inches working area with stand 50kg

First Aid kit

Portable cut off machine with abrasive cutting head

Note: Gas Cylinders may be hired


Many fabrication units have speciality processes which they develop or invest in, based on their customers needs and their Expertise:

Brazing

Casting

Chipping

Drawing

Extrusion

Forging

Heat treatment

Hydro forming

Oven soldering

Plastic fabrication

Powder coating

Powder metallurgy

Punching

Shearing

Spinning

Welding

FABRICATION UNITS SPECIALITY

PROCESS


METAL FABRICATION PROCESS

Raw materials

Standard raw materials used by metal fabricators are;

Plate metal

Formed and expanded metal

Tube stock, CDSM

Square stock

Sectional metals (I beams, W beams, C-channel...)

Welding wire/welding rod

Hardware

Castings

Fittings

Cutting and Burning FormingMachining Final Assembly

ACTIVITES


SEQUENCE OF ACTIVITES IN FABRICATING UNITS

Sequence of Operation

Surface cleaning

Cutting and machining

Punching and drilling

Straightening, bending and rolling

Fitting and reaming

Fastening (bolting, riveting and welding)

Finishing

Quality control

Surface treatment

Transportation


WORKSTATION DESIGN FACTORS

Some factors to consider:

• Position of the work.

• Physical ability of the worker.

• Design and weight of the tools.

• Body mechanics of the operation.

• Type of protective equipment used.

• Workspace / environment (size, lighting, temperature, noise, vibration, etc.).

• Physical requirements of the job (lifting, turning, reaching, etc,).

• Mental requirements (motivation alertness, concentration).

• Strength and size of the workers.

DESIGN FACTORS


HOUSEKEEPING

Poor housekeeping can result in an increased risk of injury and a decrease in work efficiency.

By implementing a good housekeeping plan, areas are kept clean and free of waste and the risk of injuries occurring due to slip, trips and falls, together with injuries resulting from hitting stationary objects, are reduced.

Items should be stored correctly with no parts protruding onto walkways.

Electrical cords should not be on the floor, tools should have designated areas for storage and bins for waste should be readily available and be easy to empty.

Structured programs that focus on organisation, cleanliness and standardisation can be introduced to the workplace to assist with this.

Cleanliness can be maintained in a ‘clean as you go’ manner or the need for constant housekeeping can be eliminated from the source e.g. leaks, etc. HOUSEKEEPING


LIGHTING

The quality of lighting in a workplace has a significant effect on safety and productivity. Good lighting in the workplace promotes:

• A reduced risk of injuries through better visibility

• A reduced risk of short and long term health problems such as headaches and eye strain and vision impairment loss.

• A brighter, cleaner workplace resulting in a more active, cheerful environment.

This can be achieved by:• Making full use of natural light by installing windows and skylights

• Ensuring overhead and fixed lighting is at appropriate levels and is appropriately maintained and replaced

• Using task lighting with a flexible arm to enable light to be directed to the spot where light is needed

• Painting ceilings and walls a lighter colour allowing more light to be reflected and assisting in increasing the light within the workplace.

LIGHTING


TEMPERATURE OF WORKPLACE

Under the OHS Act, employers have a responsibility to provide a safe and healthy workplace. This broad duty of care includes ensuring workers are not subjected to excessive heat or cold that may cause illness. Heat illness covers a range of medical conditions that can arise when the body is unable to properly cope with working in the heat. Signs and symptoms of heat illness include nausea, dizziness, weakness, clumsiness, collapse and convulsions. Employees exhibiting these symptoms should seek immediate first-aid/medical attention.

Some conditions are:• Heat stroke – a life threatening condition that requires

immediate first aid and medical attention• Fainting in heat (heat syncope)• Heat exhaustion• Heat cramps• Heat fatigue.

As with any other occupational health and safety risk, there are general procedures to follow when assessing the risk of heat at work. These include consulting the employees who are exposed to the heat as well as their health and safety representatives. In consultation with your employees a Heat Alert Program should be considered as it is the best way to minimise the risk of heat illness.

For indoor work• Air conditioning/air circulation fans/good ventilation• Insulation of roof and wall insulation or shielding of sources of heat and external ducting of hot exhausts.

For outdoor work• Suitable protective clothing with ventilation, sunburn creams and skin protector, air-conditioned vehicles and rest areas. In addition, ensure employees have access to adequate supplies of cool drinking water. Allocated breaks should also be made available as determined by the conditions, preferably providing shade during their breaks.

TEMPERATURE OF

WORKPLACE


HAND AND TOOLS

‘Hand tools’ refers to `a tool used with a person’s hands’, these include:

• Tools designed for force to be applied by the person, such as screwdrivers, hammers, chisels, and hacksaws.

• Tools where force is applied by a power source,

but a person is still needed to hold the tool, such as portable electric or battery drills, grinders, saws or pneumatic impulse tools, spray guns or nail guns, etc.

Hand tools are used in static workplaces, such as a workshop, and in an environment external to the workshop, like a construction site or an installation on a client’s site.

Task design – frequency, duration, speed of tool usage

Tool design – weight, shape, fit to user, vibration, recoil, shockloadingWorkstation design – size, shape and layout

Tool maintenance – poorly maintained toolsPoor hand tool design and excessive use of hand tools are associated with chronic disorders of the hand, wrist and forearm, such as carpal tunnel syndrome and wrist tendonitis.

Major factors affecting the potential for injury include:• Muscular effort in using tools (holding, operating and guiding) because of poor handle design, or heavy, poorly balanced and/or poorly maintained tools

• Static loading of arm and shoulder muscles from holding tools can lead to fatigue when maintained for prolonged periods and eventually to injury

• Awkward wrist positions such as holding tools with the wrist bent up, down or sideways causes additional muscular effort in using tools

• Contact pressure on tissues or joints, from tools pressing into the palm at the base of the thumb where blood vessels and nerves pass through the hand contributes to the development of carpal tunnel syndrome

Hand tools


STRATEGIC GOALS

Cost/productivity/markets/applications reduce the average cost of welding by one-third, by providing better process selection guidance, increasing the use of automation and robots, and lowering reject and repair rates; increase the use of welding by 25%

Process technologyEnhance the use of welding in manufacturing and construction operations by integrating welding with other manufacturing and construction disciplines, at the engineering level and also at the operational level.

Materials technologyDevelop welding technology along with new materials so practical fabrication methods are available are available for all engineering applications

Quality technologyThrough the use of modeling, systematic process selection and procedure development, and NDE technologies,assure that welding can be part of a six sigma quality environment

Education & TrainingIncrease the knowledge base of all people employed in the welding industry, at every level, enabling them to make decisions that will result in utilization of the best welding technology for each application

Energy & environmentReduce energy use in by 50% through such productivity improvements as decreased pre- and post-heating operations, and use of advanced, lower heat input welding processes, and avoidance of over welding.

Strategic Goals


PHYSICAL WORK PLACE RISK FACTORS

Welding tasks may expose workers to physical workplace risk factors (or ergonomics stressors). If tasks are performed repeatedly over long periods of time, they can lead to fatigue, discomfort and injury.

The main physical workplace risk factors (ergonomics stressors) associated with the development of a work-related musculoskeletal injury in welding tasks include:

• Awkward Body Postures• Heavy Lifting• Static Position

Common causes of injury are:• Repetitive gripping / twisting• Repetitive reaching• Repetitive moving• Static postures• Lack of rest to overcome fatigue

These causes fall into six major physical workplace risk factors:• Force to perform the task• Highly repetitive tasks• Poor, awkward or static postures• Pressure points or compression• Vibration• Duration

Physical Work Place Risk

Factors


Ergonomics in the Welding Environment


ERGONOMICS

INTRODUCTIONErgonomics is the science of arranging or designing things for efficient use. Ergonomics is also called Human FactorsEngineering. It involves making the workplace fit the needs of workers. It does not try to make workers adjust to theworkplace. When a workplace is designed properly, the worker feels comfortable. Quality and production increase. Everyone benefits.

PROBLEMS FROM POOR ERGONOMICS• Musculoskeletal Disorders (MSDs).• Repetitive Motion Injury.• Lower productivity.• Lower quality.• Worker dissatisfaction.• Increased absenteeism.• Increased compensation costs.• Increased turnover rate.• Decreased compliance with regulations.• Increased insurance costs.

PRACTICAL SOLUTIONS—HOW TO AVOID THE HAZARDS• Avoid fixed work positions. They reduce the blood supply

to muscles.• Keep elbows close to the body.• Avoid positions where arms are raised above shoulder level.• Use lighter hand tools.• Suspend tools.• Support your elbows.• Provide sufficient rest.• Utilize jigs and fixtures.

ERGONOMICS


ERGONOMICS

CAUSES OF THE PROBLEMS• Reaching.• Bending.• Heavy lifting.• Using continuous force.• Working with vibrating equipment.• Repetitive motions.• Awkward postures.• Temperature.

SYMPTOMS OF MSDs• Less gripping strength.• Less range of motion.• Loss of muscle function.• Painful joints.• Pain, tingling, or numbness.• Shooting or stabbing pains.• Swelling or inflammation.• Stiffness or burning sensation.

OBJECTIVES OF ERGONOMICS• Reduce injuries and disorders.• Ensure worker safety.• Ensure worker health.• Ensure worker productivity.• Reduce compensation costs.• Reduce absenteeism.• Comply with regulations.

Ergonomics focuses on changing things (tools, equipment, facilities, etc.), not changing people.

ERGONOMICS


ERGONOMICS

Common WMSDs for welders include:

Back Injuries From strains and sprains to degradation of the vertebral disks

BursitisInflammation of a saclike bodily cavity, containing a viscous lubricating fluid located between a tendon and a bone or at points of friction between moving structures(i.e. inflammation of a bursa)

Carpal Tunnel Syndrome A complex disorder that starts with the inflammation of the tendon sheaths in the wrist and progresses into the degradation of median nerve

TendonitisInflammation of the tendons

TenosynovitisInflammation of tendon sheath

Thoracic Outlet Syndrome A disorder in which blood vessels and nerves in the upper shoulder region are compressed and cause pain. This condition is sometimes caused by chronic postures associated with overhead work.

Trigger Finger Tendons in the fingers “lock down” due to injury to the tendons

SUMMARYConsider ergonomic solutions for all welding situations. Many can be improved. Evaluate and apply ergonomic principles and avoid the hazards.

ERGONOMICS


ENVIRONMENT

PLANT LAYOUTThe layout of plant should always be considered from a health and safety perspective as well as from a production perspective.The following matters should always be considered:

• The location of designated raw material and delivery areas• That raw materials are stored in an easily accessible area

close to the start of the production area• Lineal workflow through the production line• Clear areas of work• Reduction of blind spots throughout the plant, and• Traffic management and designated forklift and

pedestrian segregation.

WORKPLACE TRAFFIC MANAGEMENTA documented Traffic Management Plan is an invaluable aid to resolving many hazards and issues associated with forklift operations and heavy vehicle movements. The plan should be based on an assessment of forklift hazards and issues. It will govern all activities and procedures relating to forklift operations, and should cover areas such as:

• Seat belts• Pedestrian exclusion zones• Blind spots• Loading and unloading• Right of way• Policy development• Maintenance• Incident reporting and investigation• Site layout• Designated traffic zones• Use of attachments• Signage• Purchasing• Training.

ENVIRONMENT


ENVIRONMENT

NOISEIn the metal product manufacturing industry, numerous items of plant and various activities such as grinding, hammering steel, guillotining, cutting metal, pressing and even disposing of metal objects in bins can produce noise that can be damaging.

If employees are exposed to noise that exceeds the exposure standard of 85 dB(A) averaged over an eight hour period or a peak noise level of 140 dB(c) then your workplace is too noisy and one or more of the controls must be implemented to ensure employee noise exposure does not exceed the standard.

Furthermore if any of the following occurs, noise controls are likely to be required:

• Employees have to raise their voice to communicate at a distance of one metre, or

• Employees have a temporary reduction in hearing or ringing in the ears after leaving work for the day.

The noise regulations set out a hierarchy of controls to be applied when fixing noise hazards.

These are:1. Elimination of noise sources2. Substitution of quieter plant or processes, or use of engineering measures3. Administrative measures, and4. Hearing protectors.

Hearing tests must be provided where hearing protectors are required to make sure that employees’ exposure does not exceed the noise standard. It is worth noting that if there are changes to the workplace, like a new machine coming in or more machines being compressed into a smaller area then it may be necessary to redo noise level tests.

ENVIRONMENT


Opportunity Mapping

DesignIssues

Product/ProcessIntegration

Regulation,Certification, &Standards

Education/Workforce/Image

New & ExistingMaterialsDevelopment

InformationTechnology

Design Reference Materials ionArt, Traditional and Modern Design.

Integration ofsensing, processcontrol, materials(more communicationbetweenparties)

Certificationissues

De-emphasis onmanufacturingcareers in UnitedStates

Development ofweld able materials

Growth of informationtechnologies(the Internet)

Design to processCapability

Weld processmodeling is nonexistenttoday

Linkage of weldingthroughoutwhole manufacturingprocess

Environmentalregulations

lack of weldingengineers- loss of corporateknowledge- lack of designengineers- lack ofmanufacturingengineers

New level ofunderstanding inmetallurgy (fundamentalthroughapplied)

Applying latestcomputer techniquesto solvemulti-attributeproblems

Welding industryis forced to waitfor material -joining must beconsidered indesign

Incorporate weldingprocesses intoagile manufacturingwork cells -embed weld technology

Code development- increasesacceptabilitylimitations tonew/existingjoining methods- centralizedcontrol ofspecifications

Need for talentedpeople -industryimage discouragestalented people

Purity of products(gases, fillerwires, weld andability to monitorpurity)

Safety & HealthSafety of productsin terms ofhow they impacttheir customers.

Processes that aremore friendly tofactory workers(noise, heat, etc.)


Opportunity Mapping

DesignIssues

Product/ProcessIntegration

Regulation,Certification, &Standards

Education/Workforce/Image

New & ExistingMaterialsDevelopment

InformationTechnology

Ability to predictdesign allowable

Computerizedautomation fromdesign to fabrication

Public awarenessof strategic needfor welding

Development ofmaterials toreduce energyrequirements- preheating andpost-heating

Designers willneed knowledgebases to supportsimulations

More efficientdesigns; need todesign from weldingstand point,not just structural


Opportunity Mapping

Joining Technology &Processes

Markets & Customers Quality Reliability& Serviceability

Business &Practices Economics

Modularize variousaspects of technology

Competition with alternativeprocesses

Product performance,endurance, and lifetime(repair ability

Productivity pressures forimprovement (faster,cheaper, better)

Joining of advancedmaterials- ceramics- inter-metallic's- non-traditionalmaterials andcombinationsmetal matrixcomposites

- net shape processes- deposition processes- adhesive technology- hybrid processes -joining and alternativeprocesses

- accuracy ofpredictions- joints are seen asweak link in

Funding availability

Compressing time fromday of design to start ofproductions

Need to eliminate deformationin metal

Customer specific fabrications

Drive to aesthetics(quality)

Move toward shorter workWeeks

Labour costsCost of capital equipment

Difficulty welding inthe field (difficult ambientsurroundings)- hostile environments

New energy requirements(different systemsand fabrication methods)

Better communicationsbetween customers andmanufacturing

Need to understand andcontrol distortion inwelds for highquality/low costs

Supplier alliances

Customers need to monitorthe integrity of fabricatedproducts

Improved energy efficiencyTax policy and its effecton how companies invest


CHAPTER-3DESIGN AUDIT UNITWISE


Unit 1 MSME UNIT Name : Hazarika Engineering Works

NAME : Mr.Mridul HazarikaYEAR OF OPERATIONS : (1990)Mob. No : +91 9854583761PRODUCT RANGE : Steel furnitureTURN OVER : Approx. 21.60PRODUCTION VOL. : 3000 MT p.a. (Capacity - 7000 MT p.a.)MAJOR Customers(S) : Household/contracts etcNo of Employees : 7MAJOR MACHINARIES : Welding, Oxygen cylinder, Power shearing machine, grinding machine,

Trolley for cylinders, Gas welding, Welding torches, Hand hacksaw.Expectation from DIC : Bend Machine for metal sheet

MSME Expectation From DIC :

I. Bend Machine for metal sheet II. Main Issue : Electricity and New Technology Tools


S.No Opportunity areas for Design Intervention Remarks

1 Product Design, Redesign, Product Development Fair

2 Technology, Modernization, Collaboration Fair

3 Research and development directions for future initiatives. Poor

4 Innovation in process and related areas for design intervention. Poor

5 Workstation & Tooling Design Good

6 Market & competitive study for design advantage and distinction Excellent

7 Training and skill up gradation Good

8 Ergonomic and environment factors Poor

9 Packaging, logistics and storage related design opportunities N/A

10 Infrastructure and capability Enhancement from design perspective

Fair

11 Exhibition /Display design opportunities Poor

12 Visual identity and branding from communication design point of view

Fair

13 Inter cluster communication Good

14 To create a visible impact and effectively develop the capabilities of MSME

Good

15 To improve the process of manufacturing and productivity Fair

16 To increase the market share and profitability Good

17 To reduce rejections, wastages in material, process, resources and the drudgery on labour

Good

18 To improve product manufacturing, serviceability, manufacturing process, logistics operations etc.

Poor

19 To add value to the products or services concerned and increase their competitiveness

Good

20 To create positive difference to the MSME, either in absolute revenues(indicating higher profits) or in percentage terms)

Good


S.No Problem Identification Description

1 New Product and Design Development No idea about new product development and creative design pattern creation

2 Future Vision No vision

3 Advance Tools and Technology Having general tool so not able to focus on complex design

4 Visual identity and branding Not realized the important of branding

5 Workstation ergonomic and environment Not aware of ergonomics and safety environment

6 Labour safety and Health Insurance Not aware of health insurance for labour

7 No Design Books Latest design trend book can issued to MSME to attract market

Problems Identification in Unit wise and Scope for Interventions

C) Scope for research and development direction for future initiatives

Remedial Design Solution Suggested, if any1. Common Support (Advance tools and technology etc.) for the cluster is highly demanding.2. Unit has been looking to do more products but lack in design pattern and material merging so cluster can invest perhaps DIC and NIDMSME can fund them more to help them achieve in their business.3. Design books can issued to all MSME to develop the design in the market



Steel and metal put across every where on the floor workers need to care while walking inside.

Can be kept in order in one way rhythm approach. if it is placed in one side ample amount of place can be found.

Unsecured head, hands and legs and wearing a ordinary cloths which can be possible to get fire.

Proper hand cloves, shoes, and welder helmet could save vulnerable cause to the worker during welding

Company name board not installed, so customer not having trust to give orders and issue in identifying company.

Company name board and contact details so that customer can easily reach for orders and identify the unit. also customer can refer to others and so business opportunity grows up.

Waste iron rod are just kept aside across the places in the shop. which is occupying needful space and creating congested look. some time its hard to find certain tools which have been put inside

Allocated place to keep waste items so that would create ease to know where things are placed as well as create cleanliness in the unit.



Machine is placed in the entrance and close to that metal and iron items kept. while running machine which will start shaking and around the items all would get shake and create mess.

other metal items should not be kept next to the machine and putting wires on top of the machine would cause heat and possibility for dangerous causes.

Very poor and dangerous electric wires hanging which is not at all safety for even regular person who operates daily.

Safety concern need on rewiring the electric box

Designed grills are not properly placed in the right place. which would cause rust in it and possibility to rework on it which is time, man power and cost consumption would be more.

Better place to keep completed order items.

Placed on the floor which is hard to lift and move to other places

Can be placed on wheelers so that easy to roll to other places as well easy to handle rather calling more people for help.

Working on/over metal that is lying on the floor

Lifting metal product on and off a work bench with high force

Working in awkward postures above shoulder height

Awkward postures when applying high force to push, pull or restrain metal products

Lifting heavy metal onto machinery

Moving heavy materials or other products from station to station manually

Lifting metal from storage areas that are above shoulder height or below knee height

Manually handling heavy materials

Use of slings or chains not marked with SWL (safe working load) or in poor condition

Manual tensioning in awkward postures

Awkward postures when welding

Large weights of finished product being moved manually


MAN HANDLING ANALYSIS IN THE UNIT

Risk Fair Excellent

Exerting force while in an awkward posture

People other than person grinding exposed to dust and particulates

Grinding without guarding

Excessive noise

Welding in confined areas without ventilation

Welding in awkward postures

Welder exposed to flash

Exposure to gases such as ozone, carbon monoxide and toxic substances

Excessive noise

People other than welder exposed to flash


HAND TOOL USAGE ANALYSIS IN THE UNIT

Risk Fair Excellent

Air conditioning/air circulation fans/good ventilation

A brighter, cleaner workplace resulting in a more active, cheerful environment

Making full use of natural light by installing windows and skylights

Painting ceilings and walls a lighter colour allowing more light to be reflectedand assisting in increasing the light within the workplace.

Clear walkways avoid trips and falls.

Designated areas for parts keep the workplace tidy

Readily available bin disposal with crane attachment for ease of emptying

The location of designated raw material and delivery areas


ENVIRONMENT ANALYSIS IN THE UNIT

Risk Fair Excellent


Unit 2MSME UNIT Name : J P Engineering

NAME : Mr.jayin HazarikaYEAR OF OPERATIONS : (1995)Mob. No : +91 986433007PRODUCT RANGE : Steel furniture, Trusses ShetterTURN OVER : Approx. 19.25MAJOR Customers(S) : Household/contracts etcNo of Employees : 10MAJOR MACHINARIES : Welding, Oxygen cylinder, Power shearing machine, grinding machine,






1 Product Design, Redesign, Product Development Good

2 Technology, Modernization, Collaboration Poor



5 Workstation & Tooling Design Fair

6 Market & competitive study for design advantage and distinction Good





Good



Poor



Good

15 To improve the process of manufacturing and productivity Excellent

16 To increase the market share and profitability Excellent


Good


Good


Good


Good



paint has been sprayed into the lock which will require an amount of time to rework and clean the lock area, also the handle (stainless steel)got sprayed with same body color

A small piece of round sticker can be used and easy to remove after sprayed. Handle can be covered, which can bring quality in work

a single light fixed which is less than 40 watts in the night time the visibility is very less.

Tube lights can be used to give more lights in the environment, if power consumption is the issue then LED light can be used which is less in power consumption and less cost.

Completed items not kept in flat surface possibility to fall down get break. open glass can have dust as well as spray paint affect the glass surface, which will add additional cost and affect timely deliverable

Right material should be used to cover the glass items till the delivery happens, finished item should be taken care to avoid unnecessary issues.

Environment is too dark in the noon imagine late night night works with a small bulb!

good amount of lighting systems should be given inside and outside. Day Light and good ventilation required.



Steels and electric main board all placed too closer. the floor is in mud. Possibility to get shock during rainy season.

Electric main board should keep at little above and the floor can be construct with cement to avoid slippery during rainy season.

Machinery items not taken care

lengthy rods can be placed in the corner of the wall and would be good to keep machine area free without any rods and metal.

Customers not able to find which shop recommended to give order, not able to identify the quality of work through set up

Name board and some photos of items delivered can be post so that customer can know what work had been done. it would be easy approach to grab more customers

no proper floor fully mud most of the machine supported by bricks. At entrance wires put, no proper closing door

well cemented floor, right place to keep machines and hanging wires need to taken care










N/A






Risk Fair Excellent

Excessive vibration while grinding




Excessive noise





Excessive noise




Risk Fair Excellent



Risk Fair Excellent










Unit 3MSME UNIT Name : Baba Trinath works

NAME : Mr,Ganesh Pd Gupta YEAR OF OPERATIONS : (1995)Mob. No : +91 9435087230 PRODUCT RANGE : Gate,Grill, Trusses, Windows,FrameTURN OVER : Approx. 24.80MAJOR Customers(S) : Household/contracts etcNo of Employees : 12MAJOR MACHINARIES : Welding, Oxygen cylinder, Power shearing machine, grinding machine,









4 Innovation in process and related areas for design intervention. Fair




8 Ergonomic and environment factors Fair

9 Packaging, logistics and storage related design opportunities Good


Fair



Poor



Fair




Fair


Fair


Good


Fair



Machines, rods, metals, are tightly close to each other. when the machine was on there is a vibration on surrounding thingsElectric main board is kept open with fuse and wires hanging.

Things should be placed with little distance and electric main board should be covered. when machines generates heat there might be chance of fire accident.

No name board, not able to find which engineering works and what work have been done

Name board must be placed and clear information about what kind of product has been developed.

broken bricks used to build as staircase to enter, workers might get slipped while carrying weight and steeping on it

Proper staircase should be build or wooden steeper can be placed. Injury can be avoided and unwanted major issue can be stopped

Opened electric main box, scary to do any task. wooden material is not used

Close with right material sheet in proper way, also make sure to give access to switch off power in case of emergency. wooden shelf should be used in the back ground not a metal sheet.



clothes are put over the steel, which can cause health issue when they wear back. tumbler is kept in open workers might drink without washing it. health concern is poor

keeping clothes and drinking water, tumbler in the right place. Health concern awareness need for workers.

very confused environment with scattered things all around the place. when clients comes to give order they get worried about deliverable and quality

try to keep things neatly and keep machines is safety place.

Machines are not taken care

weekly workers should clean the machines and keep them out of dust and mist to run smoothly for longer years

wastage things can be cleared up unwanted stuff occupying more spaces

Monthly once wastages can be removed so that space can be utilised rightly.















Risk Fair Excellent





Excessive noise





Excessive noise




Risk Fair Excellent



Risk Fair Excellent










Unit 4MSME UNIT Name : Modern Engineering

NAME : Mr.Adul HussainYEAR OF OPERATIONS : (1990)Mob. No : +91 9854314734PRODUCT RANGE : Gate, Grill, Trusses.TURN OVER : Approx. 9.8MAJOR Customers(S) : Household/contracts etcNo of Employees : 4MAJOR MACHINARIES : Welding, Oxygen cylinder, Power shearing machine, grinding machine,









4 Innovation in process and related areas for design intervention. Fair



7 Training and skill up gradation Fair




Fair



Poor



Good


16 To increase the market share and profitability Fair


Poor


Fair


Fair


Fair



spray paint machine kept on the floor with tighten bold possibility in getting earth leakage in electric for workers and the spray container not cleaned with certain oils. machine is full of dust

should be covered after cleaned and wooden board can be given at bottom. try to replace in better place not in entrance.

No lights and No windows

make sure lights are on when clients come switch order they see environment

welder face mask is not kept in right place and all rods are spread across the places.

keep a right place to hang face mask and other safety things.

Welding machine kept on the floor, if workers step on it bad incident is for sure.

Give a place where welding machine can be kept properly just to make sure workers safety in environment















Risk Fair Excellent





Excessive noise





Excessive noise




Risk Fair Excellent



Risk Fair Excellent










Unit 5MSME UNIT Name : Das Steel Fabrication

NAME : Mr.Kamal DasYEAR OF OPERATIONS : (1996)Mob. No : +91 9854392632PRODUCT RANGE : Gate & GrillTURN OVER : Approx. 2.5MAJOR Customers(S) : Household/contracts etcNo of Employees : 3MAJOR MACHINARIES : Welding, Oxygen cylinder, Power shearing machine, grinding machine,







2 Technology, Modernization, Collaboration Good




6 Market & competitive study for design advantage and distinction Poor





Poor



Poor

13 Inter cluster communication Poor


Fair




Good


Good


Good


Good



Cooking inside the work place should be partitioned, probability of chemicals getting mixing with food utensils is more. Cylinder kept open for cooking

All the utensils should be covered and try to have partition between work place and cooking place. make sure you wash utensils before you start cooking.

Tools are thorwn every where on the floor. nails and sharp bit and piece of metal can poke into foot.

a small box should be kept to keep all these sort of ready to use tools

no place for shirt hanging and keeping trousers and drinking water

provide place for keeping shirts and trousers and help workers to drink water easily by giving hands cloves during work in progress.

don’t have eatable or vegetables in open air might be chances pain and dust will stuck on it and when you prepare food without proper cleaning of food will cause really severe health issue.Always dont keep the nob up in the cylinder when cooking is done close the nob which would help to prevent fire accident.



Dumping waste paint box inside room will occupy more space and create tension when need of search of an item also there is a chance to miss tools and items when you clear up the paint boxes

Try to clear up the empty paint box on a month basis or keep storage waste items out side of the work place. Having mixed of tools and needful items together will confuse when need of or search of one item.

keep the place clean so that when new customer comes can have good discussion in neat environment. make sure of having design books and pens.

If the box contain paint make sure to close it tightly and keep preserve it for next time use. have a cupboard type of item where you can store balance paint and use it when need.

not clean and less appearance of owner place. No clock and fans. Floor not clean . no place to have sit when customer comes in for placing order















Risk Fair Excellent





Excessive noise





Excessive noise




Risk Fair Excellent



Risk Fair Excellent










Unit 6MSME UNIT Name : kangkana Engineering

NAME : Mr.Chitta KuntaYEAR OF OPERATIONS : (1998)Mob. No : +91 9854583761PRODUCT RANGE : Steel furnitureTURN OVER : Approx. 21.60MAJOR Customers(S) : Household/contracts etcNo of Employees : 7MAJOR MACHINARIES : Welding, Oxygen cylinder, Power shearing machine, grinding machine,
















Fair



Poor

13 Inter cluster communication Fair


Good

15 To improve the process of manufacturing and productivity Good



Fair


Fair


Good


Good



Looks neat, wires spreading on the floor. Workers might stuck and fall down. a machine on table is not tightly fixed

Roll up wire when machine is not in use, when fixing machine on table or stool for relevant purpose make sure it fixed tightly to avoid dangerous accident

Well placed bars at a corner. make sur e to check rust and species

The types of bar can be classified and grouped with specific size and weight. it would help to choose which one to use when order comes.

Keeping certain items in the floor will not be such noticeable for new worker or customers. leaving sharp metals and tool on the floor will poke into foot

Once the job is done try to clean up place and take tools keep it aside

The power is on, welding rods and pins kept on the walking path, which would be bad idea or careless of the workers to end up with major bad incident

Safety concern make sure and educate workers about the safety and accident free work place










N/A






Risk Fair Excellent





Excessive noise





Excessive noise




Risk Fair Excellent



Risk Fair Excellent










Unit 7MSME UNIT Name : S K Engineering

NAME : Mr. S N KonowarYEAR OF OPERATIONS : (1998)Mob. No : +91 9854583761PRODUCT RANGE : Steel furnitureTURN OVER : Approx. 8MAJOR Customers(S) : Household/contracts etcNo of Employees : 3MAJOR MACHINARIES : Welding, Oxygen cylinder, Power shearing machine, grinding machine,










5 Workstation & Tooling Design Poor






Poor



Poor



Fair




Good


Fair


Fair


Fair



Less bright light which is not suitable for night work in welding, will cause eye problem and worker might step on any dangerous metals.

Better to have tube light which can produce white light. ability to be focus and prevent accident and having concern about workers health and eye sight kindly use better lights for working in the night time.

Bad in Ergonomic, worker sitting down and bowing will cause abdomen pain and will create back pain

Better to have some set up so that worker can stand and work for a while. it will help to keep them out from stress and back pain.

Chair is provided is not ergonomically proper, which can cause serve back pain and knee pain

Give better chair/stool/to sit and work for workers. dont try to use wastage metal/irons and create chairs. try to have it in wood for safety purpose

Raw materials are kept unorganized way

A proper wall mounted shelf should be used to keep raw materials such as paint boxes and other chemicals










N/A






Risk Fair Excellent





Excessive noise





Excessive noise




Risk Fair Excellent



Risk Fair Excellent










Unit 8MSME UNIT Name : Shiva Steel Industries

NAME : Mr.Nabin KalitaYEAR OF OPERATIONS : (2000)Mob. No : +91 9707281123PRODUCT RANGE : Steel furnitureTURN OVER : Approx. 24MAJOR Customers(S) : Household/contracts etcNo of Employees : 11MAJOR MACHINARIES : Welding, Oxygen cylinder, Power shearing machine, grinding machine,











6 Market & competitive study for design advantage and distinction Fair





Fair



Poor



Fair




Good


Good


Good


Good



The location of designated waste material are not properly fixed in the units. As you can see the waste materials are thrown and formed dust in the units. Worker sneeze because of the dust.

Unit should maintain cleanliness environment by having separate area for keeping waste material

Completed metal cup board kept inside and being used for keeping all the wastage and tool. It is also occupying space in the unit

It can be kept in exhibition show case , so that when customer wants they can buy . Keeping things inside and using it for different purpose should be avoidable.

Regular usage tools are kept in the rust box and many things are put around it.

Unit should keep tools in one place where they can find tools in urgent need. as for as ergonomic concern it height should be equal to shoulder.

On top of the machine the rugs are kept and the wires are not rolled up properly and paint box are kept open around the machine . The most notable thing is fuel is kept in the can near to the machine which can cause hazard to the unit

The machines should be well maintained and unit need to aware of what not to place near the machines and how safely maintain machines in unit.



Welder is not having face mask and not weraing shirt when welding. Unit has the safety things but welder ignored to use that .

An awareness should be given to employees in the each units to know about causes on skin disease and safety in work place.

The machine are not taken care away from dust. As in the image other rods and wireframe around the machine sometime people come and sit on top of the machine.

Units should have place to keep unused machines and materials which can also help to give cleanliness in the units . And create healthy environment

The sitting position of the employee is awkward. For eight hour jobs the employee spending 4 hours continuously sitting in this awkward posture. Until and unless he feel pain he works in this same posture.

The units is not worried about employee comfort level in terms of ergonomics. Mostly all units should be get aware of ergonomic importance and causes.

Natural light and good amount of Ventilator are made but when rain there is chances of water running inside the unit and I see rods are rusted

Unit have to plan well to keep waste materials and raw material in certain place safely out from rust. Many unwanted items are put together and the rust rod ruin other rods. Unit should know how to maintain units environment










N/A






Risk Fair Excellent





Excessive noise





Excessive noise




Risk Fair Excellent



Risk Fair Excellent










Unit 8MSME UNIT Name : Hazarika Engineering Works

NAME : Mr.Mridul HazarikaYEAR OF OPERATIONS : (1990)Mob. No : +91 9854583761PRODUCT RANGE : Steel furnitureTURN OVER : Approx. 21.60PRODUCTION VOL. : 3000 MT p.a. (Capacity - 7000 MT p.a.)MAJOR Customers(S) : Household/contracts etcNo of Employees : 7MAJOR MACHINARIES : Welding, Oxygen cylinder, Power shearing machine, grinding machine,
















Fair



Poor



Fair




Good


Fair


Fair


Fair



welder not wearing safetty clothes and face mask . Welder not aware of gas usage and how it will affect skins and breathing.

Welder should know about safety concern and health hazard

lighting in a workplace has a significant effect on safety and productivity. The singlelight is not enough to direct to the spot where light is needed

Ensuring overhead and fixed lighting is at appropriate levels and is appropriately places

Very bad posture of employee sitting and working on bending metal parts . Worker feel hip ache and feel spinal cord badly aching in the night time.

Unit and workers should get aware of ergonomic postures to avoid health issue strains and sprains to degradation of the vertebral disks.

Working on/over metal that is lying on the floor and wires and metals are just lying on the floor. All the rods and metal put in middle of the place. And no place to walk safely.

Unit should get an idea about layout planning on maintaining place to keep waste materials and raw materials and safety concern and tool storage area.










N/A






Risk Fair Excellent





Excessive noise





Excessive noise




Risk Fair Excellent



Risk Fair Excellent










Unit 9MSME UNIT Name : Sharma Steel Engineering

NAME : Mr.Mridul HazarikaYEAR OF OPERATIONS : (2001)Mob. No : +91 9854583761PRODUCT RANGE : Steel furnitureTURN OVER : Approx. 16.04MAJOR Customers(S) : Household/contracts etcNo of Employees : 6MAJOR MACHINARIES : Welding, Oxygen cylinder, Power shearing machine, grinding machine,
















Poor



Poor



Fair




Poor


Fair


Fair


Fair



Waste materials items kept in the unit for long which can be altered and sale it to customer

An thinking process should be thought to units how to alter the waste items and make it useable product.

The overview of the unit interior is bad and materials have been put on floor across the places, which is very tough for worker to walk and carry heavy metal

A proper planned layout should be implemented by units. Units should get idea about how to organise space environment

Designated areas for parts keep the workplace tidy. In designated place all the items put to gather whci so cramped and when need of some material it’s hard for worker to take it .

Worker apply thought to store waste items in usable manner.

Metals and rods are kept on the path way, it so difficult to walk without stepping on rods and metal sheet which is put on the floor.

Unit should have enough of place to walk , it would helps worker to carry metal from one place to an other place. As of now situation is very tough for worker to walk and carry materials since the floor is fully occupied by materials.



Unit wall is not proper built and entire environment looks abandon. As the image of unit gives impression of not cleaned and well maintained unit.

Units should understand the importance of clean environment and know about how customer judge the units performance.

The machine at unit fully dusted and no visual clue of its current function. But really it works. Machine are not properly taken care

Unit should be aware of how to maintain machines and cause for not taking care.

The metal rods are kept on the floor which is mixed of old items and newest one. Worker find difficulty to carry rods .

Workers should know about placing rods in the right place which can bring easy access when need to use the items.

The poor interface machine has been used in the unit. The wires are old and it might bring bad incident to workers .

An awareness of machine usage and prevention thought should be shared with units.















Risk Fair Excellent





Excessive noise





Excessive noise




Risk Fair Excellent



Risk Fair Excellent










Unit 10MSME UNIT Name : Rajamahal Fabrication

NAME : Mr.Sanjay Mandal.YEAR OF OPERATIONS : (1990)Mob. No : +91 9854141212PRODUCT RANGE : Steel FurnitureTURN OVER : Approx. 14.30MAJOR Customers(S) : Household/contracts etcNo of Employees : 4MAJOR MACHINARIES : Welding, Oxygen cylinder, Power shearing machine, grinding machine,
















Good



Poor



Fair




Good


Fair


Fair


Fair



Welding material are kept on the floor and moving items became very hectic for workers.

A movable stand can be used to place such type of materials after welding worker can easily move things from one place to an other place.

Pain boxes and clothes and waste materials are put in one place, worker placed rods with support on wall. Worker should concern about the safety when they pick one items it might fall on .

An awareness of which items should keep in which orientation is important to prevent critical accident

After completion of work the product kept inside and with that all other rusted rods and metal sheet placed on top of it.

Units are not concern about exhibit their works . Help units to realize that exhibition of work is an push strategy for their business growth

The wires are rolled up and hanged in the metal, in terms of electrical structure and wires units are not giving importance to those.

Unit should concern about electrical wiring running around work place. They should know some time period to check out wiring in the unit.



It’s good to see a place for owner table , but it’s such clean on the table and materials kept around the table if any items fall the owner cant escape from the place.

A well maintained and clean table should be having in every units so that when customer visit they would feel comfort of good hospitality given by units.

The drill machine is not properly take care the wastages are left as it on the machine and the kerosene bottle kept in machine. In addition worker are not able to sit in right direction to perform task. Because of the rods placed on the floor which is near the place where worker sit to perform task with the machine

Unit should realise the important of workers job easiness when worker perform an action with this machine he need to place his legs and give support to legs but right now no places found and worker bow very much down and performing action. A guide to units about how to maintain machine and what thing should not be around the machine should be shared with units.

Worker clean up manufactured product, there is no proper stand to place the product , as you can notice they kept such a heavy material on plastic bucket. As well as worker sitting poster is really awkward to do the job with out pain.

Proper mechanism of stand should be used to place such heavy items and ergonomically sitting should be provided.










N/A






Risk Fair Excellent





Excessive noise





Excessive noise




Risk Fair Excellent



Risk Fair Excellent










Unit 11MSME UNIT Name : Rodall Engineering

NAME : Mr.n HaqueYEAR OF OPERATIONS : (2003)Mob. No : +91 9854141212PRODUCT RANGE : Steel FurnitureTURN OVER : Approx. 18.20MAJOR Customers(S) : Trusses, Shutters, Gate,Grills.No of Employees : 9MAJOR MACHINARIES : Welding, Oxygen cylinder, Power shearing machine, grinding machine,










5 Workstation & Tooling Design Poor


7 Training and skill up gradation Poor


9 Packaging, logistics and storage related design opportunities Poor


Poor



Poor



Fair




Fair


Fair


Fair


Fair



In the night time units do work late night to deliver to customer but the lights in the units are so much dull which is just like having candle in the unit and working.

Unit should have proper lighting system

Workers placed rods and things all in one place, units is already having very dim bulb for lighting and workers didn’t realise the difficulty when walk in the units and perform job.

Right layout for keeping things in the unit and unit should realize the lighting system in the unit that too when units ready to work late night then they must consider the workers eye sight efficeny

Workers place thier dresses unused machine and rods and rusted metals

Units need to understand health care about the diseases which caused due to unclean environment

Too many wires rolled up and hanged in a place where other metals and rods also placed and on walk path many metals are lying in this dim light worker need to do job. Units has to have concern about their workers.

Better lighting system and awareness of eye sight and worker health concern should be shared with units.










N/A






Risk Fair Excellent





Excessive noise





Excessive noise




Risk Fair Excellent



Risk Fair Excellent










Unit 12MSME UNIT Name : J B Engineering Works

NAME : Mr.AhmedYEAR OF OPERATIONS : (2007)Mob. No : +91 9854547166PRODUCT RANGE : Gate & GrillsTURN OVER : Approx. 14.00MAJOR Customers(S) : Trusses, Shutters, Gate, Grills.No of Employees : 7MAJOR MACHINARIES : Welding, Oxygen cylinder, Power shearing machine, grinding machine,
















Good



Poor



Good




Good


Good


Good


Good



Worker just wearing simple slipper while performing job in the unit. worker mixing paint into bucket with out any hand cloves.

There should be a place to mix paints to avoid accident of paint pouring on the floor and worker should know about hand cloves usages

The cutting machine kept in the entrance and you can notice there is key place holder at top. Workers need to stretch up every time when taking keys. The machine which is kept can cause injury to the worker when they perform job in urgent all the fours edge of the machine is sharp and worker not wearing safety shoes in the units

An awareness about safety items for the workers is needed.

Worker sitting in a place to cut metal sheet, no hand cloves and wearing simple slipper and space of sitting and performing this action is not convenient to the worker

Unit should think of worker comfort of performing their tough job by giving good amount of space















Risk Fair Excellent





Excessive noise





Excessive noise




Risk Fair Excellent



Risk Fair Excellent










Unit 13MSME UNIT Name : Pankaj Steel Industries

NAME : Mr.Pankaj DasYEAR OF OPERATIONS : (2009)Mob. No : +91 9854238833PRODUCT RANGE : Steel FurnitureTURN OVER : Approx. 4.92MAJOR Customers(S) : Trusses, Shutters, Gate,Grills.No of Employees : 9MAJOR MACHINARIES : Welding, Oxygen cylinder, Power shearing machine, grinding machine,
















Poor



Poor



Fair




Good


Good


Good


Good



Units doesn’t have name board, mots of the units not having name board , so it’s hard to find units

Branding awareness is necessary to all units

No lighting in the unit even though there is an window in the units. Proper lighting system environment should be maintained in units.

An awareness should bring to units about lighting environment and how it increase the production

Scattered screws and nets and bolds are on the floor , since workers are not wearing safety shoes there is a chance to get inject these metals into workers foot. Cleanliness is much lacking most of the units.

Workers should underrated the consequence of metals scattered on the floor. And safety items need in units

Food cleanliness in the work place is not at all given concern, as you can see the utensils are kept open and when spray works goes on there is a chance of pain spread on the plates. Drinking water at units is not kept in most the units. Some of the basic need should be kept in units

Units shouldknow about some basic amenities to keep in every units for workers










N/A






Risk Fair Excellent





Excessive noise





Excessive noise




Risk Fair Excellent



Risk Fair Excellent










Unit 14MSME UNIT Name : J B Steel Enterprises

NAME : Mr. Jyotish Kr BaruahYEAR OF OPERATIONS : (2009)Mob. No : +91 9864190674PRODUCT RANGE : Steel FurnitureTURN OVER : Approx. 4.30MAJOR Customers(S) : Trusses, Shutters, Gate,Grills.No of Employees : 2MAJOR MACHINARIES : Welding, Oxygen cylinder, Power shearing machine, grinding machine,
















Good



Poor



Good




Good


Good


Good


Good



Table used to prepare vegetable for food is not hygienic,

Unit should have separate place for cooking partitioned with curtains to protect dust and other mist

Cooking table is in wood and kept stove on top of that, it might cause dangerous accident when fire happens on the wood table, as well as the cylinders are kept each other open and sealed one.

Unit should have cooking place separately and prevent the accidents

Drinking water can kept on top of iron made stand which is very tough to change water and the place is full of mosquitoes

Unit need to understand the hygienic work style.

Workers hanged their dresses in open place where spray and duct falls on the shirts.

Curtain could cover the hanged shirts and keep away from duct particles.















Risk Fair Excellent





Excessive noise





Excessive noise




Risk Fair Excellent



Risk Fair Excellent










Unit 15MSME UNIT Name : Hazarika engineering works

NAME : Mr.Mridul HazarikaYEAR OF OPERATIONS : (1990)Mob. No : +91 9854583761 PRODUCT RANGE : Steel FurnitureTURN OVER : Approx. 21.06MAJOR Customers(S) : Trusses, Shutters, Gate,Grills.No of Employees : 6MAJOR MACHINARIES : Welding, Oxygen cylinder, Power shearing machine, grinding machine,
















Poor



Poor



Fair




Good


Good


Good


Good



Dim light have been used in the unit and performing late night job

An awareness about lighting system in the unit sis very much for each units

Due to dim light the machine interface is not visible

Lighting system should be improved in the unit

Tools are put on the floor and no brightness lights in the unit. Workers might forget to clear up tools or they might trample on the tools which can cause serious injury on their foot

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Risk Fair Excellent





Excessive noise





Excessive noise




Risk Fair Excellent



Risk Fair Excellent










Unit 16MSME UNIT Name : Maa Steel Furniture

NAME : Mr.Nur HussainYEAR OF OPERATIONS : (2010)Mob. No : +91 PRODUCT RANGE : Steel FurnitureTURN OVER : Approx. 3.80MAJOR Customers(S) : Trusses, Shutters, Gate,Grills.No of Employees : 2MAJOR MACHINARIES : Welding, Oxygen cylinder, Power shearing machine, grinding machine,
















Poor



Poor



Fair




Good


Good


Good


Good



Tools are placed on table in unorganized way which gives more cognitive load to workers to find certain tool in a need. The main electric box wires are rolled up and kept under the table which is seems more dangerous at work station.

The main electric box fuse is kept open and the wires seems very old, on the floor things are placed across the floor workers might be stumble upon thing and there is probability of severe accident.

Units should understand the safety environment in workstation in terms where should place electric main box and what items shouldn’t be near to that.

The entire work station is not properly maintained , tools are scattered on the floor and dress hanging in middle of path way and much worst part is a single light had been used for this entire unit.

Units needs to understand environment planning and keeping work station clean. So that workers feel healthy environment to perform better job.

Unit constructed by temporary sheets and rust metal sheets.

Units need to understand the risk of constructing units by using rusted metals and an awareness on unit construction material is necessary for each unit owner should know.















Risk Fair Excellent





Excessive noise





Excessive noise




Risk Fair Excellent



Risk Fair Excellent










Unit 17MSME UNIT Name : K N Steel Industries

NAME : Mr. K k NathYEAR OF OPERATIONS : (2009)Mob. No : +91 9859054123PRODUCT RANGE : Steel FurnitureTURN OVER : Approx. 4.25MAJOR Customers(S) : Trusses, Shutters, Gate,Grills.No of Employees : 9MAJOR MACHINARIES : Welding, Oxygen cylinder, Power shearing machine, grinding machine,
















Poor



Poor



Good




Fair


Good


Good


Good



Rusted iron metals have been used and made as sitting stool for worker for welding purpose

Unit need to understand the risk of using rusted items and ma

Wastage items are being loaded in the units and seems like its been long years never has been disposed wastage items.

Allocate a common place to keep waste items and make unit aware of disposing time or how to recycle the items which has been wasted

Storing micro tools in the box ,which is not clean enough since the box and items inside are rusted and its also ruining new tool which has been kept .

A separate wood can used to stores micro tools which wont get rust when putting irons and metal tool in it.

In the unit the floor is not laid by cement nor any other better surface material, it is in sand and with many screws and iron particles spread on the floor. When rain the floor will be much slippery

Unit need to understand the floor surface importance since its a heavy work station and metals, screws and iron rod particles scattered on the floor the surface has to help worker to clean it up easy way. Unit worker must wear safety shoes whil in workstation.















Risk Fair Excellent





Excessive noise





Excessive noise




Risk Fair Excellent



Risk Fair Excellent










Unit 18MSME UNIT Name : Das Engineering

NAME : Mr.Putul DasYEAR OF OPERATIONS : (2009)Mob. No : +91 9854258129PRODUCT RANGE : Steel FurnitureTURN OVER : Approx. 4.25MAJOR Customers(S) : Trusses, Shutters, Gate,Grills.No of Employees : 4MAJOR MACHINARIES : Welding, Oxygen cylinder, Power shearing machine, grinding machine,
















Good



Poor



Fair




Fair


Fair


Fair


Fair



Working in awkward postures above shoulder height and Awkward postures when applying high force to push, pull or restrain metal products

In work place make sure safety is given more consideration make a rule to workers to start welding by wearing welding mask, shoes, dress and hand cloves. also when welding make sure you have fire extinguishes and oniment in first aid box.

The electric main box seems like carelessly left for many years which out proper maintenance as you can see the box is kept open with all the wires hanging and the worker performing job near that electric box.

Units need to understand the safety concern in wiring structure in the work station.adn should not keep any machine to work by worker near the electric box

Awkward postures when welding without any safety concern and no shirts!

Units owner has to strongly recommend to workers to wear safety things while performing welding















Risk Fair Excellent





Excessive noise





Excessive noise




Risk Fair Excellent



Risk Fair Excellent










Unit 19MSME UNIT Name : B A Steel fabrication

NAME : Mr.Babul AliYEAR OF OPERATIONS : (2009)Mob. No : +91PRODUCT RANGE : Steel FurnitureTURN OVER : Approx. 7MAJOR Customers(S) : Trusses, Shutters, Gate,Grills.No of Employees : 2MAJOR MACHINARIES : Welding, Oxygen cylinder, Power shearing machine, grinding machine,
















Good



Poor



Fair




Fair


Fair


Good


Fair



The location of designated raw material and delivery areas not in the unit and no clear walkways to avoid trips and falls.

Unit need to know risk of putting materials on the floor with out having concern on workers. A proper guidance and an awareness should be given to units to have separate disposal bin area and keeping floor clear from many metals scattered

The whole unit environment looks like second market of selling iron and metal items. Units owner encourage worker to maintain cleanliness in the work station.

No place to walk and worker walking on the rods with out shows/saddler, sometimes it would have welded might be chance to get severe wound

Ask workers to wear shoes or saddle, try to give place to walk inside the work place















Risk Fair Excellent





Excessive noise





Excessive noise




Risk Fair Excellent



Risk Fair Excellent










Unit 20MSME UNIT Name : Bright Steel Fabrication

NAME : Mr.Azarudhin AhmaedYEAR OF OPERATIONS : (2010)Mob. No : +91 9859054123PRODUCT RANGE : Steel FurnitureTURN OVER : Approx. 4.80MAJOR Customers(S) : Trusses, Shutters, Gate,Grills.No of Employees : 2MAJOR MACHINARIES : Welding, Oxygen cylinder, Power shearing machine, grinding machine,
















Poor



Poor



Fair




Good


Fair


Fair


Good



With the metal rods and completed grill work are kept inside the unit. unit can keep in exhibit to capture customer attention.

Unit need to know the value of exhibiting and displaying work in their premises. Which can help to capture more customers.

Metals rods and wiring are lying on the ground and their no proper steps to climb into unit. As there is some bricks kept which can risk when worker carrying heavy and step on it to enter into unit.

The electric box, machines and tool storage place cramped to gather and no proper lighting system in the units and no ventilation

Unit owner need to make pal on where things should be kept neatly and easy top access. Also most of the units didn’t concern about drinking water for workers. There should be partition in the work station to have food and water away from dust and noise.

Unit worker placed welding machine on the floor without safety concern , and many iron particles lying on the floor. It high critical to walk in the unit without stepping on rods or metals.

Workers need to concern about safety factor in the work station.

Workers should understand risk factor when assembling used things around work station.















Risk Fair Excellent





Excessive noise





Excessive noise




Risk Fair Excellent



Risk Fair Excellent










Unit 21MSME UNIT Name : Mayur Steel Furniture

NAME : Mr.Ripul DekaYEAR OF OPERATIONS : (2010)Mob. No : +91 989192215PRODUCT RANGE : Steel FurnitureTURN OVER : Approx. 18.45MAJOR Customers(S) : Gate & Grills Furniture IndustriesNo of Employees : 4MAJOR MACHINARIES : Welding, Oxygen cylinder, Power shearing machine, grinding machine,
















Good



Poor



Good




Good


Good


Good


Fair



A place is allocated for the owner to sit and talk with customers.

Unit owner need to understand how to sustain customer relationship and how attract new customers. Also how to change design from monotony to ground breaking.

The water bucket is kept inside the unit and chance to get fever if insects and mosquitoes form on the water and that will affect production in the unit. Also at right side pic and waste materials have been kept inside the unit which can cleared up else some insects and it will spoil the entire place

Wall color are painted in light color and it increase brightness in the unit . The workers place their dresses in the grilled metal which might have dust which can casuesever skin disease

Worker should also be aware of cleanliness of taking care of the dresses in the work station. And drinking water is an other major factor unit should consider

Unit need to understand the cleanliness factor in their work station.















Risk Fair Excellent





Excessive noise





Excessive noise




Risk Fair Excellent



Risk Fair Excellent










Unit 22MSME UNIT Name : Deka Fabrication Works

NAME : Mr.DepakYEAR OF OPERATIONS : (2010)Mob. No : +91 7399621016PRODUCT RANGE : Steel FurnitureTURN OVER : Approx. 8MAJOR Customers(S) : Gate & Grills Furniture IndustriesNo of Employees : 2MAJOR MACHINARIES : Welding, Oxygen cylinder, Power shearing machine, grinding machine,
















Good



Poor



Good




Good


Good


Fair


Good



Things are placed in the entrance of the unit, the battery and machine kept close to each other and welding work has been done near to the open electric main box.

Welding action should be performed away fro other electric items mainly should be away form main electric box cause some time the fire spark can cause any major accident.

The allocated in th eunit to keep rods and bars in the separate place which is so well thought. Over all this unit look clean and welcoming.

A well lighting atmosphere environment with walls painted lighter color. Unit owner need of support to see future product and sustain in the market, and seeking advise to know how to scale up the business















Risk Fair Excellent





Excessive noise





Excessive noise




Risk Fair Excellent



Risk Fair Excellent










Unit 23MSME UNIT Name : Freya Steel Fabricaton

NAME : Mr.Aftav Uddin Ahmed SaikiaYEAR OF OPERATIONS : (2010)Mob. No : +91 985912457PRODUCT RANGE : Steel FurnitureTURN OVER : Approx. 9MAJOR Customers(S) : Gate & Grills Furniture IndustriesNo of Employees : 3MAJOR MACHINARIES : Welding, Oxygen cylinder, Power shearing machine, grinding machine,
















Good



Poor



Fair




Fair


Fair


Good


Good



Welding in awkward posturesWelder exposed to flash. Welder is not concern about safety , as we can see no shoes, no hand cloves and face mask to prevent fire accident on body.

Unit owner need to take responsibility to tell workers about the safety need and commend to work only with safeties in the work station

In the unit there is no painting ceilings and walls are not painted with lighter colour, which can allow more light to be reflected and assisting in increasing the light within the workplace. There is no clear walkways avoid trips and falls. Unit doesn’t have designated areas for parts keep the workplace tidy

Unit need to understand the importance of work station planning in terms lighting, environment, safety

Things are placed on the floor and the chair is put for customer which is not clean, full of dust and mist . These unit has good ventilation, but still in the night time no support of good lighting system in the unit.

Unit need to understand customer hospitality in their premises.















Risk Fair Excellent





Excessive noise





Excessive noise




Risk Fair Excellent



Risk Fair Excellent










Machinery Recommendation for Advanced design



The advent of new technology in every sector is making difference in market and possibility of seeing business growth, in the same line engineering and fabrication units need to ready to adopt new technology machine to develop new design to the market which can help them to see disruptive design in the market. Since every units have been using age old machine and general basics machine to bend sheet metal and weld rods which wouldn’t be enough to come up different model of design in this sector. Every unit should ready to adopt new technology machine in their unit to see the successful business. DIC can support units by giving training to the units member who willing to get the machine in their units.


Safety Needs

“Prevention is better than cure” by implementing safety needs in every unit it would good for unit growth as well as labor wellness. Thought out the need assessment survey there is no one unit which has safety equipments in the unit an awareness should be created to each unit about the crucial consideration of the safety needs should be kept in every units for labor and the unit wellness environment.


An Analysis of other minerals to combined with steel and attract new market trend

Every unit in the market is focused on regular product material usage the paradigm should be change by fabricating with different materials in the product. With cross design thinking analysis mind I have reached out different place where brass has been polished and making plate . As of now the current market as product like locker, wardrobe , grill gate and window gate .

Each unit should take a chance to integrate the brass material in their product to see how the customer react with the product by doing so each unit perform research and development in their own premises and gain the best business out from the effort.


An Analysis of Current Market Trend

S – StrengthLow to Medium Industry.Needs average investment infrastructure and high income.Easy availability of Raw materials and labourEasy availability of steel andRaw material is available at low costHigh demand from steel manufacturing industries located nearby area.It has a high demand in both in city and village market demand

W- WeaknessesNo proper Design booksUnhealthy competition exists due to numerous units in close proximityMostly process is manual, not semi-automatic or fully automaticUnit wise test lab is not available.Most units have no brandingUnit is run by not well qualified /technically sound ownersNot enough aware or conscious about new trends and market and new designsNot regularly participating in display /exhibition of productsDue to unawareness, owners are not able to avail the benefits of government policies.Mostly are using oldest MachinesMost of them not having bend machineUnstable market demand has led to steady/good production units to storeproducts stored in and outside the plant.Collaborative efforts with Academic /R&D institution is missing.

O- OpportunityCommon facility centre may be developed for Standard quality of raw materials, steel andtesting facilities.Scope of research and product development. availableMore production using or applying skill up gradationVisual identity of product.Interior roadway.Proper training on new tools and machinesExpansion from local market to global marketSkill up gradation of laboursTraining for use of recycled /waste materialsAwareness program on quality of raw materials, steels for better production.More scope for employment of people.Awareness programme for setting up of new plants or up gradation with the help ofProvision of loan and profitable policies for small units.


SWOT - ANALYSIS

T- Threats

Absence of quality inspection has led to waste and low delivery to market.Technology for efficient use of disruptive design makingDue to 100 days work facility of government, sometimes labours become unavailable.Due less awareness about market competitiveness and quality consciousness, selling price of the products becomes marginal.In-efficient electric city reducing productionMarket of refractoriness dependent directly on steel manufacturing units demand.Very few young entrepreneurs in the profession.No Safety & Health concern, need awareness programmeMost Units are old, inherited and not motivated enough for future development.Systematic plan for future intervention /development from Government agencies missing.Need to come up with new product design to market to sustain and develop new trend


SWOT - ANALYSIS


Interview with Unit Owners


CONCLUSION

This NAS /study of Engineering and Fabrication cluster is good step towards understanding their full potential and a footstep toward their betterment and utilization of the same for revenue generation of government units. Mostly the cluster units are located in the village area and far away from the local towns, Except a few units, quality products are not emphasized as they are getting direct orders from the steel industries. In order to make and sell the product in lowest possible rates the manufacturers do not make quality product. Branding is also not done in most of the units as the standard or quality is not maintained. Also they do not have any sort of collaboration with technical institutions to improve growth pattern. Also some of units are working in an organized way following semi-automatic technology while others are in an unorganized way and running somehow. Hence attention may be paid to built up technically sound processes, systems, product and brand with fuel efficient techniques. Moreover training programmes may be arranged for awareness of the owners /Labour's and skill up gradation of workers. This is possible if we acutely understand the culture, the people and their aspirations. This holistic view and understanding would provide authentic guidelines for changes that may be beneficial for this of Engineering and Fabrication cluster

Thank You

need assessment survey report 2013 -...

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