INTRODUCTION:

Indian Welding Industry, by and large, has done well as a contributor to national economy and industrial progress. In doing so, technological advancement has been a key factor which has prepared the industry to face the turbulent times with requisite confidence. The welding fraternity and professional bodies have ensured forward movements through regular technical seminars, which also helped researchers, young and not so young. These efforts have sustained industrial growth.

We did not forget the issue of welding education and training and we kept deliberating on it from time to time in our seminars, highlighting the need to act, but the action remained restricted The technological developments have contributed to innovation, quality, & productivity with cost effectiveness. In the process, the period of three decades or more, has only widened the gap between demand and supply of educated welding personnel. Let us look at how big the gap is, because even in preparing a roadmap to rectify the situation, we need to know the magnitude of the problem of acute dearth of personnel.

STEEL PRODUCTION:

As steel production can be looked

upon as an indicator of country’s

industrial progress and

overall economy. Figures of steel

production for the top ten steel

producing countries serve to

highlight India’s achievement and its

current status, ranking at 4th place

with steel output of 76.7 million

tonnes in 2012.

TOP 10 STEEL PRODUCING COUNTRIES.

Rank Country 2012 ( Mt ) 2011 (Mt) 2012 / 2011 (%)

1 China 716.5 694.8 3.1

2. Japan 107.2 107.6 -03

3. United States 88.6 86.4 2.5

4. India 76.7 73.6 4.3

5. Russia 70.6 68.9 2.5

6. South Korea 69.3 68.5 1.2

7. Germany 42.7 44.3 -3.7

8. Turkey 35.9 34.1 5.2

9. Brazil 34.7 35.2 -1.5

10. Ukraine 32.9 35.3 -6.9

TABLE: IA

(Source: World Steel Association)

Country 2010 2009 2008 2007 2001

China 638.7 577.1 512.3 489.0 150.9

Japan 109.6 87.5 118.7 120.199 102.866

U.S.A 80.5 85.2 91.4 97.212 90.104

India 69.0 63.5 57.8 53.08 27.29

Russia 66.9 60.0 68.5 72.22 58.97

South Korea

58.9 48.6 53.6 51.5 --

Germany 43.8 32.7 45.8 48.55 44.80

Turkey 29.1 25.3 26.8 25.76 14.98

Brazil 32.9 26.5 33.7 33.784 26.717

Ukraine 33.4 29.9 37.3 42.83 33.10

TABLE: I-B (Source: World Steel Association

India recorded growth of 4.3% over the

previous year 2011 when most parts of

the world recorded a slow down. Per

capita consumption (Kg/Year) is

another encouraging feature. Despite

the rising population India recorded

an increases of 41% during the period

2005 – 2010.

PER CAPITA FINISHED STEEL CONSUMPTION (Kg.)

Sr.No. Country 2005 2006 2007 2008 2009 2010 % rise

2010/2005

1 China 266.0 287.4 319.6 326.9 409.4 427.4 61

2. S. Korea 981.6 1042.6 1144.1 1210.7 936.1 1077.2 10

3. Japan 601.6 619.5 637.0 612.1 415.6 502.9 16.4

4. USA 356.5 400.9 358.5 323.6 192.7 258.2 28

5. Russia 204.9 245.8 285.6 251.7 178.1 256.2 25

6. Ukraine 118.4 142.5 173.9 149.5 86.6 121.0 2

7. Germany 427.7 475.6 518.4 514.3 342.7 440.8 3

8. India 36.6 41.2 45.8 45.1 47.8 51.7 41

9. World (Avg.) 173.9 188.0 199.4 194.4 181.0 202.7 17

TABLE-1C. Source: World Steel Association.

QUANTUM OF WELDING:

Welding is indispensable to modern

society to sustain industrial growth

and national economy. Steel and

welding go together and quantum of

welding has increased sharply over

the years up to a level of about 3,50,000

tonnes of weld metal.

Market for all welding consumables,

machines and systems may be

estimated at Rs.70 billion per year. It

indicates the robust status of welding

industry. This also implies the

steadily rising manpower requirement

for handling welding operations at

various levels.

Another highly encouraging figure

relates to year-wise demand for

finished steel during the period 2011 –

2017 i.e. 12th plan of the Government of

India . Projected demand for the year

2016-17 is at a healthy figure of 113

million tonnes as against 77.3 million

tonnes in the year 2012-13. From the

stand point of welding activity it gets

converted into more than 500,000

tonnes of weld metal, that is an

increase of about 50% in four years.

MANPOWER REQUIREMENT –

EDUCATED & TRAINED:

Quantum of welding 3,50,000

tonnes of weld metal per year ,

rising to 5,00,000 tonnes per year

by 2017. Manpower requirement

will be in excess of 10,000 and this

is potential for industry academia

partnership.

TECHNICAL EDUCATION SCENARIO

IN INDIA.

Projected in Table II-A output of about one million diploma and degree

holders in engineering in the year 2010 is highly impressive figure.

Particulars. In 1997 In 2004 In 2010

Industrial Training Institutes 1,580 4,038 8,039

Diploma level Technical Institutions 976 1344 --

Degree level Technical Institutions 604 1,346 3,573

Post graduate level Technical Institutions 140 389 800

Graduate Engineers per year 80,000 4,39,689 6,00,000

Diploma Technicians per year 1,25,000 2,65,416 3,00,000

Skilled workers per year 2,60,000 6,64,481 11,15,628

Master degree holders in Engg. per year 7,000 31,354 60,000

Doctorate degree holders in Engg. per year 400 4,000 8,000

TABLE : II-A

Table-IIB summarises figures for six years from 2016 to 2012. Figure

3393 for technical institutes and the figure of 1.5 million indicate

students in the year 2011-12, an indication of sustained growth. It is

highly satisfying.

GROWTH OF TECHNICAL INSTITUTES (ENGINEERING) & GROWTH

OF INTAKE (UNDER GRADUATE & POST GRADUATE).

Year No. of Technical

Institutes. Intake of Students

(UG + PG)

2006-07 1511 5,50,986

2007-08 1668 6,53,290

2008-09 2388 8,41,018

2009-10 2972 10,71,896

2010-11 3222 13,14,594

2011-12 3393 14,85,894

TABLE : II-B

On the other hand, a closer look

into the figures from the stand

point of welding education brings

out the harsh reality that the field

of welding education and training

lagged far behind the

technological advancement. Lack

of courses and facilities even at

the diploma level is the situation

we are facing today.

Fast changing scenario in the

pattern of engineering education.

Hence the need for close

interaction between industry and

academia in formulating

academic courses and

establishing adequate facilities at

educational institutes.

STATUS OF WELDING ENGINEERING EDUCATION:

Immediate needs are for diploma courses at selected polytechnics to turn out reasonable number of qualified welding technicians. Two levels of courses are required :

Elementary course as a part of mechanical engineering course, and

Advanced course for students who want to specialize in welding after securing diploma in mechanical engineering.

After this is implemented we have to ensure suitable placements for the candidates by encouraging the welding industry to employ them. The next step is to strengthen the role of welding technicians in manufacturing activity by giving them due status and authority. This will happen when the inspection bodies start insisting on welding related documents to be signed by such qualified technicians as it is the practice in several countries. In the long term planning an attempt as to be made to make the conditions favourable for welding to be integrated into other engineering operations.

APPROPRIATE CURRICULA FOR DIPLOMA AND

DEGREE COURSES IN WELDING ENGINEERING:

Sad part of the Indian scenario is the absence of appropriate curriculum even today. Hence the need to tackle this issue speedily. In doing so, we should examine the curriculum for degree and diploma courses in welding engineering offered by Sant Longowal Institute of Engineering & Technology, Punjab.

EXISTING FACILITIES:

In trying to tackle the issue, problem starts with lack of information of what already exists. The limited information can be listed as hereunder:-

Sant Longowal Institute of Engineering & Technology, Punjab, offers two year diploma course and four year degree course in welding engineering, with 30 seats and 40 seats respectively.

National Institute of Technology (earlier Regional Engineering College) Tiruchirappalli) offers a post-graduate two year course with 15 seats (the number may have been increased by now).

IIT, Roorkee, has 15 seats for post-graduate studies in

welding.

IITs at Chennai, Mumbai, Delhi, Kharagpur, and Indian Institute of Science, Bangalore, have been active in post-graduate studies with M.Tech degree .

Maharaja Sayaji University in Vadodara offers two year post graduate course for M.E. (Welding), with 15 seats. This is well supported by L & T Ltd. and is a fine example of industry – academia cooperation.

Two or three polytechnics in Andhra Pradesh have been offering diploma courses.

One polytechnic in Bhavnagar, Gujarat, has been offering a four year course in fabrication technology, with large content of welding technology.

The number of Doctorates in welding may be 15 to 20 per year.

ROLE OF CONFEDERATION OF INDIAN INDUSTRY:

it is clear that the industry and academia have their own priorities which impose limitations on joint efforts. This has been happening over the years and we have to find a solution. We need industry representative body CII to take the role of coordinator and provide the “METHOD”. Working together all three can prepare an action plan with a time frame

ACTIOIN PLAN:

Take appropriate steps to secure recognition for welding in the Ministry of HRD & AICTE.

Prepare curriculum for diploma courses of two levels – elementary & advanced.

Elementary course to be made a part of mechanical engineering course at polytechnics.

Select at least one polytechnic in each key industrial / city centre for introduction of the advanced course.

b.1) In case, for any reason, it is found difficult to have the elementary course

incorporated in mechanical engineering course meant for polytechnics, introduce this same course in polytechnics selected for advanced course.

Collect data on existing facilities for academic courses, & try to optimize their utility, with requisite publicity & support. This is probably the grey area in our activities, due to inadequate information.

Optimize the utilization of existing facilities for training courses.

Explore speedily the possibility of inviting the German Welding Society to join hands so as to accelerate the education drive. CII has to handle this issue, as commercial considerations will demand attention to fund raising to meet the cost.

Make every national/international welding seminar a venue for presentation of progress reports and further steps planned. Allot adequate time. Take the entire membership into confidence, utilize their presence to make them feel a part of the ongoing exercise, & motivate them to contribute, in whatever measure, to the National Movement in the area of Welding Education, Training & Certification.

Publicity Drive (as a part of Action Plan):

I should point out the need for special efforts to attract

engineering students to the proposed academic and / or training courses. We all are well aware that unlike the mechanical and metallurgical engineering branches, welding engineering seldom finds a place in the list of career options. This implies that CII will have to launch an awareness programme at selected engineering colleges and polytechnics and if need be publicity through proper channels. In this connection I may be permitted to refer to my numerous lectures at engineering institutes in the last seven years on the topic of “Career in Welding – An Appraisal for clear Perspective”. I shall handover a copy to DrAbhayankar, Convener and CII may consider utilizing it, partially or wholly, for the awareness drive.

(b) Marketing Drive (As a part of Action Plan):

Such a drive will be required to facilitate

placements for qualified candidates.

Hopefully, campus interviews will not

remain a distant dream.

CONCLUSION:

It has to be noted that a country like Germany having advanced technology in proper place and under constant scrutiny for further steady advancement, recognizes the increasing need for welding education & training. Obviously, for our country to remain in the race for advancement, the need for a national programme for education, training and certification has to be met on top priority. The leaders of the entire welding fraternity and CII have to get involved in the exercise of national importance. Only then can we expect the Ministry of Human Resources Development to extend support in terms of funds and introduction of appropriate curriculum in engineering colleges and polytechnics i.e. as an integral part of engineering education system. For the future of welding technology and development of educated, trained manpower, a limited course in welding engineering has to be integrated with Mechanical Engineering course.

CII ought to get fully involved in this

exercise of national importance, with

active support from leading

corporates, such as L & T & BHEL,

having vast experience in

sophisticated welded fabrication on all

India basis.

Pune is the city which offers scope for

favourable conditions in terms of

number of industries – large & small, and

number of educational institutions

combined with relatively shorter

distances, which has today become an

important factor.

CII Pune can become a trend setter in

establishing such facilities based on the

report of the task force. This can then be

replicated in other centres which offer

scope for such a partnership.