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Scientific glaSSwareambala cantt i haryana
DeSign awareneSS program report
DeSigneD anD DocumenteD by kulveer Singh bhati
DeSign awareneSS program reportmSme niD DeSign clinic Scheme
SupporteD by phD chamber
aSima
in association with
Designed and Documented by
kulveer Singh bhatiinDuStrial DeSigner . architect
Scientific Glassware I Ambala Cantt I Haryana
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table of content
neeD aSSeSSment Survey
i. introductionii. about ambala cantt industrial towniii. time frame
cluSter level macro StuDyiv. cluster information and Details of units 01. Detail Of Units 02. Demographic Distribution Of Units 03. Business Models 04. Product Range 05. Tools And Machinery 06. Process & Techniques 07. Labour Intense Process
unit level micro StuDyv. common problems and recommendation 01. Worker Related Problems 02. Pre Manufacturing 03. Manufacturing Processes And Techniques 04. Post ManufacturIng
vi. product Study 01. Product Design And Aesthetic 02. Branding
Vii. Unit Specific Problems, Remedies And Opportunity
vii. Swot analysis
viii. on a Serious note
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Kulveer Singh Bhati I Industrial Designer I 2013
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DeSign clinic workShop
I. Workshop Methodology
II. schedule of Workshop
III. openIng sessIon
Iv. guest lectures
v. dIscussIon And BrAInstorMIng 01. Manufacturing Processes 02. Packaging Ideas 03. Value Addition To Existing Products 04.New Designs In Existing Product Range 05. New Opportunity In Parallel Industries
vI. desIgn opportunItIes
vII. prototypIng
vIII. conclusIon
Annexures
photo credIts BIBleogrAphy
Scope of intervention anD SuggeStionS
i. Design intervention on Different production Stages ii. industrial Design opportunities
iii. Short term interventions iv. long term interventions
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introDuctionthe industrial heritage city of ambala cantt has more than 1200 scientific equipment manufacturers. More than 200 falls in the category of medium scale industries and traders. ambala cantt is the largest manufacturer of scientific glassware in the country.
The Ambala Cantt scientific glass manufacturers not only caters to the pan india demand but also export to various parts of the world including europe and uSa.
The scientific glassware industry began in India before independence. initially raw material used to came from england then it started in india as borosil be the first company to produce raw materials but due high completion from chinese material borosil stopped manufacturing glass tubes and the complete supply had shifted to china in last few years.
The Scientific Glass manufacturing is completely a skill based industry because of glass blowing processes. it makes the industry production limited. in last few years micro industries are coming up very fast most of them are set up by senior workers and traders. they have started the competition by reducing rates and quality. ultimately to sustain all industries are compromising on quality to keep cost low.
now lot of small and medium scale industries are going through a tough time because of low margins, extreme completion and old technologies.
Scientific GlaSSware
Kulveer Singh Bhati I Industrial Designer I 2013
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ambala cantt
ambala cantonment is a cantonment town in ambala district in the state of Haryana, India. It is a major market for scientific products for school and colleges.The city is famous for producing great academicians.
locationit is next to ambala and is on the grand trunk road. it is some 200 kilometers north of Delhi and 50 km south from chandigarh.
climatethe climate of ambala over most of the year is a pronounced continental in character. it is very hot in summers and markedly cold in winters. may and June can be really hot with the temperature soaring to over 48°C,while in winter it can be as low as -1°c. ambala has a semi-arid as well as tropical climate.
DemographyAs of 2011 India census, Ambala had a population of 1,136,784, consisting of 640,044 males and 532,740 females. Ambala has an average literacy rate of 82.9%, with 88.5% of males and 76.6% of females literate. 11% of the population is under 6 years of age
economyAmbala is known as city of scientific instruments. It is a major scientific products market and is a hub for products like glass apparatus, microscopes, laboratory equipment etc. Ambala constitutes nearly 34% of the total production of scientific instruments produced in India.
Scientific Glassware I Ambala Cantt I Haryana
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nee
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time frame
Weeks
Kulveer Singh Bhati I Industrial Designer I 2013
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neeD aSSeSSment Survey
Kulveer Singh Bhati I Industrial Designer I 2013
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Cluster InformatIon and detaIls of unIts
01. Detail of unitS
02. Demographic DiStribution of unitS
03. BUSIneSS MOdelS
04. proDuct range
05. toolS anD machinery (a) hand tools (b) machinery
06. proceSS & techniqueS
07. labour intenSe proceSS
Scientific Glassware I Ambala Cantt I Haryana
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01. DetailS of unitS
S.n. name of unit name of owner worker details
turn-over
contact details
01. Gupta Scientific industries
bhusan gupta 22 m01 f
1,5 Cr 3703/1 Ambala Cantt (T) 0171-2631837
02. glassco laboratoryequipments Pvt ltd
Sameer jain 200 m+f
27 cr manglai, Ambala cantt(t) 0171-6451250
03. Science Zone vikas gupta 8 m2 f
25 l 982-e, HBC, Ambala cantt(t) 0171-4005855
04. rama thermometer industries
Subodh goyel 2 m 45 l 987, HBC, Ambala cantt(T) 0171-2654534
05. D r glass works
Sunny aggarwal 5 m2 f
__ Plot no- 5, HBC, ambala cantt(t) 09416555191
06. JmD glass ware mahesh gupta 4 m 20 l 981F, HBC, Ambala cantt(T) 09416430332
07. Malik Scientific glass works
Surander kumar 1 m 25 l 2503, Bangali street, ambala cantt(T) 09416824347
08. amit enterprises amit bansal 11 m 1.4 cr 1222 Bengali street, ambala cantt(T) 0171-2643336
09. paras instruments co.
Subhash Jain 11 m03 F
70 l 5363 Punjabi Mahulla, ambala cantt(T) 0171-2644663
10. Kunal Scientific industries
Amarjit Saini 3 M 7 l Gausala Market, ambala cantt(t) 09812522856
Kulveer Singh Bhati I Industrial Designer I 2013
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01. DetailS of unitS
S.n. name of unit name of owner worker details
turn-over
contact details
11. aD glass printers
Shyamlal Sharma 6 m 10 l Patel nagar, ambala cantt (T) 09466288038
12. SR Scientific industries
ravinder kumar Sharma
7 m 40 l patel nagar,ambala cantt(t) 09896068991
13. Parban Scientific glass works
ashok kumar 3 M 5 l Sikligar mahulla, ambala cantt(T) 0171-2618836
14. Sanky Screen printing
rampal Sharma 3 M 3 l P P Puram,ambala cantt(T) 09315899570
15. Standard scientific Glass works
S K Rajjanwal 8 m 35 l 12, Kardhan Road, Industrial Area, ambala cantt(t) 0171-2699517
16. Super lab glass works
naresh kumar 12 m 25 l Ram Bagh road, ambala cantt(t) 09896105944
17. aggarwal enterprises
prem chand aggarwal
4 m 8 l near hargolal post office, Ambala Cantt(t) 09896796269
18. Jain Scientific glass works
Himanshu jain 100 + 5 cr 14 Industrial estate, ambala cantt(t) 09896181044
19. Jain laboratory glassware co.
Jaswant rai Jain 10 + __ # 2580/29, Subhash Park Road, ambala cantt(t) 0171 - 4005584
Scientific Glassware I Ambala Cantt I Haryana
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02. Demographic DiStribution of unitS
the entire glassware industry placed in a very close proximity of 10-15 Km radius in ambala cantt area, hSiDc industrial estate and outskirts on Jagadhari road.
the close proximity gives opportunity for small set-ups to grow and supply to big industries and traders. Since glassware has more then 1000 products so to manufacture all options is difficult since demand for few products is very limited. So it gave a good opportunity to small vendors/ industries to specialize in mass production on limited/ single products.
opportunitieSSince the entire cluster is within a close proximity it is also beneficial to implement different schemes like common facilities centre,
Kulveer Singh Bhati I Industrial Designer I 2013
1503. BUSIneSS MOdelS
enD uSer
. laboratorieS. inStitution
out Station traDer
local traDer
SMAll/ MedIUMMAnUFACTUReRS/
inDuStry
microMAnUFACTUReRS/
inDuStry
Scientific Glassware I Ambala Cantt I Haryana
1604. proDuct range
The product range in Scientific glassware industry is huge since a lot of products are customized for specific laboratory experiments/ use. Broadly it can be categorize on requirement basis as:
General products like volumetric flask, burettes, cylinders etc. the production of these products can be done faster and can be completely automatic in some cases.
labware/ customized products like separating/ dropping funnels, assemblies for various lab experiments. These products are highly customized and requires a very good workmanship.
Kulveer Singh Bhati I Industrial Designer I 2013
17The broad categorisation of scientific glassware can be done on the following basis:
a. Volumetric & Graduated Glassware
burettes
volumetric flask measuring cylinder
Measuring, Graduated pipettes
Scientific Glassware I Ambala Cantt I Haryana
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coil condenser
Flask round bottom, three neck
Flask round bottom, three neck
Kulveer Singh Bhati I Industrial Designer I 2013
19B. standard joints, stoppers and adapters
C. still heads and splash heads
Tapered joints
flow control vacuum transfer adapter
Short path distillation reactor glass head
Dean stark trap
Scientific Glassware I Ambala Cantt I Haryana
20d. separating/ dropping funnels
e. fractionating columns
Dropping funnel Pressure equalizing funnel
columns
Kulveer Singh Bhati I Industrial Designer I 2013
21f. sintered glassware
H. General glassware
Membrane filter holder assembly
beakers
essential oils setup
bottels
Scientific Glassware I Ambala Cantt I Haryana
22G. Interchangeable ground joint assemblies
Steam distillation unit assembly water distillations
Kulveer Singh Bhati I Industrial Designer I 2013
23
water distillations
05. toolS
Spanner Metal flatSewing awlplier
clipflat
Tri square chiselawlFlat file Round fileTaper file Half Round file
outside swing caliperinside swing caliper cylindrical tool
Scientific Glassware I Ambala Cantt I Haryana
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Single chuck grinding machineburner
glass cutter calibration machine
marking set
glass cutter
Digital weighing machine
Single chuck blowing machine
Double chuck blowing machine
heat furnace
machinery
Kulveer Singh Bhati I Industrial Designer I 2013
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borocilicate tubes 4mm Dia to 150 MM dia, lPG gas cylinder, packaging and finished products
Based on different requirements the glass tubes are cut to size in batch
The most important process, the glass is blown with help of lPG gas flame combined with oxygen cylinder
volume of each product is different after blowing, In water calibration process each product is measured and marked individually for required volumes
unit marking is done using screen printing process for various sizes
to release the stress from product that developed during after blowing process
wood wool or paper waste are commonly used to pack the products for transportation
06. proceSS & techniqueS
Storage
cutting
blowing
calibration
printing
annealing
packaging
Scientific Glassware I Ambala Cantt I Haryana
260 7. labour intenSe proceSS
high Skill proceSS
glass blowingcalibration
marking
meDium Skill proceSS
glass cuttinggrindingprinting
packaging
general proceSS
Storagetransportation
glass cutting
blowing and shaping
grinding
calibration
marking
printing
annealing
packaging
Storage
transportation
Kulveer Singh Bhati I Industrial Designer I 2013
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01. worker relateD problemS (a) lack of technical skills (b) labour shortage (d) Frequent job change
02. pre-manufacturing (a) raw material procurement (b) lpg gas
03. MAnUFACTURInG PROCeSSeS And techniqueS (a) Storage (b) cutting (c) blowing (D) grinding (e) calibration (f) marking (g) Screen printing (h) annealing (g) packaging
04. poSt-manufacturing (a) Storage (b) transportation
Common proBlems and reCommendatIon
Scientific Glassware I Ambala Cantt I Haryana
2801. worker relateD problemS
Scientific glassware industry completely dependent on labour skills because of glass blowing process. blowing requires sharp skill and it takes years to develop skills because of complicated nature of the process. being labours a very important part of the industry, the units are facing following problems related to labours:
(a) lack of technical skillsas a practice new workers learn the skills under senior workers. The labour training requires lot of time and there are no training program, labourers are not technically trained and lacks technical knowledge to handle glass production. Since the production highly depends on labour skills. Ultimately quality of manufacturing goes down and it reflects in the finished products.
Recommendation:. Skill development program .technical training workshops
(B) skilled labour shortagein ambala cantt area small and micro industries has grown rapidly in past few years, most of these industries were started by senior workers/ skilled labours and ultimately there is shortage of skilled labours. Due to that in few industries production and quality has gone down.
Recommendation:. automation of units for selected items. introduce ways to retain good labour with incentives etc.
(B) frequent job changeAs mentioned there is a shortage of skilled labour, few industries are also facing problems due to frequent change by labours. it not only effects the production also is shows different quality of production since all labours have different ski sets and finishing levels.
Recommendation:. Standardization of production. introduce ways to retain good labour with incentives etc.
Skill development
required
Kulveer Singh Bhati I Industrial Designer I 2013
290 2. pre-manufacturing
the pre-manufacturing stage involves procurement of raw material for glassware as well as basic energy requirements like lPG gas.
(a) raw material ( glass tubes)The raw material for the scientific glassware industry is borocilicate glass tubes in different Diameters ranging from 04 mm to 150 mm. the tubes are available in different qualities as A grade and B grade. The raw material for the whole market is 100% imported largely from china. local glass traders import raw material and supply it to units on retail prices.
(B) lpG gasThe scientific glass industry’s glass blowing process completely depends on lpg gas> so the demand for commercial gas is very high in the city. in fact to meet the gas requirement units buy it from black market. Till now the domestic cylinders were easily available with a little more margin with landing cost of lPG at Rs. 60/- but from ast 6 months even the commercial cylinders are not available easily hence the increased price of gas is effecting margins.
Recommendation:. lPG gas pipe line for glassware industries/ for industrial town. . easy availability of commercial gas cylinders.
Recommendation:. raw material procurement by cfc and make it available to units on nominal margins. . Demand for a local manufacturer of glass tubes.
Scientific Glassware I Ambala Cantt I Haryana
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3. MAnUFACTURInG PROCeSSeS And TeCHnIqUeS
(a) raw material storagethe main raw material is in form of borocilicate glass tubes is very fragile material and requires a very careful storage to avoid breakage. the total wastage of industry is around 8-10% of total raw material procured and only storage wastage is more then 3-4%. It id due to improper system. only by improvising on raw material storage system units can reduce wastage and it will finally reflect into better profits.
edges of tube may get damaged while accessing material
recommendation and remedial solutions:. Dedicated space for storage..Segregation system based on tube diameters.. basic training to handle raw material.
Improper packaging while stored
Designopportunity
glass Storage system specially designed for glass tubes and for different diameters
Kulveer Singh Bhati I Industrial Designer I 2013
31(B) CuttingThe first step of manufacturing starts with cutting of the tubes. As per the production requirement the tubes are cut for the complete batch at once and transferred to the blowing section from here. there are two ways to cut tubes with manually (glass cutters) as one by one piece and secondly with semi automatic machines in batch. The manually is a labour dependent job also edges of the tubes are rough after cutting. also there are some wastage in while cutting due to human error.
Semi-automatic cutting machine manual cutting
Proper lighting solutions
Use of proper uniform while working
Use of clear eye protection
Avoid storage around machine
Proper hand gloves, glass can incurred injuries while cutting
Dedicated space to keep finished goods and raw material to avoid breakage
recommendation and remedial solutions:.technical training workshops. time to time maintenance of machine and change of cutting blade.. Shifting to automatic cutting machines
Designopportunity
. locally developed cutting machine .paddle operated glass cutting machine
Scientific Glassware I Ambala Cantt I Haryana
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(C) Blowingglass tube blowing is the most important stage of the entire process. During this stage skilled labours blow the standard glass tubes and shape them in final product.there are lot of challenges and shortcoming on workstation and processes that results into a bad working environment and subsequently a compromised product.
tools for shaping glass machinery
Kulveer Singh Bhati I Industrial Designer I 2013
33Step 1
Fit glass tube on lathe chuck and start heating glass with low flame
blowing proceSS
Step 2
Gradually increasing the flame and till the time glass becomes soft to shape
Step 3
Start blowing calculated air by mouth or by pump operated by feet
Step 4
Shaping glass with a good balance of flame and air blow using a carbon die/ template
Template gets damaged due to heat and friction and results into defects on following products
Low grade/ no safety gears for workers effects their health
Heat generated from high flame makes working environment very hot and very difficult for worker
Better tools required since damaged tools leaves marks on surface of product
Wastage of Gas flame in between two blowing process
Step 5
After it comes to desired shape, cutting it with remaining tube
Step 6
Finishing bottom/ edges with help of special toolson rotation condition
Step 7
Removing finished product from chuck and keeping it to gradually reduce temperature
Designopportunity
. locally developed Automatic / paddle flame control machineto reduce wastage
Scientific Glassware I Ambala Cantt I Haryana
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Recommendation and remedial solutions:. better working environment. mandatory safety gears to use by workers . highly recommended safety for use of lgp cylinders and other equipment . introduce ways to reduce wastage of lpg and raw material. alternative materials for template to avoid wear n tear. Better hand tools for good finish . technical training to staff for better blowing practices
Better tools required since damaged tools leaves marks on surface of product
Process space for workers to keep personal belongings clothes are prone to catch fire in this zone
Better furniture for worker to sit since it directly effects his performance and health
Dedicated space to keep raw material and finished goods
LPG gas cylinders are directly exposed and kept very near to high flame, are very risky
Weather control units in summers because of excessive heat generated by blowing process
Wastage of Gas flame in while changing glass tubes
Typical scenario around workstation of Glass blowing
Low grade/ no safety gears for workers effects their health
Designopportunity
Workstation design, Urgent need of the industry
protection for worker excessive heat from blower
Kulveer Singh Bhati I Industrial Designer I 2013
35(d) Grindinggrinding is a post blowing step to maintain the standard inner diameter for different products like Flask, Bottles etc. the process involves a single chuck motor with a metal tool fixed in front. There is a special coating on Od of tool to make it temper proof and maintain oD for long time.
Recommendation and remedial solutions:
.technical training for skill development workshops
. Finding alternative/ hard materials for tool making
. Safety gears needs to me introduce by employer
. need to enhance working area
Lighting levels are very low for working
Gloves for working with water for long time
Protection for eyes while working with glass
The tool’s outer diameter gets reduced after long use and it start reflecting errors in size of ID of final product
Designopportunity
finding alternative material for grinding tool to maintain diameter in long run
Scientific Glassware I Ambala Cantt I Haryana
36(e) Calibration the celebration is the most important part for volumetric scientific glassware. each glassware has variations in wall thickness because of heat blowing and can not be marked with same template. So individual calibration of products is required. Any error on this stage can completely make product volume wrong and if the product is used in laboratory will project wrong result because of wrong volumes hence it is very critical to calibrate the glassware correct.
recommendation and remedial solutions:.technical training for workers. Better equipment for calibration . automatic calibration facility in cfc
1. automatic calibration machine
2. manual calibration Design
opportunity
locally developed automatic calibration machine
Kulveer Singh Bhati I Industrial Designer I 2013
37Step 1
Filling water in volumetric peppet, the water filled a little extra from marking.
Step 2
The extra quantity of water is released and a particular volume is maintained by the worker
Step 3
Same water is released into a new empty product
Step 4
The water is crosschecked on digital weighing machine as per the water temperature the volume also differs. so the same volume is maintained
Marking is done as per water level
manual calibration
Its a very skill based job and completely depends on labour to labor
There are chances that water quantity may differ each time
Its a additional process and makes it time taking job
Designopportunity
Scientific Glassware I Ambala Cantt I Haryana
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(f) markingpermanent marking is done post calibration and temporary marking on volumetric product. there is a special marking machine for manual marking with a base to rotate product and a diamond head to mark on outside the product. in this method of marking diamond head engraves on upper layer of product. it makes the product weak on neck. another limitation of manual marking is during the screen printing the printing does not cover the complete circumference of product due to matching issues.
Recommendation and remedial solutions:. Skill development program for workers. need to shift to automatic system for accuracy. automatic marking facility in cfc
Designopportunity
locally developed automatic Screen printing to avoid error and marking on outer part of glass
Kulveer Singh Bhati I Industrial Designer I 2013
39(G) printing
printing of volumetric units and branding need to be permanently printed on products. as discussed earlier also each product has variations so after marking the surface/ length needs to be divided equally and marked. there are different ways of marking as Screen printing and chemical marking.
chemical markingit is used when no of products are very less and to avoid screen cost the marking is done manually and chemically etched.
Scientific Glassware I Ambala Cantt I Haryana
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Recommendation and remedial solutions:. Skill development program .technical training workshops . automatic printing machines at cfc. proper storage system for screens. working posture of workers needs to be improved
Step 1
Selection of screen based on marking of product
Screen printing
Step 2
Preparation of paint commonly used colors are white and blue
Step 3
Application of paint on screen
Step 4
Rolling the product carefullyAgain a skill based job
Skilled based job, still variations can be there as well as alignment issues
Low grade/ no safety gears for workers effects their health
Good quality paint required for a better printing
Step 5
Checking of product post printing
The printing does not cover the complete circumference of product due to matching issues
Storage system for screens required
there are different screens developed for different variations of markings and a screen is selected accordingly.
Kulveer Singh Bhati I Industrial Designer I 2013
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(H) annealingHeating is required to release the stress of glass product developed during blowing process. it also make the printing permanent on product surface. post screen printing products are kept in a metal basket/ or directly on tray in a heat furnace and kept on heating for 2-3 hrs on a constant temperature of 540-560 c. post heating the products are kept out side furnace for some time to gradually cool down to room temperature.
there are breakages sometime during heating processand cracked product goes for scrap. it is also part of the total wastage.
Recommendation and remedial solutions:. Developing big furnaces for cluster level for batch annealing. provision can be made in cfc new age furnaces for save electricity consumption
Development of low power consumption furnace or Solar power furnace
Designopportunity
Scientific Glassware I Ambala Cantt I Haryana
42(I) packaging
Packaging is equally important for glassware to protect products while transportation. the traditional ways of packaging are commonly used in almost all units. There are two filling materials mainly used as wood wools and paper cuttings. wood wool is a very heavy material and makes transportation costly. also it makes products dusty by the time it reaches destination.
Designopportunity
light weight and cost effective packaging design
Kulveer Singh Bhati I Industrial Designer I 2013
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Recommendation and remedial solutions:. opportunity to design new packaging systems. innovative ways to make packaging lightweight and compact. common packaging design for all variations . Designing workstation for packaging
Step 1
Selecting the paper size for product
packaging
Step 2
Wrapping product in paper
Step 3
Keeping in box and filling the remaining space with wood wool
Step 4
Closing the box with tape
Individual boxes occupies more space and effort for packaging and cost
Wood wool makes boxes heavy which results into extra transportation cost
Wastage of paper and effort
For different product sizes different paper sizes are required
Step 5
Placing individual product boxes into a big box for transportation
Designopportunity
innovative design to pack different types of glassware in same pack
Scientific Glassware I Ambala Cantt I Haryana
4404. poSt manufacturing
(a) storagePost production storage of finished products is required in glassware industries. reason being there are few products with a running demand and few special product with very rare demand but to meet the customers demand industries maintain certain inventories for both type of products.there are few products that dose not move for years and needs a good storage systems to keep it in good condition even after 2-3 years. most of the units in ambala do not keep good storage systems and it results into lot of breakage . alsopoor storage occupies more space and makes the workflow very slow.
Recommendation and remedial solutions:. Storage management systems needs to be designed. training to keep inventories minimum as per demand
Designopportunity
light weight and cost effective packaging design
Kulveer Singh Bhati I Industrial Designer I 2013
45(B) transportationambala glassware industries supply products locally and out of state. there are few industries they export material to europe, America and Africa. So the transportation plays an important role to reach out to costumers. most of the units currier their products due to small quantities. So for interstate level truck and trains becomes important.
Recommendation and remedial solutions:. Packaging designs to minimize breakage while transportation.. clear branding and labelling on packaging for better communication
Designopportunity
Design of packaging boxes to reduce breakage during transportation
Scientific Glassware I Ambala Cantt I Haryana
46
01. DeSign anD aeStheticS
02. branDing
produCt study
Kulveer Singh Bhati I Industrial Designer I 2013
4701. DeSign anD aeStheticS
Scientific glassware products are completely a functional driven shapes and designs are same for decades. the main categorisation can be done based general ware like flask, bottles, pipettes etcCustomized products since lot of products go for laboratory experiments they are made for specific requirements of scientist/ users.
as far as the shape of product concerns there is hardly any scope for design, but there is a good chance for process design, packaging design, storage systems, tools, machineries can be designed and developed for the industry.
02. branDing
there is a good scope for branding in the industry on different levels. As first level only few units have branding, logo designed. most of the units still lacks a good branding. also products can be branded with scree printing friendly deigns. also the marking on volumetric glassware can be re-defined in terms of font, graphics etc.Communication signvages in industry, instruction manuals etc can be developed by units. entire packaging can be designed from individual box to big boxes for shipments.
as branding plays an important role in any industry this domain should be explored more.
Scientific Glassware I Ambala Cantt I Haryana
48
01. unit 1 to 19
(a) introDuction
(b) proDuct & proceSSeS
(c) workmanShip anD labour
(D) market
(e) buSineSS
(f) SuggeStionS given During naS
(g) remeDial DeSign SolutionS
(h) Scope of DeSign intervention
unIt speCIfIC proBlems, remedIes and opportunIty
Kulveer Singh Bhati I Industrial Designer I 2013
49
Gupta Scientific Industries is one of the oldest and pioneer in the glassware manufacturing. the root of the industry are from post independence period. the owner of the unit mr. bhusan gupta is a engineer and has experience close to 40 years.
Better storage design
Scope for packaging and workstation design
Low level of lighting on workstations
unit 01Industry name: Gupta Scientific worksnature of work: Manufacturing
Scientific Glassware I Ambala Cantt I Haryana
50
proDuct & proceSSeS orienteD
Speciality > Customized products with high quality
product range > The industry in all kind of scientific glassware general or laboratory.
Specialize in different laboratory assemblies.
Production quality and finishes > very good compare to the other units
key problem in process > Age old manual process, need for automation of process
visual identity and branding > Perfit India, weak
packaging > Basic wood wool filling and packaging used, need for redesign
it increases the weight hence more transportation charges
workstation and tool design > old workstation designs need to redesign of workstation
ergonomics and environment factor > Issues with working postures and ventilation , clear scope for improvement
Scope of new design and r&D > Wide scope to develop machinery for calibration, blowing and marking
Scope of technology modernization> good scope in calibration, blowing and marking etc
Scope for production in parallel > not interested
industries
labour anD workmanShip orienteD
Skilled/semi-skilled/non-skilled labour > 8 skilled, 6 semi skilled and 8 non skilled
need of labour training > Yes for blowing, cutting
common health problem faced by > too much heat during summers and ventilation labour
key problem faced from labour > no problems with labour, they are old and honest
UnIT SPeCIFIC PROBleMS, ReMedIeS And OPPORTUnITY
Kulveer Singh Bhati I Industrial Designer I 2013
51market orienteD
How do you market/sale your products > unit > traders > out station traders > costumers
Who are the major competitors > no names
Competition within Ambala/rest of India > lot of competition coming from locally market also import from china and europe
product exhibition in any trade fair > ambala and Delhi
Any qualified marketing person > no
Do you feel need of inter cluster > yes, but difficult to achieve and implement in Ambala
communication
buSineSS orienteD
Problems like electricity, labour union, > locally made raw material and govt policies raw material, space, Govt. support to address small industries
Margins/ profits are sufficient ?? > not good these days, hardly 15-20%
Scope of infrastructure development > Yes, building and machinery both
Major challenges > finance and competition within cluster
Available space is sufficient or not > no
SuggeStionS given During naS . common facility centre. For improvement in workflow. ideas on better storage systems and packaging.
remeDial DeSign Solution
. light weight packaging materials instead of wood wool
. better storage system to reduce wastage
. better lighting provisions and ventilation in workshop
Scope of DeSign intervention
. branding and labelling on products
. workstation Designs
. Packaging design, Glass cutter design
Designopportunity
Scientific Glassware I Ambala Cantt I Haryana
52Special opportunity
mr bhusan gupta has a very deep knowledge of the glass blowing and the manufacturing process. Also he has a very experienced team of workers in blowing, calibration and heat furnaces. it gives him an upper handin developing new products or customize products for specific laboratory use. the same can be made brand strategy to promote the brand.
Kulveer Singh Bhati I Industrial Designer I 2013
53
unit 02Industry name: Glassco nature of work: Manufacturing
Automatic set up for mass production
Large blowing section
Packaging section
Scientific Glassware I Ambala Cantt I Haryana
54
proDuct & proceSSeS orienteD
Speciality > Mass production with good and consistent quality
product range > The industry in all kind of scientific glassware general or laboratory. They specialize in different laboratory assemblies.
Production quality and finishes > very good
key problem in process > advanced machinery and automation of process
visual identity and branding > glassco
packaging > Better then others, can be redesign
workstation and tool design > can be redesign of workstation
ergonomics and environment factor > Minor issues, scope for improvement
Scope of new design and r&D > Scope for r&D in the processes of blowing
Scope of technology modernization> good scope
Scope for production in parallel > Can be, if profits are better
industries
labour anD workmanShip orienteD
Skilled/semi-skilled/non-skilled labour > all, infect they have started paying them on per piece basis, so the labours are paid as per their capabilities
need of labour training > yes for core processes
common health problem faced by > Heat during summers, not much
labour
key problem faced from labour > no problems with labour
UnIT SPeCIFIC PROBleMS, ReMedIeS And OPPORTUnITY
Kulveer Singh Bhati I Industrial Designer I 2013
55market orienteD
How do you market/sale your products > unit > out station traders > export
Who are the major competitors > local and abroad
Competition within Ambala/rest of India > lot of competition coming locally as well as from china
product exhibition in any trade fair > in and outside country
Any qualified marketing person > yes
Do you feel need of inter cluster > Yes, can be done, but Govt need to play role communication of mediator
buSineSS orienteD
Problems like electricity, labour union, > lpg gas and electricity some time
raw material, space, Govt. support
Margins/ profits are sufficient ?? > not very good now
Scope of infrastructure development > yes
Major challenges > finance and government support
Available space is sufficient or not > Yes
SuggeStionS given During naS
. For improvement in workflow and assembly line
. inter cluster development ideas
remeDial DeSign Solution
. light weight packaging materials for easy transportation
. better storage system to reduce wastage
Scope of DeSign intervention
. branding and marketing
. workstation designs
. innovative packaging design for export
Designopportunity
Scientific Glassware I Ambala Cantt I Haryana
56
UnIT 03Industry name: Science Zonenature of work: Manufacturing
Punching and cutting machine for packaging boxes
Blowing facility
Calibration facility, need for improvement
Workstation needs to be organized well with LPG cylinder out side
Kulveer Singh Bhati I Industrial Designer I 2013
57
labour anD workmanShip orienteD
Skilled/semi-skilled/non-skilled labour > 4 skilled, 5 semi skilled, 3 non skilled
need of labour training > Yes, very much, moral education, honesty
common health problem faced by > not much, designer feels problems can be from excessive heat
labour
key problem faced from labour > Frequent change in job,
UnIT SPeCIFIC PROBleMS, ReMedIeS And OPPORTUnITY
proDuct & proceSSeS orienteD
Speciality > packaging manufacturing inhouse
product range > 7-8 Types, measuring cylinders, conical flask etc
Production quality and finishes > average
key problem in process > old processes and unskilled labour need for advanced machinery
and automation of process
visual identity and branding > Science Zone, need to design branding and logo
packaging > In house facility, but old designs, need for innovation
workstation and tool design > need to redesign
ergonomics and environment factor > Minor issues, scope for improvement
Scope of new design and R&d > Require to progress further, Scope for r&D in the industry processes like blowing and calibration
Scope of technology modernization> never gave a thought
Scope for production in parallel > will continue in same
industries
Scientific Glassware I Ambala Cantt I Haryana
58market orienteD
How do you market/sale your products > To traders local and out station, directly to customers By internet search costumers, scientific
business india website,
Who are the major competitors > local small units/ manufacturers
Competition within Ambala/rest of India > lot of competition coming locally
product exhibition in any trade fair > Ambala, delhi ( 2 years ago)
Any qualified marketing person > no
Do you feel need of inter cluster > yes, depends on setup
communication
buSineSS orienteD
Problems like electricity, labour union, > electricity some time, labour shortageraw material, space, Govt. support
Margins/ profits are sufficient ?? > average 20% and 10% profit
Scope of infrastructure development > yes
Major challenges > Competition from small players, reduces margins
Available space is sufficient or not > Yes
SuggeStionS given During naS
. enhance packaging facility
. For improvement in workflow
remeDial DeSign Solution
. better storage system to reduce wastage
. better lighting provisions and ventilation in workshop
Scope of DeSign intervention
innovation in packaging design . Separate packaging design for local transportation and export
Designopportunity
Kulveer Singh Bhati I Industrial Designer I 2013
59
unit 04Industry name: Rama Thermometer Industriesnature of work: Packaging and Trading
Storage needs to be more organized for maximum utilisation of space
Finished products requires dedicated space, it will reduce wastage
Scientific Glassware I Ambala Cantt I Haryana
60
proDuct & proceSSeS orienteD
product range > The industry in all kind of scientific glassware general or laboratory. They specialize in different laboratory assemblies.
Production quality and finishes > n/A
key problem in process > n/A
visual identity and branding > Ramin, god Shiva on business card as logo
packaging > Basic paper filling and packaging used, need for redesign
workstation and tool design > need to redesign of workstation
ergonomics and environment factor > Working on floor, issues with working postures and ventilation
, Clear scope for improvement
Scope of new design and r&D > Do answer
Scope of technology modernization> no answer
Scope for production in parallel > n/A
industries
labour anD workmanShip orienteD
Skilled/semi-skilled/non-skilled labour > 2 semi skilled
need of labour training > n/A
common health problem faced by > back ache
labour
key problem faced from labour > n/A
UnIT SPeCIFIC PROBleMS, ReMedIeS And OPPORTUnITY
Kulveer Singh Bhati I Industrial Designer I 2013
61market orienteD
How do you market/sale your products > unit > outside traders
Who are the major competitors > local small time players
Competition within Ambala/rest of India > ambala mainly
product exhibition in any trade fair > no
Any qualified marketing person > no
Do you feel need of inter cluster > don’t know
communication
buSineSS orienteD
Problems like electricity, labour union, > electricity sometime
raw material, space, Govt. support
Margins/ profits are sufficient ?? > not good these days, Profit 10-12%
Scope of infrastructure development > n/A
Major challenges > less margins and extreme competition
Available space is sufficient or not > ok
SuggeStionS given During naS
. working postures
. ideas on better storage systems and packaging.
remeDial DeSign Solution
. light weight packaging materials
. better storage system for better utilisation of space
Scope of DeSign intervention
innovative marketing modelspackaging design and workstation for packaging
Scientific Glassware I Ambala Cantt I Haryana
62
unit 05Industry name: d R Glass nature of work: Manufacturing
Automatic machine to make beakers/ tubes etc
Glass cutting facility
Compartmental Packaging of tubes
Tubes ready for annealing
Kulveer Singh Bhati I Industrial Designer I 2013
63
proDuct & proceSSeS orienteD
Speciality > Mass production of tubes/ beakers (2-3 products)
product range > 7-8 types
Production quality and finishes > Good and consistent quality in limited designs
key problem in process > need automation of process of cutting etc
visual identity and branding > d R Glass works, need for branding
packaging > Basic wood wool filling and packaging used, need for redesign
workstation and tool design > Designer feels the machines are randomly arranged with basic
setup, urgent need for a work station
ergonomics and environment factor > there seems to be issues with working posture and safety gears
Scope of new design and r&D > May be, not sure
Scope of technology modernization> Automation of processes like cutting, calibration etc
Scope for production in parallel > not sure
industries
labour anD workmanShip orienteD
Skilled/semi-skilled/non-skilled labour > 2 skilled, 3 semi skilled and 2 non skilled
need of labour training > Yes for core processes like blowing, cutting to enhance their skills
common health problem faced by > no problems, designer feels there can be problems like skin burn,
labour excessive heat and eye problem
key problem faced from labour > Frequent job change, lack of commitment
UnIT SPeCIFIC PROBleMS, ReMedIeS And OPPORTUnITY
Scientific Glassware I Ambala Cantt I Haryana
64market orienteD
How do you market/sale your products > unit > traders > manufacturers
Who are the major competitors > local units and traders
Competition within Ambala/rest of India > locally, units are compromising on quality in competition
with each other, this issue needs to be addressed
product exhibition in any trade fair > -
Any qualified marketing person > no
Do you feel need of inter cluster > May be it will work, don’t have any idea
communication
buSineSS orienteD
Problems like electricity, labour union, > electricity and lpg gas
raw material, space, Govt. support
Margins/ profits are sufficient ?? > around 10-15%
Scope of infrastructure development > yes
Major challenges > Finance and small percentage of profit
Available space is sufficient or not > Shifting in a bigger space will ease the production operations
SuggeStionS given During naS
. Assembly line working method and benefits
. importance of light and ventilation
remeDial DeSign Solution
. Focus on Mass production of specific products
. attention to small details
Scope of DeSign intervention
. Design of more products with same machinery Designopportunity
Kulveer Singh Bhati I Industrial Designer I 2013
65
unit 06Industry name: J M d glassware nature of work: Manufacturing
Very compact space with 4 workstations (10’ x 12’) workshop
Single chuck machine for blowing process
Oxygen cylinder storage outside
Scientific Glassware I Ambala Cantt I Haryana
66
proDuct & proceSSeS orienteD
product range > 30 products, Beaker, burette etc
Production quality and finishes > average
key problem in process > Age old manual process, need for modernisation in process and
technology
visual identity and branding > J M d Glass ware, need for branding
packaging > Basic, don’t know if the designing is required
workstation and tool design > compact and economic solutions to increase the efficiency
of workers, to improve working postures
ergonomics and environment factor > Issues are there with working postures, safety and heating problems
Scope of new design and r&D > not clear
Scope of technology modernization> latest tools and machinery will definitely benefit and improve the
production quality
Scope for production in parallel > don’t know
industries
labour anD workmanShip orienteD
Skilled/semi-skilled/non-skilled labour > 2 skilled, 2 semi skilled
need of labour training > Can look for it, but not sure what kind of training
common health problem faced by > Heat during summers, not much
labour
key problem faced from labour > no problems only 4 person in unit
UnIT SPeCIFIC PROBleMS, ReMedIeS And OPPORTUnITY
Kulveer Singh Bhati I Industrial Designer I 2013
67market orienteD
How do you market/sale your products > unit > local manufacturer > local trader
customers
Who are the major competitors > local and similar scale units
Competition within Ambala/rest of India > don’t supply out
product exhibition in any trade fair > no
Any qualified marketing person > no
Do you feel need of inter cluster > don’t know how it will work
communication
buSineSS orienteD
Problems like electricity, labour union, > electricity and lpg gasraw material, space, Govt. support
Margins/ profits are sufficient ?? > not much, only 10-15 %
Scope of infrastructure development > yes
Major challenges > finance
Available space is sufficient or not > Yes, but designer feels bigger space will
benefit
SuggeStionS given During naS
. To specialize in product range and concentrate on few only
. For improvement in workflow
remeDial DeSign Solution
. being a small unit they should shortlist few products and must focus on them only
. try to sell products outside through internet etc
Scope of DeSign intervention
. compact and economic solutions for workstationDesign
opportunity
Scientific Glassware I Ambala Cantt I Haryana
68
unit 07Industry name: Malik scientific Glass Works nature of work: Packaging and Trading
Store of finished goods in unorganized condition
Showroom of malik scientific glass works
office space
Kulveer Singh Bhati I Industrial Designer I 2013
69
proDuct & proceSSeS orienteD
product range > mini Distillation units and general lab glass
Production quality and finishes > n/A
key problem in process > n/A
visual identity and branding > Malik Scientific Glass Works, no need for branding since
traders put their brand name on products
packaging > Basic paper filling and packaging used, need for redesign
workstation and tool design > need to redesign workstation, currently working on floor
ergonomics and environment factor > Working on floor, issues with working postures
Scope of new design and r&D > Manufacturers may need, we don’t
Scope of technology modernization> no answer
Scope for production in parallel > n/A
industries
labour anD workmanShip orienteD
Skilled/semi-skilled/non-skilled labour > 1 semi skilled
need of labour training > n/A
common health problem faced by > nolabour
key problem faced from labour > n/A
UnIT SPeCIFIC PROBleMS, ReMedIeS And OPPORTUnITY
Scientific Glassware I Ambala Cantt I Haryana
70market orienteD
How do you market/sale your products > unit > outside traders > customers
Who are the major competitors > Minesh scientific , out side manufacturers
Competition within Ambala/rest of India > ambala mainly
product exhibition in any trade fair > -
Any qualified marketing person > nO, no need for marketing
Do you feel need of inter cluster > don’t know, how it will work and benefitcommunication traders
buSineSS orienteD
Problems like electricity, labour union, > lack of govt support to market products
raw material, space, Govt. support
Margins/ profits are sufficient ?? > Gross Profit 30-40%
Scope of infrastructure development > n/A
Major challenges > limited demand and extreme competition
Available space is sufficient or not > ok
SuggeStionS given During naS
. posture during packaging activity
. ideas on better storage systems and packaging.
remeDial DeSign Solution
. light weight packaging materials
. better storage system for better utilisation of space
Scope of DeSign intervention
packaging design and workstation for packaging
Kulveer Singh Bhati I Industrial Designer I 2013
71
unit 08Industry name: Amit enterprises nature of work: Manufacturing and Trading
Workshop area looks a bit un-organized
Showroom cum office in a close proximity to workshop
Working table with a close proximity with LPG gas cylinder can be dangerous since its a high flame blowing job
Scientific Glassware I Ambala Cantt I Haryana
72
proDuct & proceSSeS orienteD
product range > The industry in all kind of scientific glassware general or laboratory. They specialize in different laboratory assemblies.
Production quality and finishes > average
key problem in process > Age old manual process, need for automation of process
visual identity and branding > Amit enterprises, logo is designed and looks good
packaging > Basic packaging, need for redesign
workstation and tool design > need to design the workstation
ergonomics and environment factor > Issues with working postures and ventilation ,
clear scope for improvement
Scope of new design and r&D > not much scope for R&d, designer feels there is a good scope for
r&D in tool design and processes
Scope of technology modernization> Always good to upgrade, but cost is more
Scope for production in parallel > not sure
industries
labour anD workmanShip orienteD
Skilled/semi-skilled/non-skilled labour > 3 skilled, 3 semi skilled and 5 non skilled
need of labour training > Yes for manufacturing processes like blowing, cutting
common health problem faced by > no but designer feels Heat during summers, not much labour
key problem faced from labour > Commitment and availability is a major issue, they also change jobs frequently even for a small elevation in salary
UnIT SPeCIFIC PROBleMS, ReMedIeS And OPPORTUnITY
Kulveer Singh Bhati I Industrial Designer I 2013
73market orienteD
How do you market/sale your products > unit > local trader> out station trader > costumer
Who are the major competitors > local traders and manufacturers
Competition within Ambala/rest of India > locally and outstation both
product exhibition in any trade fair > -
Any qualified marketing person > no
Do you feel need of inter cluster > yes but what is the method to achieve
communication understanding on that level
buSineSS orienteD
Problems like electricity, labour union, > electricity and lpg gas and off course support of govt on
raw material, space, Govt. support different levels
Margins/ profits are sufficient ?? > not always equal, in some products profits are nil
Scope of infrastructure development > yes
Major challenges > quality of products is a long term threat to entire industry, small players does not pay taxes hense its easy for them to sell products on very less margins, its effecting the quality drastically and ultematily no product for export
quality
Available space is sufficient or not > Yes
SuggeStionS given During naS
. common facility centre
. ideas on better storage systems and packaging.
remeDial DeSign Solution
. Ways to improve quality
. Storage designed specifically for glassware products
. better working conditions
Scope of DeSign intervention
Redefine the workshop space and hand tools
Designopportunity
Scientific Glassware I Ambala Cantt I Haryana
74
unit 09Industry name: Paras Instruments Conature of work: Manufacturing
Showroom cum office and workshop behind
Storage system
Finished goods holding unit
Calibration facility
Kulveer Singh Bhati I Industrial Designer I 2013
75
proDuct & proceSSeS orienteD
Product range > 30-40 products
Production quality and finishes > below avarage
key problem in process > basic techniques and machinery like double chuck lathe, grinding
machine etc
visual identity and branding > Paras Instruments co, need to redesign since its an old design
packaging > has been explored enough by exporters but designer feels the need to redesign
workstation and tool design > Bad condition, urgent attention required
ergonomics and environment factor > no, but designer feels issues with space, working postures is there
Scope of new design and r&D > Scope for design is very less but r&D can play a vital role for future directions, specially reverse engineering of german products can be
use full for indian market
Scope of technology modernization> Very open scope for technology mordenization in tool making and
calibration kind of processes
Scope for production in parallel > glass manufacturing unit can be opened in india to avoid import
industries hence material cost Its difficult to work in home glassware sector due to extra manufacturing cost
labour anD workmanShip orienteD
Skilled/semi-skilled/non-skilled labour > 5 skilled, 6 semi skilled and 3 non skilled
need of labour training > Yes its always good to learn but course has to be industry specific
common health problem faced by > not much, but designer feels unit needs to create good environment
labour to work
key problem faced from labour > Shortage of good labours and commitment
UnIT SPeCIFIC PROBleMS, ReMedIeS And OPPORTUnITY
Scientific Glassware I Ambala Cantt I Haryana
76market orienteD
How do you market/sale your products > Unit > local traders/ manufacturers > out station > costumersWho are the major competitors > names not mentioned
Competition within Ambala/rest of India > local and out station both
product exhibition in any trade fair > In Ambala once, but not very good results
Any qualified marketing person > no, but marketing is a main problem
Do you feel need of inter cluster > cluster system possible with govt support
communication
buSineSS orienteD
Problems like electricity, labour union, > Govt support first and then electricity and lPG gas
raw material, space, Govt. support
Margins/ profits are sufficient ?? > average
Scope of infrastructure development > Yes, but its very costly only automation will cost you 4-5 cr Major challenges > quality with low price
Available space is sufficient or not > no
SuggeStionS given During naS
. Improvement/ re planing the industry layout
. cfc
remeDial DeSign Solution
. layout re designing
. need specific storage systems
Scope of DeSign intervention
good scope in tool design and exploration on new materials Designopportunity
Kulveer Singh Bhati I Industrial Designer I 2013
77
unit 10Industry name: Kunal Scientific Industries nature of work: Manufacturing
Workshop in a very cluttered condition
Raw material storage in a most un organized manner
Blowing section
Grinding section
Finished goods storage in same condition
Scientific Glassware I Ambala Cantt I Haryana
78
labour anD workmanShip orienteD
Skilled/semi-skilled/non-skilled labour > 1 skilled, 2semi skilled
need of labour training > Ye, specially for quality production
common health problem faced by > no, but designer feels heat and smoke may be causing problems
labour
key problem faced from labour > no problems since only 3 guys running the unit
UnIT SPeCIFIC PROBleMS, ReMedIeS And OPPORTUnITY
proDuct & proceSSeS orienteD
product range > 5-7 products
Production quality and finishes > Poor quality
key problem in process > basic techniques and machinery like double chuck lathe, grinding
machine etc
visual identity and branding > Kunal Scientific Industries, no idea about branding
packaging > not required since they supply only to local traders
workstation and tool design > Bad condition, urgent attention required
ergonomics and environment factor > no, but designer feels urgent attention required on working
postures
Scope of new design and r&D > no idea but designer feels role of r&D in tools and production
processes
Scope of technology modernization> no idea, but designer feels urgent need for upgradation in good machinery and hand tools
Scope for production in parallel > no clue at all, designer feels the unit should first focus on current job
industries
Kulveer Singh Bhati I Industrial Designer I 2013
79market orienteD
How do you market/sale your products > Unit> local manufacturer/ trader
Who are the major competitors > no name
Competition within Ambala/rest of India > with in micro industries
product exhibition in any trade fair > no
Any qualified marketing person > no
Do you feel need of inter cluster > no idea, but designer feels small players can support big
communication industries on specific product range
buSineSS orienteD
Problems like electricity, labour union, > electricity and lpg gasraw material, space, Govt. support
Margins/ profits are sufficient ?? > not good these days, hardly 15-20%
Scope of infrastructure development > Yes, good machinery and tools Major challenges > cut throat competition and low price
Available space is sufficient or not > no
SuggeStionS given During naS
. To improve quality
. to arrange workshop properly
remeDial DeSign Solution
. improvement in processes and tools
. quality improvement by constant focus on production
Scope of DeSign intervention
. workstation design
. layout of workshop
Scientific Glassware I Ambala Cantt I Haryana
80
unit 11Industry name: Ad Glass Printersnature of work: Manufacturing and Printing
Screen printing posture and process in workshop
Finished product
Blowing process, tools and hand tools not up to the quality it results to bad quality product
Workshop entry and approach not convenient while shifting material
Kulveer Singh Bhati I Industrial Designer I 2013
81
proDuct & proceSSeS orienteD
Speciality > Screen printing
product range > 4-5 products
Production quality and finishes > below average
key problem in process > Age old manual process, need for automation of process
visual identity and branding > aD glass printers
packaging > not required, only supply to local manufacturers
workstation and tool design > tools and hand tools needs improvement
ergonomics and environment factor > there are issues with working postures and ventilation of space
Scope of new design and r&D > no idea
Scope of technology modernization> Will be good, but don’t know the scope
Scope for production in parallel > not sure
industries
labour anD workmanShip orienteD
Skilled/semi-skilled/non-skilled labour > 2 skilled, 2 semi skilled and 2 non skilled
need of labour training > Yes, specially in screen printing
common health problem faced by > Heat during summers, not much
labour
key problem faced from labour > Only sometime, workshop strength only 6
UnIT SPeCIFIC PROBleMS, ReMedIeS And OPPORTUnITY
Scientific Glassware I Ambala Cantt I Haryana
82market orienteD
How do you market/sale your products > Unit > local Manufacturers/ traders
Who are the major competitors > no name
Competition within Ambala/rest of India > lot from micro scale industries
product exhibition in any trade fair > no idea
Any qualified marketing person > no
Do you feel need of inter cluster > no idea, but designer feels they can collectively make
communication more difference even they can control price of products also
buSineSS orienteD
Problems like electricity, labour union, > electricity and lpg gas
raw material, space, Govt. support
Margins/ profits are sufficient ?? > not good these days, hardly 15-20%
Scope of infrastructure development > yes
Major challenges > low price/ margins
Available space is sufficient or not > yes
SuggeStionS given During naS
. arranging workshop on priority
. assembly line productions
. quality management
remeDial DeSign Solution
. improvements in local transportation to reduce wastage
. be cautious while using screens
Scope of DeSign intervention
. locally developed semi automatic screen design machine
. Screen storage system design
Designopportunity
Kulveer Singh Bhati I Industrial Designer I 2013
83
unit 12Industry name: SR Scientific Industries nature of work: Manufacturing
Automatic blowing machine
Sky light enhances light quality inside
Storage of raw material in bad condition increases breakage
Scientific Glassware I Ambala Cantt I Haryana
84
proDuct & proceSSeS orienteD
Speciality > Mass production of tubes/ beakers (2-3 products)
product range > 10-12 types
Production quality and finishes > Good and consistent quality in limited designs
Manual blowing quality not good
key problem in process > need automation of process of cutting etc
visual identity and branding > S R Scientific Industries, need for branding
packaging > not required, only local supply
workstation and tool design > Designer feels the machines are randomly arranged with basic
setup, urgent need for a work station
ergonomics and environment factor > there seems to be issues with working posture and safety gears
Scope of new design and r&D > If it is good for industry, but don’t know the scope
Scope of technology modernization> Automation of processes like cutting, calibration etc
Scope for production in parallel > not sure
industries
labour anD workmanShip orienteD
Skilled/semi-skilled/non-skilled labour > 1 skilled, 4 semi skilled and 2 non skilled
need of labour training > Yes for core processes like blowing, cutting to enhance their skills
common health problem faced by > no problems, designer feels there can be problems like skin burn,
labour excessive heat and eye problem
key problem faced from labour > lack of commitment, Frequent job change
UnIT SPeCIFIC PROBleMS, ReMedIeS And OPPORTUnITY
Kulveer Singh Bhati I Industrial Designer I 2013
85market orienteD
How do you market/sale your products > Unit > local traders/ manufacturers
Who are the major competitors > no name
Competition within Ambala/rest of India > locally, units are compromising on quality in competition
with each other, this issue needs to be addressed
product exhibition in any trade fair > -
Any qualified marketing person > no
Do you feel need of inter cluster > May be it will work, don’t have any idea
communication Designer feels it will contribute to collective growth
buSineSS orienteD
Problems like electricity, labour union, > electricity and lpg gas
raw material, space, Govt. support
Margins/ profits are sufficient ?? > around 10-15%
Scope of infrastructure development > yes
Major challenges > Finance and small percentage of profit
Available space is sufficient or not > yes, it might help
SuggeStionS given During naS
. Assembly line working method and benefits
. importance of light and ventilation
remeDial DeSign Solution
. Focus on Mass production of specific products
. attention to small details
Scope of DeSign intervention
. Design of more products with same machinery
. finished product container design for local transportationDesign
opportunity
Scientific Glassware I Ambala Cantt I Haryana
86
UnIT 13Industry name: Parban scientific Glass Worksnature of work: Manufacturing
The workshop dose not have any opening for ventilation except door
Bad working conditions inside may increase health issues
Precision in job done manually
Kulveer Singh Bhati I Industrial Designer I 2013
87UnIT SPeCIFIC PROBleMS, ReMedIeS And OPPORTUnITY
proDuct & proceSSeS orienteD
Speciality > Customized products
product range > 50 + products
Production quality and finishes > very good compare to the other units
key problem in process > Age old manual process, need for automation of process
visual identity and branding > Parban Scientific Glass Works, require branding
packaging > no need, supply locally only
workstation and tool design > old workstation designs need to redesign of workstation
ergonomics and environment factor > Issues with working postures and ventilation ,
clear scope for improvement
Scope of new design and r&D > Scope for r&D in ne processes of blowing can be done
Scope of technology modernization> no, but designer feelsGood scope in calibration, blowing and
marking etc
Scope for production in parallel > not sure
industries
labour anD workmanShip orienteD
Skilled/semi-skilled/non-skilled labour > 3 skilled
need of labour training > no need, already skilled
common health problem faced by > heat during summers, not much
labour
key problem faced from labour > no problems with labour, they are old and honest
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SuggeStionS given During naS
. making provision for ventilation on urgent basis
. on new hand tools
remeDial DeSign Solution
. better space utilisation
. Use of latest/ better tools
. better lighting provisions and ventilation in workshop
Scope of DeSign intervention
. To focus on customized products
market orienteD
How do you market/sale your products > Unit > local traders/ manufacturers
Who are the major competitors > no name
Competition within Ambala/rest of India > locally, units are compromising on quality in competition
with each other, this issue needs to be addressed
product exhibition in any trade fair > -
Any qualified marketing person > no
Do you feel need of inter cluster > no,
communication Designer feels it will contribute to collective growth
buSineSS orienteD
Problems like electricity, labour union, > lpg gas prices are very highraw material, space, Govt. support
Margins/ profits are sufficient ?? > around 10-15%
Scope of infrastructure development > yes
Major challenges > finance and small percentage of profit
Available space is sufficient or not > yes, it might help
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unit 14Industry name: Sanky Printingnature of work: Screen printing
The workshop is operational from the house
Complicated storage of screens
Storage of products in cardboard boxes may be increasing breakage
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proDuct & proceSSeS orienteD
Speciality > Screen printing
product range > na
Production quality and finishes > average
key problem in process > manual process, need for automation of process
visual identity and branding > Sanky Screen printings
packaging > not required, only supply to local manufacturers
workstation and tool design > workstation design for screen printing
ergonomics and environment factor > there are issues with working postures and ventilation of space
Scope of new design and r&D > no idea, designer feels it can be done for better and fast printing
Scope of technology modernization> Will be good, but don’t know the scope
Scope for production in parallel > not sure
industries
labour anD workmanShip orienteD
Skilled/semi-skilled/non-skilled labour > 2 semi skilled and 1 non skilled
need of labour training > Yes, specially in screen printing
common health problem faced by > Heat during summers, not much
labour
key problem faced from labour > Only sometime, workshop strength only 3
UnIT SPeCIFIC PROBleMS, ReMedIeS And OPPORTUnITY
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91market orienteD
How do you market/sale your products > Unit > local Manufacturers/ traders
Who are the major competitors > no name
Competition within Ambala/rest of India > lot from micro scale industries
product exhibition in any trade fair > no
Any qualified marketing person > no
Do you feel need of inter cluster > no idea, but designer feels they can collectively make
communication more difference even they can control price of products also
buSineSS orienteD
Problems like electricity, labour union, > electricity rates and frequent cuts effects production
raw material, space, Govt. support
Margins/ profits are sufficient ?? > very less
Scope of infrastructure development > no, but designer feels it can be enlarged to handle big
projects and automation of process Major challenges > low price/ margins
Available space is sufficient or not > Yes
SuggeStionS given During naS
. Small techniques to avoid errors
. assembly line productions
remeDial DeSign Solution
. improvements in local transportation to reduce wastage
. Organized storage of screens
Scope of DeSign intervention
. locally developed semi automatic screen design machine
. alternative source of energy for furnace
Designopportunity
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unit 15Industry name: Standard scientific Glass Worksnature of work: Manufacturing
Need for safety gears for workers like hand gloves
Improper storage for finished goods increases breakage and wastage
Unorganized storage like boxes, gas cylinders near to furnace can be dangerous at times
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proDuct & proceSSeS orienteD
product range > The industry in all kind of scientific glassware general or laboratory.
Production quality and finishes > above average
key problem in process > Old manual process, Urgent need for semi automation
visual identity and branding > Standard scientific Glass Works
packaging > Few packaging design being used by entire industry, need for
redesign specifically for the category
workstation and tool design > tool design will help
ergonomics and environment factor > Issues with working postures, Clear scope for improvement
Scope of new design and r&D > It might help, need to define scope
Scope of technology modernization> automatic calibration and semi automation of different processes
Scope for production in parallel > no
industries
labour anD workmanShip orienteD
Skilled/semi-skilled/non-skilled labour > no information
need of labour training > definitely will improve the quality of production
common health problem faced by > no but designer feels Burns marks, eye irritation and heat problems
labour
key problem faced from labour > frequent job change and low quality production
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94market orienteD
How do you market/sale your products > unit > local traders > out station traders
Who are the major competitors > no names given
Competition within Ambala/rest of India > local small industries and micro units
product exhibition in any trade fair > _
Any qualified marketing person > no
Do you feel need of inter cluster > Yes, But suggest the ways to achieve, its difficult
communication
buSineSS orienteD
Problems like electricity, labour union, > govt policies and rules enable small industries to
raw material, space, Govt. support grow
Margins/ profits are sufficient ?? > not at all
Scope of infrastructure development > yes
Major challenges > Govt bodies like pollution board, labour laws etc
designer feels the rules nd regulations needs to be revised
Available space is sufficient or not > Yes
SuggeStionS given During naS
. Common facility centre and its benefit
remeDial DeSign Solution
. Skill development for labourer
. Workshop re layout for better assembly line, storage etc
Scope of DeSign intervention
. Development of tools and patterns for blowing
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unit 16Industry name: Super lab Glass worksnature of work: Manufacturing
The workshop dose not have any opening for ventilation except door
Bad working conditions inside may increase health issues
Workstation condition are severe and needs immediate improvement
Most Unorganized storage system
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proDuct & proceSSeS orienteD
product range > 50-100 different products
Production quality and finishes > poor
key problem in process > old processes are in practise
visual identity and branding > Super lab Glass works, need for branding
packaging > Basic wood wool filling and packaging used, need for redesign
workstation and tool design > need to redesign of workstation
ergonomics and environment factor > issues with ergonomics of worker as well as working environment
inside, closed workshop and lack of ventilation
Scope of new design and r&D > don’t now
Scope of technology modernization> It will be good, not knowledge of latest technologies
Scope for production in parallel > no idea
industries
labour anD workmanShip orienteD
Skilled/semi-skilled/non-skilled labour > 4 skilled, 3 semi skilled and 5 non skilled
need of labour training > no, but designer feels its urgently required for the unit
common health problem faced by > no, but designer feels there will be problems with excessive heat
labour and bad atmosphere inside
key problem faced from labour > Frequent change in jobs, no commitment, unreasonable rates
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SuggeStionS given During naS
. making provision for ventilation on urgent basis
. Requirement for new hand tools and benefit
remeDial DeSign Solution
. better space utilisation
. Use of latest/ better tools
. better lighting provisions and ventilation in workshop
Scope of DeSign intervention
. Focus on super specialization on certain products since setup supports only few products
market orienteD
How do you market/sale your products > Unit > local traders/ manufacturers
Who are the major competitors > no name
Competition within Ambala/rest of India > locally, units are compromising on quality in competition
with each other, this issue needs to be addressed
product exhibition in any trade fair > -
Any qualified marketing person > no
Do you feel need of inter cluster > no,
communication Designer feels it will contribute to collective growth
buSineSS orienteD
Problems like electricity, labour union, > lpg gas prices are very highraw material, space, Govt. support
Margins/ profits are sufficient ?? > around 10-15%
Scope of infrastructure development > yes
Major challenges > finance and small percentage of profit
Available space is sufficient or not > yes, it might help
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unit 17Industry name: Aggarwal enterprises nature of work: Manufacturing
Workstation condition are severe and needs immediate improvement
Raw material is kept in open, more chances of breakage
Most Unorganized storage system
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proDuct & proceSSeS orienteD
Speciality > Manufacturing of Botany equipment
product range > 50-100 products of general glassware
Production quality and finishes > average
key problem in process > Old processes, need for semi automation
visual identity and branding > Aggarwal enterprises, requirement for a good branding exercise
packaging > Basic wood wool filling and packaging used, need for redesign
workstation and tool design > The space in worksop not utilized well due to bad layout, hand tools
need attention
ergonomics and environment factor > issues with working postures and clear scope for improvement
Scope of new design and r&D > no idea how it can benefit
Scope of technology modernization> It will be good, automation will reduce cost and labour charges
hence good margin and finishes
Scope for production in parallel > If profits are good then can try it
industries
labour anD workmanShip orienteD
Skilled/semi-skilled/non-skilled labour > 2 skilled, 2 semi skilled
need of labour training > Will not mind to participate, if it benefits
common health problem faced by > no knowledge
labour
key problem faced from labour > commitment and dedication also their skills
UnIT SPeCIFIC PROBleMS, ReMedIeS And OPPORTUnITY
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100market orienteD
How do you market/sale your products > unit > local traders > out station traders > costumers
Who are the major competitors > no names
Competition within Ambala/rest of India > has gone up in last 10 years
product exhibition in any trade fair > -
Any qualified marketing person > no
Do you feel need of inter cluster > Yes, but always face a problem in equal response
communication Spl role of association needs to be more transparent
buSineSS orienteD
Problems like electricity, labour union, > electricity and lpg gasraw material, space, Govt. support
Margins/ profits are sufficient ?? > It has dropped in last 10 years, now some time we sell on rate or even less to retail client
Scope of infrastructure development > Yes, in machinery and tools Major challenges > wrong calibration is making an impact on end user, by showing wrong results in lab results
Available space is sufficient or not > Yes
SuggeStionS given During naS
. for better planing of space
. alternative markets and possibilities
remeDial DeSign Solution
. reduce the wastage on each step
. better storage system to reduce wastage
Scope of DeSign intervention
workstation design for blowing and cutting
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unit 18Industry name: Jain Scientific Glass worksnature of work: Manufacturing
Well organized workstation
Out side provision for LPG and oxygen cylinders
Well organized workstationand well planned workshopsin a defined assembly process
Separate furnish room
Screen printing facility with a work station for screen selection
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proDuct & proceSSeS orienteD
product range > The industry in all kind of scientific glassware general or laboratory. They specialize in different laboratory assemblies.
Production quality and finishes > very good compare to the other units
key problem in process > Age old manual process, need for automation of process
visual identity and branding > Jain Scientific Glass works, branding is good logo is well design
packaging > new packaging designs are adopted from export packaging standards, still packaging can be re designed for
various products
workstation and tool design > already separate tool design workshop, may be work can
be done on new materials
ergonomics and environment factor > Working postures needs attention, good scope for improvement
Scope of new design and r&D > R&d is required in tool development and locally made
automatic machines
Scope of technology modernization> Off course, specially in automation of processes
Scope for production in parallel > Can be tried as an pilot project
industries
labour anD workmanShip orienteD
Skilled/semi-skilled/non-skilled labour > no clear information
need of labour training > Yes, open to it
common health problem faced by > not any serious problem other then burn marks etc
labour
key problem faced from labour > quality of work and frequent job change
UnIT SPeCIFIC PROBleMS, ReMedIeS And OPPORTUnITY
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103market orienteD
How do you market/sale your products > unit > dealers local > dealers outstation > clients
Who are the major competitors > no name
Competition within Ambala/rest of India > local medium scale industries also imported glassware
product exhibition in any trade fair > in india and abroad as well
Any qualified marketing person > yes
Do you feel need of inter cluster > yes very much, all industries can grow together
communication
buSineSS orienteD
Problems like electricity, labour union, > govt support and policies not supportive and raw material, space, Govt. support energy supply like electricity and lpg gas
Margins/ profits are sufficient ?? > ok
Scope of infrastructure development > yes
Major challenges > finance and govt support
Available space is sufficient or not > Yes
SuggeStionS given During naS
. For improvement in workflow
. ideas on better storage systems and packaging.
remeDial DeSign Solution
. light weight packaging materials instead fo wood wool
. better storage system to reduce wastage
. improvement on packaging to suit export standards
Scope of DeSign intervention
. design ideas for storage of finished good
. branding and labelling on products
Designopportunity
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unit 19Industry name: Jain laboratory Glassware co.nature of work: Manufacturing
Well organized workstationand well planned workshopsin a defined assembly process
Screen printing facility with a work station for screen selection
Calibration lab in a well defined space with basic facilities
Factory shed with proper natural light and ventilation
Workstation needs to be organized will, spl provision for LPG cylinder outside
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proDuct & proceSSeS orienteD
product range > Manufactures all kind of scientific glassware general or laboratory.
Production quality and finishes > above average
key problem in process > lather for blowing and manual cutting machine, need semi
automation of processes for export quality
visual identity and branding > Jain laboratory Glassware co, branding is good logo is well design
packaging > packaging needs to be designed to target scientific glassware and aiming to reduce wastage while transportation standards, still packaging can be re
designed for various products
workstation and tool design > not very well organized, need a separate tool room
ergonomics and environment factor > working postures needs attention to reduces physical and mental stress, also safety gears to be made mandatory to wear while working
Scope of new design and r&D > R&d in developing automatic machines for calibration, marking, blowing and cutting. it will change the entire market quality and standard of production
Scope of technology modernization> Off course, specially in automation of processes
Scope for production in parallel > need to give it a thought, if works fine can be adopted industries
labour anD workmanShip orienteD
Skilled/semi-skilled/non-skilled labour > no clear information
need of labour training > yes will participate actively and give all possible support
common health problem faced by > not aware about it much except some burn marks etc
labour
key problem faced from labour > Skilled labour and increasing salaries are effecting production quality
UnIT SPeCIFIC PROBleMS, ReMedIeS And OPPORTUnITY
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106market orienteD
How do you market/sale your products > unit > Dealers local > Dealers outstation > clients
Who are the major competitors > no name
Competition within Ambala/rest of India > local micro and medium scale industries
product exhibition in any trade fair > Yes, in India
Any qualified marketing person > no
Do you feel need of inter cluster > Yes, together units can work like a big industry communication and can target big orders
buSineSS orienteD
Problems like electricity, labour union, > need of a local manufacturer of raw material raw material, space, Govt. support also electricity and lpg gas
Margins/ profits are sufficient ?? > very competitive
Scope of infrastructure development > yes
Major challenges > Dependency on imported machinery
Available space is sufficient or not > Yes
SuggeStionS given During naS
. on mSme design schemes
. need for a product designer for heating and cooling equipment designs
remeDial DeSign Solution
. Re define a well organized workshop and store room
. improvement on packaging to suit export standards
Scope of DeSign intervention
. developing automatic machines for calibration, marking, blowing and cutting
. branding and labelling on products
Designopportunity
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107Swot analySiS
strength. Ambala Cantt scientific industry is more then 60 years old and now well established in market.
. proximity to national capital and chandigarh gives more opportunities.
. well connected with rail and road network
. education level amongst unit owner is very high in some cases, se they set bench marks.
. exposure to international market
. formation of association to address concerns collectively.
. good skill set with in the industry.
Weakness.Dependency on old technologies.
. lack of r&D facility for development of tools and machinery
. Dependency on imported machinery
. Dependency on skilled labour
. Brand imag of cluster is bad due to bad quality products.
. inter cluster cut throat competition responsible for quality degradation
. lack of local manufacturer of raw material and complete dependency on china.
. lack of technical knowledge amongst workers
. micro scale industries are cutting costs due to less over heads and this trend is ultimately effecting entire cluster
. Poor quality of calibration is resulting into wrong results in labs
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opportunities. Being the largest Scientific equipment industry, cluster has potential to lead in the category if improve quality and consistency.
.potential for locally developed machinery like calibration machine, marking and screen printing.
. finding alternative energy resources for furnace
. good scope for branding and labelling design
. Alternative/ parallel industrial products with same setup.
. Packaging design specifically for glassware industry to reduce weight and breakage of products while transportation.
. Work station designs to increase efficiency and addressing ergonomic issues.
threat. If the ignorance for quality and compromise with calibration/ volumetric marking of products continues the cluster will completely loose its reputation and as well as business.
. If the margins/ prices continue to fall many more units will shut business and quality will definitely dip.
. complete dependency on china on raw material gives it monopoly and it can be a serious danger for industry in case if china refuse to supply or increase rates.
. Being a skill based industry, lack of skilled workers can pose a serious threat to industry.
. health and ergonomically issues are being ignored completely and it can have severe effects on workers health.
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109on a SeriouS note
i am constantly highlighting the issues of wrong volumetric measurement of glassware. the industry is constantly ignoring importance of calibration process, marking process and measurement printing on volumetric products. hence the products are going in market with 80-90% or more tolerance level/ accuracy level with actual measurement. once these volumetric products goes to laboratories like pathology labs etc they become responsible for wrong results because of inaccuracy in markings.
now one can understand the serious impact of a wrong medical result to a patient. here the main problem comes with insensitive attitude of manufacturer and lack of governing body to maintain standards.
the possibility of wrong marking during the following manufacturing process stages :1. manual calibration always have the chances of human error, low skilled labour, variation in room temp, fast speed of work etc 2. manual marking can be wrong due to unskilled labour or human error as well.3. Screen printing also leads to errors as most of the units makes some standard printing screens and try to use the screen most close to the making, but some time the difference in marking and screen is more, but units ignore it to save screen cost.4. variation in wall thickness of glass while blowing can also be responsible, lack of wall thickness measuring machine gives units completely ignore this aspect.
There is a urgent need for a governing body/ quality check body from govt of india to keep a check on cluster the production because it is ultimately effecting health of citizens if used in hospital labs or educating students wrong if used in school/ college labs.
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there are different units involved in different parts of the glassware industries like manufacturing, trading and micro scale sub vendors to big industries. to address all their need and opportunities on cluster level the approach can be in phases as following:
1. Short-term interventions2. long-term interventions
these improvisations could happen at individual as well as group level. these interventions can come in various ways as schemes, awareness programs and upgrading of the set-ups itself. a phase-wise improvisation of the units will lead to better productivity and hence better results. the design clinic has a huge role to play for making these units understand the purpose and importance of such interventions.
sCope of InterVentIon &suGGestIons
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sCope of InterVentIon &suGGestIons
Design of better storage system and storage processes
locally developed cutting machine
locally developed blowing machine, blow control machine and finding new materials for shaping tool,
locally developed calibration machine
locally developed automatic printing machine
Development of energy saving machines/ solar operated machines
innovative designs for light weight and low cost packaging
DeSign intervention on Different StageS of proDuction
Storage
cutting
blowing
calibration
printing
annealing
packaging
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112IndustrIal desIGn opportunItIes
light weight and cost effective packaging design
innovative design to pack different types of glassware in same pack
locally developed automatic Screen printing to avoid error and marking on outer part of glass
Workstation design, Urgent need of the industry
protection for worker excessive heat from blower
finding alternative material for grinding tool to maintain diameter in long run
. locally developed cutting machine .paddle operated glass cutting machine
glass Storage system specially designed for glass tubes and for different diameters
. locally developed Automatic / paddle flame control machineto reduce wastage
locally developed automatic calibration machine
Development of low power consumption furnace or Solar power furnace
Design of boxes to reduce breakage during transportation
SyStem DeSign packaging DeSign
alternative reSourceS
local Development machineS requireD
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113sHort-term InterVentIons
TRAInInG PROGRAM: Specific skill development workshops, training camps and courses can enhance the level of workmanship of the labourers.
TOOl & eqUIPMenT: improvement in existing tools and equipment will lead to less fatigue and better product.
CROSS-IndUSTRY JOB: Since different units are specialised in different products and processes, hence there strengths can be combined to bring up products range.
AWAReneSS OF SCHeMeS: There are lot of financial schemes floated by the government which can be used by these units with proper knowledge of the same.
InFRASTRUCTURe IMPROVeMenT: there could be small improvements in the infrastructure of the unit as improving the height of workstation, proper lighting, storage solutions etc. which can result in improved productivity of the unit with lesser fatigue for the workers.
MARKeTInG: proper approach to the market will lead them to improve their product offering. it will also help them know the Dna that their product should have to compete with other products in same category.
deSIGn And BRAndInG: there could be designing of packaging to improve product status in market. it could also happen as a partial addition or improvement of an existing product.
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114lonG-term InterVentIons
COMMOn FACIlITY CenTRe: Since many of the problems/requirements of these units are common, hence there could be a common facility centre to cater such needs. these centres can be well-sustained by mutual efforts from the government and the cluster itself. Such common resource centre can be developed after considering the common needs of the units.
ReSeARCH & deVelOPMenT: efforts to develop new processes, tools and strategies could result in better returns. this could happen at micro and macro level which could be supported by the units themselves.
TeCHnOlOGY UP-GRAdATIOn: phase-wise up-gradation of the technology will improve the productivity of the unit. they will also be able to reduce their dependency on less-skilled labour.
PROCeSS-AUTOMATIOn: Such advancements will lessen the mishandling of the parts while manufacturing. The quality control will be better which will result in less efforts while finishing.
DeSign clinic workShop
I. Workshop Methodology
II. schedule of Workshop
III. openIng sessIon
Iv. guest lectures
v. dIscussIon And BrAInstorMIng 01. Manufacturing Processes 02. Packaging Ideas 03. Value Addition To Existing Products 04.New Designs In Existing Product Range 05. New Opportunity In Parallel Industries
vI. desIgn opportunItIes
vII. prototypIng
vIII. conclusIon
desIGn ClInIC WorksHop
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Discussion on current issues and initial findings
discussion on individual industry/ specific problems and remedial solutions
process by process discussion and opportunity findingprototyping initiation as proof of concept
brainstorming on new product design/ opportunity finding
brainstorming on innovative thinkingprototype displayDiscussion on way forward
Day 1
introDuction
Day 2
DetaileD DiScuSSion
dAY 3
proceSS mapping
Day 4
opportunity finDing
Day 5
innovative thinking
DeSign proJectSanD follow up
workShop methoDology
desIGn ClInIC WorksHop
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day 1 SATURdAY 26.01.13
sCHedule of WorksHop 26 TO 30 JAnUARY
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sCHedule of WorksHop 26 TO 30 JAnUARY day 2SUndAY 27.01.13
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day 3MOndAY 28.01.13
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day 4 TUeSdAY 29.01.13
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day 5WedneSdAY 30.01.13
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WORKSHOP APPROACH:
The objective of the workshop was to share observations, discuss problems and find new opportunities collectively.
the best possible way to achieve our goal was to make the sessions more and more interactive. while it is important to highlight the problems in industry, processes, products on the same time solution also lies with in the same industry.
idea was to conduct interactive brainstorming sessions on all important touch points of the industry and try to initiate the innovative thinking process.
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126gueSt lectureS
Mr. Ayush and Mr. Pravesh on creative management and entrepreneurship
Mr. Ankur Choudhary on integrated industrial development
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Mr. Sunil Tyagi on Product Branding
Mr. Raja on Lean manufacturing and Six sigma
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DiScuSSion anD brainStorming
Color coding for glass tube storage
Cross Staking to reduce breakage
Trolly to shift raw material
01. manufacturing processes
storage Concepts
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Idea on calibration machine using principal of coffee vending machine
Idea on calibration machine using principal of coffee vending machine Bench press grinding process can be
adopted to bottle neck grinding for precision
Gobar gas as Alternative fuel for furnace for annealing
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product sketches for prototyping
Cart design for Glassware workstation
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product sketches for prototyping
Prototyping of material trolly in different stagesClockwise: Marking, Cutting pipeswelding parts, assembly.
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Cart
Material Trolly final prototype
Trolly handle are tapered to make it ergonomically comfortable, and easy to push with heavy material.
Cutout in Wooden box to make it easy to lift
Wheels on rear position
Casters in front position to guide the trolly
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13302. packaging ideas
Flexible design for template packaging can be used for different shapes
Air suspension for fragile glassware Air/ light weight material to create a layer to absorb impact during transportation
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134packaging prototypes
Air/ light weight material to create a layer to absorb impact during transportation
PU foam as a filling material Internal structure to air suspend products
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13503. Value additions to existing designs
Adding a silicon grip on neck of flask to hold when its hot
Make scoop cuts on cylinder neck to hold
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Top: Same Cap design for different sizes of lab glassware
Bottom: Burette With marking
Left: Flask with additional threads to increase grip
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Top: Reduction of thread pitch
Top right: Marking both ways
Bottom: Grip on bottle cap
Right: Horizontal designs of volumetricto reduce wastage
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13804. new designs in existing range
Top: Attaching a handle for better grip
Multiple use of reagent filter bottle
Flask can be used as a water tumbler
New assemblies with improved joinery
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14005. new opportunity in parallel industries
Top: Water filter design
Food grade heating rod in glass
Decorative ware for table top/ temples etc
Decorative ware for table top/ temples etc
Helmet in bulletproof glass
Top: decorative architectural features
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Glass Umbrella and bucket
Decorative ware
window blinds in glass tubes
Hukka in bor osilicate glass
Glass wind chimes
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Decorative lights Decorative lights
Products from waste
Electronics and gadgets from glass
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a. proDuct DeSign
01. value addition to existing products02. new product designs03. Parallel industries in glassware . kitchenware . hukka industry . lighting industry . decorative ware, tableware etc
b. packaging DeSign
01. lightweight 02. cost effective for mass production03. Template to pack different shapes04. Design boxes to reduce breakage during transportation
c. workShop anD proceSSeS
1. Storage design for glass tubes2. workstation design for the following . glass blowing . tube cutting . grinding . calibration . marking . packaging 3. Mobility carts/ trollies for raw materialand finished goods4. Hand tools specifically designed glass work
Designopportunity
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D. locally DevelopeD machinery for inDuStry
01. automatic calibration machine 02. automatic screen printing machine03. Automatic flame control burner04. test tube and culture tubing machine05. Socket printing machine06. beaker forming machine07. automatic glass welding machine08. automatic glass cutting machine09. pneumatic taper10. cover slip making machine11. automatic socket and cone forming machine12. laser wall thickness measuring machine13. True bore making machine14. automaic furnace
e. alternative reSourceS
01. Development of low power consumption furnace or solar power furnace02. finding alternative material for grinding tool to maintain diameter in long run
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obJectivethe protoyping was done as proof of concepts to show the possibilities of different products from same setup.
DeSigndesigns were contemporary yet simple to make in 3 days time, also from different categories like trolly, kitchenware etc.
materialSborocilicate glass main raw material of the industry and available in local workshops.
prototypInG
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prototype DiSplay on Day 5
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148PROdUCT PROTOTYPe: KITCHenWARe
Range of kitchenware items
Oil dispenser Oil lamp
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Sugar dispenser
Water Bottle Spice Bottle
Milk glass for kids
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Team NID Team NID Team NID
Team Glassware Team Glassware Future Generation
Team PHD
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I am really amazed to see the strength of the Ambala Cantt scientific industry, its not only a heritage industrial town but also a exceptional production hub with more then 1200 units.
I would like to conclude saying that there are definite challenges on their way and going to increase in the coming years.
But the industry must realize their strength and key to success for them is advancement in technology, skill up-gradation and most importantly honesty in product quality the industry has a very bright future.
Team Glassware Team Glassware
Team PHDTeam ASIMA Team ASIMA
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annexureS
checkliSt
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photo creDitS
front cover photographS kulveer Singh bhati
proDuct photographSPage 17-22 Adams & Chhetendens Scientific glassware
naS photographSpage 06-16Page 23-104 Kulveer Singh Bhati
workShop photographSPage 105-151 Ankur Choudhary, Sunil Tyagi and kulveer Singh Bhati
back cover photographS kulveer Singh bhati
bibliography
webSiteS01. www.citymediaambala.com02. en.wikipedia.or03. www.grotal.com04. www.adamschittenden.com05. www.borosil.com
DocumentS01. aSima documents02. jasdan03. Thangarh Cluster04. Blue pottery, Jaipur