indian textile accessories & machinery manufacturer's association

INDIAN TEXTILE ACCESSORIES & MACHINERY MANUFACTURER'S ASSOCIATION

NEED ASSEMENT SURVEY

MSME SECTORS

Present scenario : Indian Textile Machinery Manufacturing Industries

Newer opportunities are knocking at the doors of textile engineering industry in terms of growing demand of textile machinery in the domestic market and also exports to the neighboring countries which are emerging as significant textile producer.

“The textile machinery industry exhibits a mosaic of multi-layered production capacity and technological capability levels.” for cotton, blended and man-made fiber textiles.

TEI was producing machines mainly for the cotton textile sector. Subsequently, as the textile industry diversified the production line, TEI also taken up the production of machinery required by the man-made fibre sector, the woollen sector and even the jute sector.

Today, the entire range of equipment required for forming lint and man-made fibres up to finished fabrics are produced in India. Side by side, the ancillary and textile testing and monitoring equipment sectors too developed appreciably.

The machinery manufacturing operation takes place both in the organised and the unorganised sectors.

In the organised sector, in addition to the public limited companies, machinery manufacturing is done in independent units, which have collaborative joint ventures with the foreign entities. In the decentralised sector, there are small-scale industrial units as well as tiny units engaged in the production of accessories pertaining to the textile machinery.

In brief, the Indian textile engineering sector seems to offer the modern technically advanced machinery for spinning, weaving and processing sector as well as simple machinery required in ginning and pressing industry of the sector.

Still the performance of the Indian textile machinery industry is far from satisfactory. Competition from high tech machinery of European and South-East Asian countries is a real challenge to the very existence of this industry.

The textile engineering industry also receives its name for the segment it produces the machines. On the basis of the products they produce, the TEI is categorized in ten categories, viz;

(i) Ginning & pressing machines,

(ii) Spinning & allied machines,

(iii) Synthetic filament yarn machines,

(iv) Weaving and allied machines,

(v) Processing machines,

(vi) Hosiery/RMG machines,

(vii) Textile testing equipment,

(viii)Multiple segments (combination of the above),

(ix) Accessories and parts and

(x) Others.

Majority of the production comes from the States of Tamil Nadu and Gujarat; Collectively contributing around 84 per cent of the production worth Rs 4,855.74 crore.

Around 87 per cent of the total production, ie, textile machinery worth Rs 5,010.50 crore is coming from the six clusters namely Ahmedabad, Bangalore, Coimbatore, Ludhiana, Mumbai and Surat.

These clusters are strategically located to serve the textile industry and have the affiliation to produce the kind of machinery required by the industry.

Ahmedabad is a cluster of weaving and hence the TEI in this cluster has a speciality of producing weaving and allied machinery followed by spinning machinery.

Further, it is observed that, though there are 59.61 per cent of the units under SSI category, the production from this category is only 32.12 per cent and the rest comes from the Non-SSI category.

As far as the consumption of the machinery is concerned, around 91 per cent of the production is consumed within the country and rest 9 per cent is exported. The export basket is tilted in favor of spinning and allied machinery in the tune of 72 per cent.

The TEI has geared up for modernization and expansion of their current capacity to meet the local and global demand of the industry. Around 33 per cent of the TEI units in India are willing to modernize/upgrade their current capacities.

Out of the total of 477 units willing to modernize/upgrade, majority of these units are located in Tamil Nadu (244) followed by Gujarat (160) and Maharashtra (26).

Out of the 477 units, 77 units have reported that they will modernize by way of automation of the entire processes, procuring Computerized Numeric Controlled (CNC) machinery, etc, 265 units desired to expand their production capacity, building & infrastructure, procuring new machines, etc and 76 units are going for product diversification.

Indian machinery industry, contributes around 5 per cent to the total machinery production of the world.

In the revival scenario, the industry is looking for investment on machinery for producing quality textile products for export purposes.

The recent demand of fashion textile garments from India by retailers of the world has created newer opportunities for Indian exporters to set up new capacities for production.

Since sourcing of the most of the textile machinery today is done from the Europe which is relatively costlier and requires specialized technicians to maintain the machinery, the Indian machinery have become a better substitute to those in addition to the comfort levels of the domestic manufacturers.

In a way, newer opportunities are knocking at the doors of textile engineering industry in terms of growing demand of textile machinery in the domestic market and also exports to the neighboring countries which are emerging as significant textile producers.

The moot point is whether TEI can gear up in terms of scaling up of capacity and technology level to take advantage of the growing demand.

The recent trend of exports of textiles machinery manufactured in India shows a high growth rate of more than 30 per cent; And even the export remained stable at the time of financial crisis.

This provides enough indication that the textile engineering industry is not only ready to continue its effort to remain competitive in the export markets but also is gearing up to increase its market share.

A vibrant textile machinery industry will not only support indigenous textile industry in its accelerated growth path but will also cater to the requirement of the neighbouringcountries.

An image of ‘Global player with local prices’ will catapult this industry to the unprecedented heights in the days to come.

The total (estimated) production of textile machinery, parts and accessories during 2009-10 has recorded an increase of 4% at Rs.4, 245 crores as against production of Rs.4,063 croresachieved during 2008-09.

Exports of textile machinery and accessories are estimated at Rs.525 crores in 2009-10 as against Rs.607 crores in 2008-09. [(Import of textile machinery has been reduced from Rs.6, 500 crores during 2008-09 to Rs.5,806 crores (estimated) during 2009-10.]

As per the census of the Textiles Committee, there are about 1446 textile engineering units in the industry manufacturing textile machinery, components, accessories and attachments situated in important centres of India.

The components and accessories sector is catering to the requirements of not only the leading Indian textile machinery manufacturers but also of almost all composite and decentralized units.

The quality and design of the Spares/Components/Accessories installed over the textile machines play a vital role in the performance and sustainability of the machine.

The level of Technology & Automation has shown a remarkable improvement, which has further given rise to need for introducing Design companies in the textile machinery industry and also helps the Textile Engineering Industry in the Developmental work of R&D nature of their Machines & Accessories.

The ITAMMA Association is working towards technology up gradation of textile engineering industry through cluster approach.

With a view to assisting members to upgrade their manufacturing process under the guidance of experts from Research Institutions and NID being one of them to make the members to be globally quality- competitive and cost-effective, the Association has already signed MOUs and/or working closely with leading Research/Educational Institutions.

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While on one hand, the future of the industry looks bright, for the MSME sector it is a challenging market. It has to face stiff competition from well designed and engineered machinery from Europe and cost effective solutions from china.

In some cases refurnished European machinery which are both high performance and are available at cheaper rates.

In such a scenario, it is imperative to look for solutions that can help growth (In some cases even survive).

By large the MSME sector is aware and has risen to the task of technology up gradation, both in their machinery as well as in the production techniques of these machines.

But technology is a great leveler. When almost all manufacturers offer equal performance the differentiating factors are price and aesthetics. Gone are the days when aesthetics was seen as irrelevant cosmetic treatment for well performing machine.

Today it helps to draw attention, invoke confidence in performance and satisfies emotional needs. Especially MSME

sector also needs expert advice in value engineering and brand building. It is in all these above areas industrial designers can play a very important and pivotal role.

The case studies conducted by ‘Platypus Designs labs’ and ‘Design Edge’ in about sixteen industries try to prove this

point. The following examples are a very tentative indication in what such an exercise can achieve

ITAMMA-NASCase study

RABATEX INDUSTRIES

HARISHBHAIPlot no. 559, road no.G

Phase- 2,GIDC, Kathwada,Ahmadabad – 382430

Gujarat

PRODUCTS

• Sectional warper

• Creel

• Beam carrier

• Doffer carrier

• Hydraulic pallet trolley

• Cloth roll stocker trolley

• Beam stocker

GENERAL OBSERVATIONS

• Turnover of the company:

2008 -09 : 18 crore

2009 -10 : 14 crore

2010 -11 : 13 crore

Due to various government policies, turnover is steadily declining.

• Very keen on developing the unit further

• Attitude towards industrial design and R & D is very positive

• Brand conscious

Observation of the product

Sectional Warper RI - 106

Possibilities of design intervention

• Making the pedestal redundant.

•Pedestal is given to access the control unit, though avoidable•Pedestal can be either be completely removed by reducing the height of the machine as it is done in advanced machine, this will save the cost and avoid accidental tripping

• Left wiring cabinet can be taken in the central wiring box.• Phase indication can be shifted into machine frame.

Phase indication

Wiring cabinet

To be pushed into the machine frame

• Right side control box could be pushed inside the machine frame.

• light indicator column to be made collapsible. Which will reduce assembly time at the customer’s place

• Calculator can be placed in the machine frame. Will lead reduction in cabinet and give it a clean look.

•Or the light column and the calculator can be integrated and be given contemporary high-tech look

assembly time at the customer’s place

• Calculator can be placed in the machine frame. Will lead reduction in

• Scale and controls can be integrated• Improve color scheme and the design

• Safety bridge needs to be thought over• Making the bridge foldable, this will also help in packaging• Instead of mechanical safety photo voltaic cell ?

• Manual controls from VM 108 could be adopted.

VM 108

• Evaluate the structure for ascertaining correct specs

• Improve ventilation systems – this can give smart look

• Both side housing for motor/wiring need not be identical – they should be to suit the space requirement and re-designed to givea dynamic look

• Contraption for pouring of wax can be designed to make it convenient

• The production time between order, procurement and deliverysometimes differ from the initial plan period creating difficulty in storing the machine, machines occupies space and hinders progressof production

• Modular construction of the frame work can partially resolve the situation and also help in cutting down the inventory ,packaging orby reducing the size we can store vertically

• Creating a brand identity by following corporate color schemes.• Maintaining uniformity in colors in all the machines•Developing brand equity based on goodwill

CONTINENTAL WEAVING ACCESSORIES

MAHESHBHAI

Plot no.503/504,GIDC Engg Zone, Sector-28,

Gandhinagar- 382028

PH: +91 79 23211399

PRODUCTS

Weaving accessories

• Heald frame• Heald• Reeds• Drop pins• Electrical contact bar• Spares


• Enjoys brand loyalty

• Older generation very compresent however younger generation is keen on diversifying but no clear directions

• Has dedicated set of customers

• Outsourcing is quite a bit of products and process

• Very old set of machinery and factory layout

• Very large range of spares

• Diversification – For example , Automobile industries• Jigs and fixtures development• Developing packaging• Workers, machinery and the rest of it is laid back and lacks vibrancy

associated with manufacturing• Factory layout and illumination should be improved which will yield

in production growth

• Packaging and manufacturing process should be maintained tointernational standards

• Brand identity should be created through logos, brand image,broachers, Uniforms

• Setup should be revitalized, If any company wants to inspect the facility, they would not give them orders if their manufacturingprocess is seen

• Laying out proper flow of production process

NEHATEX.61, Yamuna estate, Nr. Vatva Railway

Crossing, Phase-1 G.I.D.C, Vatva, Ahmadabad – 382445

Gujarat

PRODUCTS

• Narrow fabric loom

• Fast knit braiding machine

• Warping machine


• Turnover of the company: around 40 lakhs.

• Very keen on developing the unit further.

• Attitude towards industrial design and R & D is positive.

• 90% of the components is outsourced.

10% of the components and assembly is done in-house.

• Has recently started foraying into exports.

• Sees tremendous potential in growth but resources is the only limitation.

• Main chassis /Overall design can be improved• Needs change of color scheme

• Materials for the cover can be changed because hand lay up FRP does not give the necessary appeal

• Control units to be modified

• Spruce up the production environment to make animpact on prospective clients

PERFECT EQUIPMENTS

NARESHBHAIC-1/503 GIDC Estate, Odhav,

Ahmebdad, Gujarat(India) - 382 415Ph: +91-79- 22871516

PRODUCTS

• Blow room

• Card

• Recycling unit

• Card maintenance machine

• Cot servicing machines


• Turnover of the company: may be around 15 – 20 crore


• Attitude towards industrial design and R & D is extreme dedication, however the general feeling for industrial design instead of an expert inhouse skills are adequate

• Extremely good quality machines, finishing of the machine is comparable to the best product in the world

• Very enthusiatic and upbeat on growth.

• Though they have a very large range of product there is no sense of identity even the logo needs to be revitalized to the contemporary environment

• There is strong need to develop a corporate color scheme and identity to match with the vision and dreams of the future.

• Each of the machine and equipments can be taken up separately for various inputs.

• However for the immediate requirement on one of the machines are as follows

• Emergency stop button can be placed in a more appropriate, easy to access .

• Panel need not be opened and kept aside during the operation of the machine, panel can simply be made foldable.

• Screws and hinges are an eyesore.

• Corners are not resolved

• Overall color of the machine looks more like a medical equipment.

• The basic form of the control panel could be made more appealing.

• Overall shape the of the machine, can also be changed.

• The machine with a new design and color scheme would make the machine look expensive.

• Semi automatic machines and automatic machines can be improved a lot more in terms of form, ergonomics.

DYNAMIC LOOMS

Plot no. 2, Road no. 1, Phase – I,GIDC, Kathwada,

Ahmedabad – 382 430Gujarat.

Ph:+91 98798 44411

PRODUCTS

• Weaving machine.

• Rapier loom.

• Drop box loom.

• Over pick loom.

• High speed shuttle loom.


• Turnover of the company: around 20 crore


• Attitude towards industrial design and R & D is positive

• Commands respect in certain machine category

• Has recently tied up with the Italian company

• Has ventured into “fiber glass fabrics”


High speed rapier loomMagic-300

• The overall design of the machine can be improvised to contain the control units also

• Control unit itself can be made more integrated

•The break and main motor points can be

arranged in a more convient way

• Overall Design and detailing can be changed and made morepleasing and compact

NEW BHAGWATI VIJAY ENGG. WORKS

Plot No. : 32/A, Gopal Ind. Estate, B/h. Harshad Chambers,

Opp. Vallabhnagar, Odhav, Ahmedabad-380 415, Gujarat

Phone : +91-79-22870454

PRODUCTS

• Fabric inspection machine

• Fabric rolling and folding machine

• Fabric cutting sample systems


• Turnover of the company: around 3 crore

• Attitude towards industrial design and R & D is unsure

• Has skills to convince


NB-105

Cloth Inspection cum Rolling M/c.

• Material consumption, form, color scheme can be changed to benefit better image

• Material can also benefit cost saving on material and processes and also assembly line

SIDDHI GROUPPRASHANT GANDHI

Survey no :767/2, At and Po Vadsar, Kalol district, Gandhinagar, Gujarat

PRODUCTS

• Aluminum precision drawn profiles

• Aluminum small diameter thin wall tubes up to 50 mm


• Turnover of the company: around 1 to 1.5 crore

• Attitude towards industrial design and R & D is positive

• Customized aluminum extrusions for industrial use.

• Reputation for quality.

• Machines and equipments look untidy.

• Post manufacturing processes seemed very cluttered.

• General ambience also gives the impression of untidiness, the setup does not match the image the group enjoys.

• As the product nature is such that no direct industrial design inputs are necessary.

• However, the production floor needs up- gradation which would help boost morale of the staff which in turn will show positive result in production.

RIDDHI PLASTICS


• Turnover of the company: around 1.5 to crore.

• Attitude towards industrial design and R & D is positive .

• Manufactures tubes and pipes from ABS.

• Engineering plastic extruded products.

• Can make very thin walled high precision plastic extrusions.

• Extremely untidy, not well lit.

Some of the processes are done by squatting on the floor, which is not highly

productive

Precarious Stacking – Can lead to loss of productive time

• Tubes are directly linked with the manufacturing and selling of cops.

• At times when the order is not adequate the machine lies idol.

• To overcome this new products using the same manufacturing process and

available skills, can be thought. ( for example during the times of recession

The company had made extruded plastic Dandias )

• Work benches .Use of Bins and Vats can help improve production

SAMRUDDHI ENGINEERING


• Turnover of the company: around 3 to 4 crore.

• Attitude towards industrial design and R & D is positive.

• Manufactures steel cops for textile industries.

• Products enjoy high reputation and generally have export orders.

• Extremely untidy, not well lit.

• Production lines need to be improved, upgraded.

• New packaging ideas can be worked out.

• Creating a new brand identity may help fetch better price and build brand equity.

Bhatt Brothers

1. Location :

BHATT BROS, N.I.D.C. Estate, B/s Trumac Engg. Co., Lambha, Post –

Narol

Ahmedabad – 382405

Turnover –

No of employees –

Production per year -

2. Processing Machinery for textile industry

The grey cloth goes through the following process – scouring, bleaching,

mercerising, dyeing, drying, printing and printwashing. The new product is

developed as the requirement comes. Reverse Engineering or benchmarking

is used to develop new products.

ITAMMA SurveyBhatt Bros

Following are the various products :

Continuous Desizing Range

Fully automatic tension control electronic jigger machine

Classic auto jigger machine

Continuous chainless merceriser Machine

Hydraulic padder

Classic anti deflection cold pad batch machine

Hot flue dryer

Mangle – Float dryer,Mangle drying range

Polymerising machine ( backing cum curing chamber )

Open width Soaping cum Washing Range

Open width after print washing range

3. During audit the classic fully covered auto jigger machine was in progress

and there are various areas where in the product can be improved in terms of

use of the product. The control panel can be made more ergonomic. Also

feeding and removing of cloth bales can be made much more convenient. A

suggestion of change in the position of clamping of the lifting chain resulted in

reducing the height of the machine by couple of feet.


4. As The production is done by using proper technology based machines

such as CNC Laser cutting machine, CNC Bending Machine, Hydraulic

Press, TIG/MIG Welding machines, Orbital Sanders, Drilling & Tapping

under one roof. A high level of accuracy is achieved through intelligent

production techniques.

5. Styling of the product is required since the products look dated.

6. Branding related issues has to be looked into. Website, Logo, Product

color and graphics, Brochure and various communication materials to be

redone to make it look international class.

7. New product development process and techniques to be incorporated

for easier and better product development.


Jayoma Industries

1. JAYOMA INDUSTRIES, 15 Gurukrupa Estate, B/h Mony Hotel , Isanpur,


Annual Turnover – 3+ crores

No of employees – 7+ workers

Production per year – 50- 60 machines

2. Manufacturer of all types of screen and plate making machines, Rotary

and Flat screen Equipment, offset plate making equipment and all

types of exposing and curing equipments.

Flat bed INK JET screen engraving machine

Rotary INK JET screen engraving machine

Other machines for flexography

ITAMMA SurveyJayoma Industries

3. Aesthetics of the product can be improved to a great extent.

Attractive shape can be incorporated to make the product look more

professional. Sharp edges can be removed.

Color scheme branding and graphics to be improved

Details of various features can be improved.


Rotary INK JET

screen engraving

machine

4. Better workshop layout be made.

Jigs and fixtures can improve productivity

Alternate use of material and process can improve aesthetics and productivity





6. New product on the lines of digital printing is being developed

presently as a future product. New product development process

and techniques to be incorporated for easier and better product

development.


ITAMMA SurveyIndian textile Engineers

Indian Textile Engineers

1. Location:

C-1,B-4, ‘F’ Road, Opp. B.O.B. Phase I, GIDC, Vatva,


Turnover – 25 crores

Number of employees –

Total number of machines per annum – 100 machines a year

2. Semi Automatic & Automatic Flat bed screen Printing Machines, Automatic

Screen washing & drying Machines and parts

Servo 2000 Hydro – Computerised Fully Automatic Flat Bed Screen

Printing M/c

Singeing machine

Step and repeat screen exposing machine

Automatic flat screen washing machine

Automatic color feeding machine


3. Scope of improvements

1. Aesthetics and looks

2. Control Panel Design

3. Production layout

4. New age machinery to be

installed – CNC, VMC

5. Quality control techniques to be

improved

6. CAD models can be developed

for designing


Brochure and website to redesigned.

ITAMMA SurveyGoldi International

Goldi International

1. Location:

18, Chakudia Mahadev, Rakhial,


Turnover – 35 lakhs

No of employees – 8 people


2. Spinning spares made by Goldi:

- Winding drums

- Lappet hooks and Pigtail guides

- TFO spindle

- Repairing work

3. Scope of improvement – productivity

Alternate material and process

ITAMMA SurveyUsha Industrial Corporation

Usha Industrial Corporation

1. Location:

P.B. No. 6015, Nr. Ajit Mills, Rakhiyal Road


Turnover – 2.4 crores

No of employees – 11

Production per year – 200 tons per year

2. Textile spinning machinery parts

- Plastic injection molded Bobbins

- Drums

3. Well equipped factory with good facilities.

The housekeeping can be improved

ITAMMA SurveyPrism Textile Machinery Pvt. Ltd.

Prism Textile Machinery Pvt. Ltd.

1. Location:

Plot No. C1b, - 4614, Phase IV. B/h IGTR, GIDC, Vatva

Ahmedabad

Turnover –

No of employees –

Production per year

2. Weaving Prepatory machines

Super Speed Drum Driven Warping Machine

Beam Compactness hydraulic automatic machine

Warping creel, Sizing machines

Indigo Dyeing preparation machines

PLC based direct spindle driven warping machine

Ball warping guide, Ball warping machine

Long chain beamer – rebeamer, Rebeamer tension

stand

Sectional warping machines

Poly beamers, roller creels

Scope of design

1. Aesthetics

2. Color scheme

3. Graphics

4. The director feels that the brand INDIA should be improved rather

than the above areas.



Styling, color , graphics and control panel design opportunity possible

Bhatt Brothers

1. Location :

BHATT BROS, N.I.D.C. Estate, B/s Trumac Engg. Co., Lambha, Post – Narol


Turnover –

No of employees –


No of employees –


2. Processing Machinery for textile industry

The grey cloth goes through the following process – scouring, bleaching,

mercerising, dyeing, drying, printing and printwashing. The new product is

developed as the requirement comes. Reverse Engineering or benchmarking is used

to develop new products.

Following are the various products :

Continuous Desizing Range

Fully automatic tension control electronic jigger machine

Classic auto jigger machine

Continuous chainless merceriser Machine

Hydraulic padder

Classic anti deflection cold pad batch machine

Hot flue dryer


Hot flue dryer

Mangle – Float dryer,Mangle drying range

Polymerising machine ( backing cum curing chamber )

Open width Soaping cum Washing Range

Open width after print washing range

3. During audit the classic fully covered auto jigger machine was in progress and there

are various areas where in the product can be improved in terms of use of the product.

The control panel can be made more ergonomic. Also feeding and removing of cloth

bales can be made much more convenient. A suggestion of change in the position of

clamping of the lifting chain resulted in reducing the height of the machine by couple

of feet.

4. As The production is done by using proper technology based machines such as

CNC Laser cutting machine, CNC Bending Machine, Hydraulic Press, TIG/MIG

Welding machines, Orbital Sanders, Drilling & Tapping under one roof. A high

level of accuracy is achieved through intelligent production techniques.

DESIGN INTERVENTION


DESIGN INTERVENTION

1. Styling of the product is required since the products look dated.




3. New product development process and techniques to be incorporated

for easier and better product development.

Jayoma Industries

1. JAYOMA INDUSTRIES, 15 Gurukrupa Estate, B/h Mony Hotel , Isanpur,


Annual Turnover – 3+ crores

No of employees – 7+ workers




2. Manufacturer of all types of screen and plate making machines, Rotary and

Flat screen Equipment, offset plate making equipment and all types of exposing

and curing equipments.

Flat bed INK JET screen engraving machine

Rotary INK JET screen engraving machine

Other machines for flexography


Rotary INK JET

screen engraving

machine

3. Aesthetics of the product can be improved to a great extent.

Attractive shape can be incorporated to make the product look more professional.

Sharp edges can be removed.

Color scheme branding and graphics to be improved

Details of various features can be improved.


4. Better workshop layout be made.

Jigs and fixtures can improve productivity

Alternate use of material and process can improve aesthetics and productivity

1. Branding related issues has to be looked into. Website, Logo,

Product color and graphics, Brochure and various communication

materials to be redone to make it look international class.



DESIGN INTERVENTION


presently as a future product. New product development process and

techniques to be incorporated for easier and better product

development.


Indian Textile Engineers

1. Location:

C-1,B-4, ‘F’ Road, Opp. B.O.B. Phase I, GIDC, Vatva,


Turnover – 25 croresTurnover – 25 crores

Number of employees –

Total number of machines per annum – 100 machines a year

2. Semi Automatic & Automatic Flat bed screen Printing Machines, Automatic Screen

washing & drying Machines and parts

Servo 2000 Hydro – Computerised Fully Automatic Flat Bed Screen Printing M/c

Singeing machine

Step and repeat screen exposing machine

Automatic flat screen washing machine

Automatic color feeding machine


3. Scope of improvements

1. Aesthetics and looks

2. Control Panel Design

3. Production layout

4. New age machinery to be

installed – CNC, VMCinstalled – CNC, VMC

5. Quality control techniques to be

improved

6. CAD models can be developed for

designing


1. Brochure and website to redesigned.

2. The machines have immense scope in being redesigned

from aesthetic point of view.

3. The control panel unit should be redesigned.

DESIGN INTERVENTION


Goldi International

1. Location:

18, Chakudia Mahadev, Rakhial,


Turnover – 35 lakhs

No of employees – 8 peopleNo of employees – 8 people


2. Spinning spares made by Goldi:

- Winding drums

- Lappet hooks and Pigtail guides

- TFO spindle

- Repairing work

3. Scope of improvement – productivity

Alternate material and process

ITAMMA SurveyUsha Industrial Corporation

Usha Industrial Corporation

1. Location:

P.B. No. 6015, Nr. Ajit Mills, Rakhiyal Road


Turnover – 2.4 crores

No of employees – 11No of employees – 11

Production per year – 200 tons per year

2. Textile spinning machinery parts

- Plastic injection molded Bobbins

- Drums

3. Well equipped factory with good facilities.

The housekeeping can be improved


Prism Textile Machinery Pvt. Ltd.

1. Location:

Plot No. C1b, - 4614, Phase IV. B/h IGTR, GIDC, Vatva

Ahmedabad

Turnover –

No of employees –

Production per yearProduction per year

2. Weaving Prepatory machines

Super Speed Drum Driven Warping Machine

Beam Compactness hydraulic automatic machine

Warping creel, Sizing machines

Indigo Dyeing preparation machines

PLC based direct spindle driven warping machine

Ball warping guide, Ball warping machine

Long chain beamer – rebeamer, Rebeamer tension stand

Sectional warping machines

Poly beamers, roller creels


Styling, color , graphics and control panel design opportunity possible

DESIGN INTERVENTION

1. Aesthetic Improvement of the machines

2. Color scheme and Graphics

3. Ergonomic improvement in the display and control areas.

4. The director feels that the brand INDIA should be improved


4. The director feels that the brand INDIA should be improved

rather than the above areas.

ITAMMA SurveySabar Machine Tools Mfg. Co.

1. Location: Proprietor Mr. H K Shah

SABAR MACHINE TOOLS MFG. CO.

Gujarat Ginning Mills Compound, Idga Rd.

O/s. Prem Darwaja, Ahmedabad 380016

Tel: 079 22125378, 22130689

Email: [email protected]

www.sabarrollshop.comwww.sabarrollshop.com

Today, Sabar ranks among one of the world’s top manufacturers of spinning roll-

shop machinery.These machines are designed to serve all cot-grinding needs

and are built to last decades. Beside this, the Company has also indigenously

designed and developed several small maintenance job machines, known as

‘servers’ in the field.

In the last 3 decades, Sabar’s status as the market-leader in cot-grinders has

been unchallenged. High performance levels, low maintenance costs, good

quality equipments, combined with efficient after sales services is the

cornerstone of ‘Sabar’.


Automatic cot grinding machine Mechanical cot grinding machine

Hydraulic cot

grinding machine


Display and control areas can be

made simpler and can be located

at one place

A simpler cover can be made to

give cleaner look from the rear

The dust collecting unit can be

integrated with the main unit so

that it becomes more compact.


DESIGN INTERVENTION

1. The aesthetics of the product to be improved further.

2. Color and graphics to be added

REPORT ON DESIGN WORKSHOP ITAMMA

AUGUST / SEPTEMBER - 2012

CONDECTED BY PLATYPUS DESIGNS PVT. LTD.

Observations and Conclusions of Need Assessment survey

and follow up action :

• Need opportunities are knocking at the doors of textile engineering

industry in terms of growing demand of textile machinery in the

domestic market and also export to the neighboring countries which are

emerging as significant textile producers.

• Indian Industry is fast catching up with technology from the advanced

countries

• Chinese industry is giving tough competition to Indian industry in prices,

and finishing.

• Technology and engineering know how is a great leveler and each one

now looks for differentiating factor

• There is a lack of awareness of product design.

• The Indian industry particularly the MSME sector has not yet understood

the need for product design. By and large engineering design was the

driving factor.

• General dearth of innovation and design conscious at all levels of the

industry.

• Having concluded the above observations, I felt there was a strong need

to introduce design thinking at all levels before visiting these industries

again with a few demonstrative ideas in relation to their products or

environment.

• We organized a session on day one where industry owners, directors and

decision makers were brought together, to hear a first person case

study of using design thinking at various levels and for different

applications successfully.

• Mr.Nahishad Parikh spoke on his experience of using design thinking

from the day when he started his career as a small scale industry and

design was used as key differentiator to catapult him into a large player

competing with Multi Nationals.

• After the talk there was an interactive session with the participants

initiating them into design thinking actively using live examples.

• On the day two similar initiating sessions was held for R & D and

production personnel. Preceding it was a lecture on what product design

is and how it is different from engineering design.

• This exercise helped to clearly define problems and seek solutions in a

very different way; “the way of a product designer”.

• ( video documentation for both events available with ITAMMA )

On the following days I visited 7 units which showed keenness and invited

me to help them identify and solve their problems.

1. Perfect Equipments

Interaction with Shri Nareshbhai Mistry Managing Director and Shri Jitubhai

Mewada Director & R& D

During the entire session, a new color scheme was suggested for their one

of the machine ACG.600. The machine was complete ready, finished and

assembled waiting for dispatch.

Because of the earlier interaction and initiation, they felt the need for giving

at least a better look to their product which excelled in engineering and

they were otherwise so proud of that achievement. Suggested them several

alternatives. One of which was selected and implemented.

I suggested also to standardize certain color scheme for their entire range of

machines. This will help them build brand equity.

2. Rabatex Industries

As a demonstration one of their successful product sectional warper RI.106

was taken up for study along with their production and R & D teams.

Several suggestions were made.

• Suggesting contemporary color scheme and standardizing the same for

use on all machines.

• Value engineering

• Ergonomics and safety Features.

- On visit to this industry later, we noticed many of these

suggestions were implemented in their next machine getting

ready for delivery.

3. New Bhagwati Vijay Engg. Works

Out of their range of machines, Fabric inspection machine was picked up to

demonstrate how design thinking can improve the product.

• Suggesting ergonomically and aesthetically proper location of the control

panel.

• Suggesting emergency switch to be continuous pipe on a lever, as the

operator has to walk the entire width of the fabric. Reaching to the

emergency stop switch located at one end increases the response time.

• Suggesting relocating the control gear, which is located at the extreme

bottom, inconvenient location for servicing. This can be easily relocated

right above its present location.

• Suggesting moulded plastic caps to cover the bolts.

4. Dynamic Looms

• Rapier loom was taken up as case study and following suggestions were

made:

• Value Engineering

• Out of the two side boxes, one of them is made purely for “aesthetic”

reasons.

• It was shown how one can have pleasant looks without the so called

balanced symmetry.

• Suggesting ‘grouping’ and improvising of product graphics.

• They had problems with the rid assembly and fabrication. Different

methods were explored.

5. Riddhi, Siddhi and Samruddhi

These are three ancillary industries owned by same set of persons. All the 3

of them are located next to each other.

The type of components manufactured by them does not need direct inputs

of product designers ,however design thinking can help them improve their

performance.

Suggestions were more in the nature of lean management, improving floor

layouts, light conditions to increase productivity. Rationalizing and

optimizing space and infrastructure. Improving packaging and branding to

leverage their brand equity.

Some of these suggestions are already implemented.

One more suggestion was using solar energy to heat the mild acid bath for

cleansing the redrawn aluminum pipes. They are exploring the feasibility.

General Suggestions:

Most of the industries studied during the survey and the interaction during

follow up, have a few common areas in which they need to improve.

1. Branding

2. Production Facility

3. Quality of finishing

4. Color scheme

5. Aesthetics

6. Packaging

indian textile accessories & machinery manufacturer's association

Documents