Slide 1NEED ASSEMENT SURVEY
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,
(v) Processing machines,
(vi) Hosiery/RMG machines,
(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 neighbouring countries.
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 crores achieved 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.
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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-NAS Case study
Phase- 2,GIDC, Kathwada, Ahmadabad – 382430
Gujarat
PRODUCTS
• 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
• 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 give a dynamic look
• Contraption for pouring of wax can be designed to make it convenient
• The production time between order, procurement and delivery sometimes differ from the initial plan period creating difficulty in storing the machine, machines occupies space and hinders progress of production
• Modular construction of the frame work can partially resolve the situation and also help in cutting down the inventory ,packaging or by 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
Gandhinagar- 382028
• Heald frame • Heald • Reeds • Drop pins • Electrical contact bar • Spares
GENERAL OBSERVATIONS
• 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
Possibilities of design intervention
• 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 to international 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 manufacturing process 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
• 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.
Possibilities of design intervention
• 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 an impact on prospective clients
PERFECT EQUIPMENTS
Ahmebdad, Gujarat(India) - 382 415 Ph: +91-79- 22871516
PRODUCTS
• Turnover of the company: may be around 15 – 20 crore
• Very keen on developing the unit further
• 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.
Possibilities of design intervention
• 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 – 382 430 Gujarat.
Ph:+91 98798 44411
• 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”
Observation of the product
Possibilities of design intervention
• 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 more pleasing 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
• Fabric cutting sample systems
• Attitude towards industrial design and R & D is unsure
• Has skills to convince
Observation of the product
Possibilities of design intervention
• 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 GROUP PRASHANT GANDHI
Survey no :767/2, At and Po Vadsar, Kalol district, Gandhinagar, Gujarat
PRODUCTS
• Aluminum small diameter thin wall tubes up to 50 mm
GENERAL OBSERVATIONS
• Customized aluminum extrusions for industrial use.
• Reputation for quality.
• 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
GENERAL OBSERVATIONS
• Attitude towards industrial design and R & D is positive .
• Manufactures tubes and pipes from ABS.
• Engineering plastic extruded products.
Possibilities of design intervention
• 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
GENERAL OBSERVATIONS
• Manufactures steel cops for textile industries.
• Products enjoy high reputation and generally have export orders.
Possibilities of design intervention
• 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
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 Survey Bhatt Bros
Continuous Desizing Range
Classic auto jigger machine
Continuous chainless merceriser Machine
Hot flue dryer
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.
ITAMMA Survey Bhatt Bros
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.
ITAMMA Survey Bhatt Bros
1. JAYOMA INDUSTRIES, 15 Gurukrupa Estate, B/h Mony Hotel , Isanpur,
Ahmedabad – 382443
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 Survey Jayoma 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.
ITAMMA Survey Jayoma Industries
4. Better workshop layout be made.
Jigs and fixtures can improve productivity
Alternate use of material and process can improve aesthetics and productivity
ITAMMA Survey Jayoma Industries
5. 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.
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.
Indian Textile Engineers
Ahmedabad – 382445
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
Automatic flat screen washing machine
Automatic color feeding machine
3. Scope of improvements
1. Aesthetics and looks
2. Control Panel Design
installed – CNC, VMC
improved
for designing
ITAMMA Survey Goldi International
Production per year -
- Winding drums
- TFO spindle
- Repairing work
Alternate material and process
ITAMMA Survey Goldi International
Usha Industrial Corporation
Ahmedabad – 380023
2. Textile spinning machinery parts
- Plastic injection molded Bobbins
The housekeeping can be improved
ITAMMA Survey Prism Textile Machinery Pvt. Ltd.
Prism Textile Machinery Pvt. Ltd.
1. Location:
Plot No. C1b, - 4614, Phase IV. B/h IGTR, GIDC, Vatva
Ahmedabad
Turnover –
Beam Compactness hydraulic automatic machine
Warping creel, Sizing machines
Indigo Dyeing preparation machines
Ball warping guide, Ball warping machine
Long chain beamer – rebeamer, Rebeamer tension
stand
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
ITAMMA Survey Prism Textile Machinery Pvt. Ltd.
Styling, color , graphics and control panel design opportunity possible
ITAMMA Survey Prism Textile Machinery Pvt. Ltd.
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
Ahmedabad – 382405
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.
Continuous Desizing Range
Classic auto jigger machine
Continuous chainless merceriser Machine
Hot flue dryer
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.
2. 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.
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,
Ahmedabad – 382443
Production per year – 50- 60 machines
ITAMMA Survey Jayoma Industries
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.
Rotary INK JET screen engraving machine
Other machines for flexography
ITAMMA Survey Jayoma Industries
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.
ITAMMA Survey Jayoma Industries
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.
2. New product on the lines of digital printing is being developed
ITAMMA Survey Jayoma Industries
DESIGN INTERVENTION
2. 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.
Indian Textile Engineers
Ahmedabad – 382445
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
Automatic flat screen washing machine
Automatic color feeding machine
3. Scope of improvements
1. Aesthetics and looks
2. Control Panel Design
installed – CNC, VMCinstalled – CNC, VMC
5. Quality control techniques to be
improved
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
Production per year -
- Winding drums
- TFO spindle
- Repairing work
Alternate material and process
ITAMMA Survey Goldi International
Usha Industrial Corporation
Ahmedabad – 380023
2. Textile spinning machinery parts
- Plastic injection molded Bobbins
The housekeeping can be improved
ITAMMA Survey Prism Textile Machinery Pvt. Ltd.
Prism Textile Machinery Pvt. Ltd.
1. Location:
Plot No. C1b, - 4614, Phase IV. B/h IGTR, GIDC, Vatva
Ahmedabad
Turnover –
2. Weaving Prepatory machines
Beam Compactness hydraulic automatic machine
Warping creel, Sizing machines
Indigo Dyeing preparation machines
Ball warping guide, Ball warping machine
Long chain beamer – rebeamer, Rebeamer tension stand
Sectional warping machines
Styling, color , graphics and control panel design opportunity possible
ITAMMA Survey Prism Textile Machinery Pvt. Ltd.
Styling, color , graphics and control panel design opportunity possible
ITAMMA Survey Prism Textile Machinery Pvt. Ltd.
Styling, color , graphics and control panel design opportunity possible
DESIGN INTERVENTION
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
ITAMMA Survey Prism Textile Machinery Pvt. Ltd.
4. The director feels that the brand INDIA should be improved
rather than the above areas.
ITAMMA Survey Sabar 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
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
give cleaner look from the rear
The dust collecting unit can be
integrated with the main unit so
that it becomes more compact.
ITAMMA Survey Sabar Machine Tools Mfg. Co.
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
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.
use on all machines.
• 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.
• 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