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Project Activities:
The activities under the project can be typified into the following phases-
1st Phase: Identification of entrepreneurs , experts and
support institutions in select industries. Initiation of dialogue for
trust building, obtaining long-term commitment from the prospective
stakeholders. 2nd Phase: Field research to understand ground realities. Developing value chain linkages and promoting cooperation.
3rd Phase: Institutionalisation of the innovation network, sustainability; assimilating learning and multiplication of initiatives.
The Foundation has initiated the first phase of the activities by
identifying few industrial sectors and analysing current status of the
clusters. The industrial sectors identified among others are-
Knitwear Machinery, Ludhiana
Medical Devices, Ahmadabad
Medical Electronics, Baroda
Perfumery cluster, Kannauj
Forge and Foundry, Sambalkha
Agricultural Implements, Karnal
Sports goods cluster, Jalandhar
Sal leaf cluster, Baripada |
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Cluster Intervention |
Knitwear Machinery cluster, Ludhiana
There are 20 manufacturing units each for circular and flat bed
knitting machinery. Although the total estimated domestic demand for
both types put together is about Rs.800 crores, Ludhiana has only 5% at
present. In the past decade the total exports from the cluster have
also declined sharply from INR 200 in early 90s to almost nil in 2008.
The main roadblocks perceived are product obsolescence, lack of
adequate technology and lack of advantages that result from
collaborative synergies.
The foundation team put together a group of experts and visited a few
units in the cluster following which a strategy has been formulated for
greater impact. The strategy for intervention can be briefly described
as follows:
- To bring in new technology for the product and manufacturing methods
- To help set up as state of the art unit within the cluster
for manufacturing the cylinder and cams of the circular knitting
machine
- To facilitate integration along the supply chain to improve profitability
It is envisaged that the above strategy will
- facilitate the cluster enhance production from the current figure
of 150 machines to over 1000 machines for the cluster implying almost
40% of the Indian market share.
- Reduction in supply lead time from 4 months on average to 2 months.
- Facilitate export of 20% of the production
- 15% increase in profitability due to specialisation at unit levels.
Workshop at Ludhiana
Agricultural Implements cluster, Karnal
Comprising 50-70
units, the Karnal cluster is engaged in the manufacture of agricultural
implements for soil preparation for example cultivators, ambiploughs
etc. Common problems faced by the manufacturing units in the cluster
images inefficient shop floor practices and management systems. Also
process automation was found to be acutely lacking and a source of
lower productivity.
The project activities aim to enhance process efficiency and hence productivity through:
- Better shop floor practices and management systems for example through process control sheets
- Assist in diffusion of best practices existing similar clusters elsewhere
- Provide linkages for training assistance in low cost automation
The Foundation has teamed up with various premier technical institutes,
sector experts and BDS providers to help implement its strategy. Some
of these are National Institute of Secondary Steel technology, MERADO,
CITD at Hyderabad, National Institute of Forge and Foundry at Ranchi,
NIT at Kurushetra, and BDS providers such as Enconsys Systems Private
Limited and L.M.Thapar Institute.
Workshop at Karnal
Medical Disposables cluster, Ahmadabad
Gujarat contributes > 30% to pharma, medical disposables and
devices in India. Ahmedabad & Baroda have 40 disposables
manufacturing units and the former has 20 units in medical devices.
Today this industry is reeling under severe competitive pressure and
most of the domestic demand is met through imports. Obsolete
technologies some of which are often health hazardous, inefficient
processes and operational issues impact efficiency and productivity.
An expert group assessment indicates that at the very minimum, there is
a crying need for (a) partial automation systems to replace the
conventional modes of production (b) need for standardization of inputs
used and the processes adopted and (c) need for diversification into
new product development. The initial assessment also found that the
cluster does not lack in innovative ideas and entrepreneurs. What is
found lacking is ways and means to translate them to commercial
products.
Workshop at Ahmedabad
Foundry and Castings, Samalkha
Samalkha a small town in district Panipat (Haryana), has about
30 big and small foundry units producing agricultural implements
particularly chef cutting machines and cane crushers with a total
production of around 3000 M.T per month employing around 2000 workers.
The owners are generally non technical people and are solely dependent
on the charge hands, who have gained experience over the years,
informally. Their technical skill and knowledge on metallurgy are at
low level.
Although the market for the products manufactured in the cluster is
very high, only a part of it is served by the Samalkha cluster and the
rest mainly by Goraya, Batala and Ahmedabad as the latter has higher
production capacity and better product quality.
The cluster faces some major challenges today including low technical
knowledge, poor process management systems, unplanned product mix,
units operating below break even volume and inferior product quality.
Foundation and its team of sector experts have surveyed the units and
held an interactive awareness workshop at Samalkha following which a
strategy has been formulated to work in a few units for technology
diffusion and upgradation to help them become market competitive.
Workshop at Samalkha
Press at Samalkha
Sal Leaf Plate making cluster, Baripada
Sal leaf plate making cluster located at Mayurbhanj in Orissa has 5000
household processing units (HPUs) engaged in this trade and caters to
the urban and rural socio-political events. One of the four clusters in
Orissa where UNIDO directly implemented its cluster development
program, the cluster has hitherto been led by larger traders which have
not been proactive in seeking to innovate and grow. Consequently, the
cluster is facing growing competition from cheaper and ostensibly
superior quality substitute products made of plastic and thermocol.
The Foundation team is considering a proposal to establish a “Product
and Technology Development Centre” where innovations will be developed
and demonstrated and disseminated in the areas of product
diversification, cost saving technologies, productivity enhancement and
quality improvement.
Sports Goods cluster, Jalandhar
The sports goods cluster at Jalandhar mainly produces footballs for
European & US markets, however about 20% of the product is also
consumed in Indian Market. The screen printing process used in printing
of football panels is highly labor intensive. The panels are printed
manually on individual screen printing stations where lot of time is
lost in moving panels from one station to another. This can be avoided
by using some semi-mechanised or innovative methodology.
The Sports Goods Foundation of India, located at Jalandhar, has
proposed two techniques to remedy the situation. The proposal
visualizes introduction of two different machines, “revolving screen
printing” and “long flat table screen printing” machines. The cluster
would be trained in the usage of these machines. It is estimated that
this will lead to 20% saving on time and 30-40% on manpower cost. |
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