sudeepa - factory visit

Respected sir,

We had an interesting trip to few small scale factories this last Thursday. Firstly, we visited a metal factory in Sudarshanpura in which aluminum was being processed. The owner Mr. Rajendra Singh gave us a detailed description of the whole process. We saw a air blasted oil fired furnace in which the scrap materials are melted. We came to know how aluminum is cleansed of all impurities by passing chlorine gas through it. Mr. Singh also showed us the book mould casting, rolling of both hot and cold metal and the cutting process. I learned that in rolling the metal sheets increases only in length and not in width. Mr. Singh finally explained us the annulling process in which the metal which becomes hard and compact in the rolling mill, is again made soft and malleable in this process. Thus, aluminum sheets and wires can easily be bended without breaking after this process.

Next we visited a wood processing factory where the owner Mr. Sameer Wheaton explained us all the processes from the seasoning of wood to cutting, planing, shaping and finally assembling the pieces to make the final product. We learned that it tales fifteen days to dry the wooden planks called sleepers. Mr. Wheaton then showed us three kinds of machines namely electrical, pneumatic and mechanical machines. We saw a machine having four sided planer blades, spindle molders, panel saws, scoring blades and groove making machines. The whole process was very systematic and time saving. He had also attached suction pumps to each of the machines to suck in the sawdust in huge sacks. He also showed us his workshop where they make foldable furniture with detachable parts. The whole range was of standard export quality.

Finally, we visited a plastic making factory of Mr. Y. S. Bhati where we saw how the raw material in the form of small plastic granules is melted and put in to moulds of the required shapes. The whole process was mechanical and very simple. We learned that the plastics come in different grades and colours and different grades had different utility.

Overall, we had a learning experience and seeing different kinds of interesting machines was very exciting. The experience has left us craving for more of such kinds of visits. The first hand knowledge that we received in seeing the machines working along with the details provided by the amiable owners have been retained better in my brain as compared to the bookish knowledge.

With regards,

Sudeepa Karmakar.

prabal - factory visit

COMMENTS ON FACTORY VISIT

We visited three factories on April 21^st, 2005:

• Aluminium sheet manufacturing unit
• Wood processing unit
• Plastic small water pump manufacturing unit.

Aluminium sheet manufacturing unit:

We visited a small aluminium sheer manufacturing unit at sudarshanpura area. It is thirty year old unit. The owner mr rajendra singh rold us the process of making metal sheet from waste materials. The waste utensils, bus body parts, wire scrap etc. it is melted in an air blasted oil fired furnace at 650 degree Celsius. The impurities are taken out with the help of chlorine. The molten metal is poured into book moulds. Then it goes through hot rolling or cold rolling according to requirement and the thickness of metal sheet is determined by the amount of pressure applied in it. then it is cut into circular sheets or square sheets . Lastly the sheets ate made soft by annihilation process and it is done at 400 degree centigrade. Mr singh showed us an another unit where machinery were being made.

Wood processing unit:

Post lunch w visited a wood processing unit. Mr samir weaton, an NIDian designer showed his advanced wood processing machines, he even demonstrated us each and every and made us understand clearly how they worked. The machines were so advanced that men’s skill was hardly required. He also showed us his design studio and tools shop.

Plastic unit:

Our last visit was to a water pump manufacture at sudershanpura, who manufactured small motor pump used for cooler. Almost all works were being done manually. Plastic granules were being used to make small machine parts by the help of moulds.

Overall, the trip was very enjoyable and informative.

raj vardhan - factory visit

Hello sir

. On 21^st of April we all went to see three different factories which are of :

1.metal

2.Wood

3.plastics

Sir metal and plastics both are small scale industry and wood factory owner Mr. samir witan sad its not a factory it’s a its my experiment center.

· Metal factory,

We reached there at 9.30 am. Rajendra Singh is owner in this factory. This factory produces aluminium sheets. Mr. Singh informed us very deeply. We all have seen the entire process.

Sir, as I am in “metal” groups so it was important for me to collect as as much information as possible about metal factory. I saw the entire process, starts from getting raw material for the market, melting of raw material to the final product (aluminium sheet) .

· Wood factory,

After lunch we went wood factory. Mr. samir witan was there to guide us. He was alumnus of NID. It was very advance unit. We saw modern machinery of woodcarving, wood planer and etc. in that factory they were making all the furniture that can be assembled. Then we went to his design studio. We came to know how a factory and a design studio work together.

· Plastics factory,

After that we went to plastics factory. it was very small unit. This factory making submersible pump. And we saw three plastics molding machine. We came to know how did it work and which types of rawmataril they use.

anang - factory visit

Respected Mr. Dinesh Korjan sir,
 
 This is regarding to the experiences of factory
visit………..
 The very first visit was of a very small unit of
aluminium sheet production at “sudarshanpura”, Jaipur.
They produced aluminium sheet of the thickness of 1 to
3 mm for utensils. The sheets are further supplied to
the utensil making unit. The raw materials they use
are aluminium scrap in the form of old utensils, wires
& bus body parts, which they get from the local
market. 
Mr. Rajendra Singh the owner of this unit told the
whole process of recycling the metal. The process is
same for all the metal but the temperatures vary at
stages for different materials.
 The whole process is started with the collection of
raw material. Then the raw material was heated till
the melting point (650o C for aluminium) in a Furness,
this unit has the “air blast oil fired farness”, in
which oil is used as the fuel & air is blow with the
help of electric blower at 3000 RPM. The oil used in
the farness is diesel grid oil called farness oil. In
this process the pure metal in liquid form is settled
down & the impurities i.e. the oxides covered that.
That oxide form called the cover flux, which contains
cobalt, Zink oxide, the metal & it’s oxides as well in
the form of ash.  Then that molted metal is pored in
the “cast iron book mould” for 10 to 15 min. to form a
thick slab called billet. These billets then further
go through the hot rolling then go to annealing & then
for the cold rolling process to give the needed
thickness (i.e. 1mm to 3 mm for that unit  to made
utensils like bowls, pressure cooker etc). The gap
between the rollers, across the roller length needs to
be maintained constant and thickness gauges of
relevant sizes would help maintain the gap. The time
consumes in the annealing process is 2 to 4 hours. The
annealing farness was also the oil fired one. Then the
sheets were cutting into circular & square form for
the given size & the remaining scrape from the cutting
was again recycled. The whole process takes 3 to 4
days.
 Then the second visit was of a small of aluminium
sheet making where the Propezene machine was using for
continuous sheet making & the sheet was engraved in a
particular pattern for making the bus flooring. 
 Then the third visit was of a wood workshop at
“malviya industrial are” where the initial steps of
furniture making were being done. The owner of the
unit is Mr. Sameer Weiton passed from NID in 1997. He
told about the work, the process, quality & basic
characteristics of wood & the need of export &
domestic market in terms of wooden furniture.
 First he told that there are 2 basic types of wood
that is the plywood & the solid wood. In the process
of making a final product of wood first there is need
of drying the wood because if the wood is not
completely dry then the product will deform latter on.
So for that the unit has a sizzling plant which was a
air tight cabin with heaters & fans & the walls of the
cabin was insulated with the thermocol & cement
applied on it. the wood in billet form was arranged in
the sizzling plant for 15 to 20 days & during the
sizzling period the wood release 15 to 20 liters water
per day.
 This unit has three types of machines the manual, the
electric & the pneumatic. The other machines were like
that:
  The lathe machine (electric) for turning the wood.
The band saw (electric) for cutting the wood at
curves, angles & straight orientation. Planer that is
one and two sided (electric) & the four sided
(pneumatic) which has blades & measurement (in mm)
option. Then the spinners molder to cut a curve. The 4
blades of this machine were arranged in a circular bit
are the tunksion carbide blade & called the FHS
(function high speed) blades. Then the router machine
(electric) for making fine grooves (specially used in
jalli making).  Then the panel saw machine (pneumatic)
for cutting the plywood of larger size. This machine
was using for the straight cut as well as for the
shampher. Then the multiple boring machine for making
more than one bore of same or different sizes at a
time. By the help of this machine one can make 20 to
22 bore at a time. The unit has it’s tooling shop
where the blunt blades of the tools can be sharpen
again. 
  The entire pneumatic machines in this unit have the
air suction feature by which the problem of
respiratory disease decreased & the disposal of
wastage became easier. In this unit we saw better
examples of contemporary work need for today’s market.
We saw here the good mixture of different materials to
get a better result.
 Then the fourth visit was plastic unit again at
“sudarshanpura”. The owner of this unit Mr. Y. S.
Bhati told us about the press molding of the plastic.
The process is remaining same for all kind of plastic.
All the plastics can be remolded except the nylons.
They are using plastic granules for molding. The unit
was making the parts of submersible pumps. They were
using delerine, nylon, abs, pp, poly carbonate
plastics for product making.
 Overall these visits provided us knowledge of the
basic materials, their characteristics, the
possibilities in the material & the way of using the
material in a proper way for the proper result.
          Regards
                  Anang    

nishi - factory visit

Respected sir,
We all visited three manufacturing units of metal,
wood, plastic. it  was really good experience which
will help us further to think of many aspects of
designing, when we design any product we only think of
look of the product or may be utility...but now we
have open mind to think of the technical aspects also.
It was really interesting.....now i feel that we
should visits many units where we can explore our mind
and can clear many doubts of materials and designing
etc. These visits encouraged me to learn all aspects
of designing where i can do better things and can
serve justified products to the new market which is
trendy and look for utility items in different looks
and style(aesthetical value).

All three visits were very interesting and encouraging
and inspiring.
thanks
NISHI SINGH
IICD JAIPUR
6th BATCH, 2nd SEM

disha - factory visit

Respected sir

21^nd April first we go to the aluminum factory. Mainly they make aluminum sheets in various sizes. We meet Mr. rajender he visited the factory to us.

The raw material comes for the factory from the rajasthan or the local market of jaipur

(Tripolia bazar) like wire scrap, bus body, used utensils and some other things. It was a small-scale industry. And they use technical and mechanical.

First it goes in melting process then the waste things (oxidized fome of metal) cleaned out form the iron roods during the malting they pass Cl tablets in it to remove the impurities. And also add the chemical powder in it. Temp of the furnace keeps 650c the capacity of the furnace was 750 kg. It furnace works like a stove that’s way its name is air blast oil fired furnace.

Then we go to the next factory in Sudarshanpura it was a machine making factory for wire. We have seen many big machines there.

The 3^rd factory was wood factory where we get a lot of information about wood. They show us their own sneezing room. Where the wood make ready for the furniture.

It was a numeric factory. He was using the new technique machine there. We went to see their studio and laboratory. They were using their mix mix materials like wood with leather, bone, stone.

Then we go to plastic pump making factory. The parts were used in coolers. Plastic used there was dellerene, nayalone. They used molding machine on 80c temp.they make pumps for cullours.pumps also tests there for the leveled or water.

The last factory was also plastic parts making factory. They were making there the lids of the bottles, switches, hangers and some other things.

It was interesting trip we really feel knowledgeable to go there. I hope in the future it is going to help us a lot. .

Thanking you

disha

shweta - factory visit

Respected sir

21^nd April first we go to the aluminum factory. Mainly they make aluminum sheets in various sizes. We meet Mr. rajender he visited the factory to us.

The raw material comes for the factory from the rajasthan or the local market of jaipur

(Tripolia bazar) like wire scrap, bus body, used utensils and some other things.

Air blast oil fired furnace-

First it goes in melting process then the waste things (oxidized fome of metal) cleaned out form the iron roods during the malting they pass Cl tablets in it to remove the impurities. And also add the chemical powder in it. Temp of the furnace keeps 650c the capacity of the furnace was 750 kg. It furnace works like a stove that’s way its name is air blast oil fired furnace.

Book molding –

The collected Al in the buckets goes to book molding for half a minuet.

Hot rolling-

The Al sheet rolled in the hot rolling machine .for required time.

Cold rolling machine-

Then the Al sheet goes to cold rolling machine.

Then it goes for cutting in require size and shape.

Annealing-

The most important process it is the final step for making anal sheet. It is also like a furnace tem. 400c. Capacity 12 kg. The final sheets goes in the furnace to increase the flexibility of the Al sheet. The tem should not be more then 400c otherwise the sheet will melt.

Then we go to the next factory in Sudarshanpura it was a machine making factory for wire. We have seen many big machines there.

The 3^rd factory was wood factory where we get a lot of new things we really feel like wood because the factory owner take us in the wood seezaning room it was really dark. The inner walls of the room were cotted by thermacole.

It was a numeric factory. He was using the new technique machine there. We went to see their studio and laboratory. They were using there mix material like wood with stone , leather ,bone.

The next factory was plastic pump making factory. There they were making the inner parts of the pumps. Plastic used there was dellerene, nayalone. They used molding machine on 80c temp.they make pumps for cullours.

The last factory was also plastic parts making factory. It was too congested fact. It is really tuff to go inside the factory. They were making there the lids of the bottles, switches, hangers and some other things.

It was interesting trip we really feel knowledgeable to go there. I hope in the future it is going to help us a lot. Nadan sir gives a lot of information about he factory. They were egger to learn.

Thanking you

Shweta Shukla

vartika - factory visit

hello sir

yesterday(21-04-2005) we were visited three small industry. first one is aluminum(Reycycle aluminum cite menufecturar unit). the name of the woner is Mr. Rajendar sing and addrres is sudersunpura industrial aria. We show aluminum recycle prosses .their rowmaterial is wires, bus body, parls etc. that rowmaterial pass throw from oil fired furnace, than book mould for moulding, than hot roling, cutting and analing. 2nd visit was wood industry (wood prosasing unit). Mr. sameer weaton is woner of this industry it is not only a industry, work stoudo as well. Mr. sameeris a NIDan and he has some new invented muchin like four -sided-palner, seasionied room etc. He is not only nich disnder but man as well. Our last visit was plastic industrywoner is Mr. Y. S.bhati It was a vary nich experince for us.that all three industry's gives us lots of imformation about materialand prosses,we show some new disgn in Mr. sameer's wood industry he disignhis products for 5star's hotal.

thinku sir.

ruchi - factory visit

Hello Sir,

Our visit to different factories provided a great exposure and was an eye opener to us. We discovered the practical difficulties that the labourers face and the different techniques of working in a particular medium. We came to know the manufacturing processes with which I was ignorant earlier.

Aluminium Factory

We first visited a small aluminium unit owned by Mr. Rajendra Singh where raw material

was procured from local places for the production of aluminium sheets. Wire scraps, bus body parts and waste utensils were used as the raw material and melted in air blast oil fired furnace. The metal gets charged at 650⁰C due to the pressure applied by the air blower. The metal settles at the bottom and the metal oxide segregates above. The cover flux which constitutes zinc oxide, salt and other impurities are removed with the help of a long iron tool. To purify the metal, a chemical quench is applied and the impurities pass out in the form of bubbles by with the passage of chlorine gas. Immediately after this process the melted metal is thrown into a cast iron book mould where it gains the shape of a sheet. This is further carried by hot rolling followed by cold rolling process which stretches the length of the metal sheet and makes it hard. In order to release the hardness the analing is done in a furnace which has the capacity of 800 kg. Finally, the metal sheets are cut in square and circular shapes and sold to the factories of nearby markets that make utensils such as pressure cooker and bus body parts. We also visited another small manufacturing unit where some machines were modified for more productivity. Though big rolling machines are available in Hindalco, grooves were being made on

checqers sheet used in floors of cars, trucks etc. These machines were made on the basis of Propergy plant and the whole unit was set up in 1973.

Wood Factory

After the visit we were back to the institute, had a short discussion with Mr. Nandan Ghiya and again left for the next visit to a Wood factory in Malviya Industrial area owned by Mr. Samir Wheaton. He had working units at Delhi and Bangalore also where further assembling of the parts of the product were carried. He made furniture for hotels as wells as conference halls; majority of which were exported. Both contemporary and traditional designs were available. They used panel and solid wood machines, the raw materials were cut in separate premises. The wood was stacked into seasoning plant for drying and rotation took place every 15 days. The walls of the seasoning plant was made of high density thermocol with a cemented layer on it. Heaters were placed in both the corners to gather 20 liters of water every day. The three type of machine used were electrical, mechanical and pneumatic. The machines were highly developed and efficient enough to require minimum amount of manpower. Multiple boring machinery was one of the pneumatic machine which could make multiple holes at a time. four sided planned having 8 blades could plan the panel precisely from all the four sides at a time. The sawdust was sucked in the air bags through the pipes attached to the planner. This provided a safe and healthy work environment. The whole process was less time consuming. A blade block made of tungsten carbide was used to cut a curved surface. Another machine which worked from top to bottom made perfect grooves in one shot. Apart from the workshop, there was a design studio above where the designing and other processes took place. He also designed furniture using different materials such as cane, leather, metal and stone and the outcome was amazingly good.

Plastic Factory

From the wood factory we departed to a small pump manufacturing unit owned by Mr. Y.S. Bahti in Surdshanpura. There we saw the process of hand and press molding. They used delerine, a non-wearing plastic granules which is not recycled. Nylon66, a polyamide was also used to make spare parts of water pump. The plastic granules melted at a temperature of 80⁰ C. The plastic moulds were covered with magnet so as to use in magnet motors. Being a very small unit this could not provide detailed information about different processes in manufacturing plastic products. Mr. Bahti the took us to another small unit nearby where mainly polycarbonate and ABS were used for making the moulds or other plastic products.

Both the units were set up on a very small scale so in comparison to the metal and wood factories the plastic factory did not prove to be of much help to us.

During all our visits we also realized the practicalities of working in different mediums and how different each manufacturing processes are from another. The visit was a good learning experience as well as a good exposure to get the feel of industrial processes.

regards

ruchi

rajani - factory visit

Brief explanation about factory visit

Yesterday dated 21^st April 22, 2005 Mr.Nandan Ghiya had organized three factory visits:

• Recycled Aluminium sheet manufacturing unit & Machinery manufacturing unit
• Wood processing unit
• Water pump manufacture unit

At first we went to the recycled aluminium sheet manufacturer unit at Sudarshan pura industrial area. Mr. Rajendra Singh owner of this unit helps allot to understand the process of extraction of Aluminium from recycled Aluminium scrap products such as bus body part, wire scrap and also utensils scrap which is procured from the market within Rajesthan. They used to do the extraction as well as casting of molten Aluminium into sheets ready for making utensils or other product. Extraction of pure Aluminium by oxidation process is done in air blasted oil furnace at 650 degree temperature. By passing the chlorine gas within the molten Aluminium the impurities comes out in the form of fumes and remains on the surface. The pure molten Aluminium is taken out by tilting the furnace on one side and it is removed in a iron bucket. Then the molten metal is poured in iron book mould and after 30sec or 1min it is removed from it and then it goes for hot rolling where the thickness of sheet is reduced and the length of sheet increases but the width of the sheet remain same. After that sheet is cut into squares or circles depending on the requirement. The hot rolling makes the molecules of the sheet more cohesive and makes it compact. And lastly, annulling process increases the flexibility and reduces the strength of the sheet. The sheets were placed in annulling furnace at 400 temperatures for 1-2hr. Then the recycled Aluminium sheets are ready to sell. Mr.Rajendra Singh also shows the machinery manufacturer unit where machinery is made.

Then after post lunch we went to the Mr.Sameer Weaton’s wood processing unit in Malviya Nagar , graduate from NID also working as consulting designer for foreign export company. He showed us all the wood processing machine and how they work which was bought from U.K. The machines were very modern and technologically sound. He also showed some of their product which is for export such as conference table, some different type of folding chairs, also some mix material product like chair, sofa where he used leather, wood, stone and metal. As a design consultant, he also give us some basic ideas about design methodology which was very clear after seeing him product.

Then we went to Mr.Y.S Bahti’s water pump manufacturing unit in Sudarshanpura industrial area, where they used to make parts of pump using different plastic granules such as Nylon 66, Delerine, Polycarbonate etc, which they directly bought from the market. The parts were made by hand moulding tools. It was small unit so it does not help us as much as we expect.

This trip was a good exposure, which helped us to understand the possibilities in working with different material and also the associated problem areas. It also opened different avenues for further developing our product.

Rajani Pandey

vineet - factory vist

Yesterday’s factory visit was a real eye opener for all of us, as we came face to face with the practicalities and limitations regarding mass production and while working with a medium. On the other hand I also realized the various possibilities that can be worked upon on one or more than one material.

Our first visit was to an Aluminium sheet manufacturing unit in Sudershanpura industrial area. The raw material for the unit was aluminium scrap (utensils, bus bodies, wires etc) collected from traders all over the city. Bauxite (aluminium ore) is used only by bigger factories like Hindalco etc. The sheets they produced of thickness 1mm to 3mm were supplied to utensil making units where bowls and pressure cookers are made from aluminium sheets.

The scrap metal was first melted in an air blasted oil( highly viscous oil) fired furnace. Pure metal is extracted by oxidation process, in which the oxidized impurities are bubbled up. A quenching chemical, (cover flux , Salts + ZnO)is added to the metal for faster oxidation of impurities, which are collected from the surface of the molten metal.

The pure metal is then poured in cast iron book moulds so that we get rectangular blocks of pure aluminium. These blocks are then sent for hot rolling to form sheets. When cold these sheets are again rolled (cold rolling) to get the required thickness, in 30 hp roller machines.

When the desired thickness is achieved the sheets are then cut to size as rectangles, squares or circles.

Since rolling hardens the metal and it becomes very stiff, the metal sheet are sent for annihilation , in another furnace where indirect heat is applied till the temperature is maintained at 400 degree C and the metal becomes more flexible.

Mr.Rajendra Singh, the owner of this aluminum unit, also showed us another machinery manufacturing unit nearby for the continuous casting of aluminium, which was originally devised in Italy by Mr.Propergene.

Next we visited Mr.Sameer Wheaton’s Wood processing unit. Though the manufacturing units of his firm are in Delhi, Mumbai and Bangalore the raw material is processed here. The logs of wood brought here are cut into huge slabs and then seasoned in the seasoning chamber for 15 days. It is an air tight insulated chamber with blowers on two sides for the moisture in the wood to dry out (15-20 lts. drained out everyday). Usually it costs about 17-18 lacs, but the one there was a cheaper but efficient one. Though their production is low quantity wise (300-400 chairs per month), but they are high on quality.

Their unit had less manpower but they were well equipped with the latest machinery.

All the machines ( Wadkin) were imported from U.K. Few of the machines that we were shown were

• Pneumatic multiple boring machine – More than one hole at a time (with standard distances).
• Four sided planer – planes all 4 sides of a plank at once.
• Spindle moulder-- works from top to bottom for planing curved surfaces.
• Router – For making grooves , works from top to bottom.
• Panel saw – For cutting more than one planks together, or cutting wood at an angle (chamfer)

All machines worked with digital precision and all had saw dust suction mechanism, so that the workplace remained clean and the workers don’t inhale too much of saw dust.

The unit also had a tool shop where machinery was repaired regularly to maintain speedy production.

He also showed us his design studio and a few of his products which he tested for shelf life simultaneously. Apart from wood he had experimented with metal, stone, leather, bone and semi precious stones too.

We also went to two units which manufactured small plastic parts.

One of them was a submersible Water pump manufacturing unit belonging to Mr.Y. S .Bhati. Pastic granules were being injection moulded (at 80 degree C) by hand for small parts of the pump. The plastics being used by them were Nylon 66 (non recyclable), Delrine (non wearing plastic) , ABS plastic (opaque) and Poly carbonate (transparent).

We all really enjoyed the day, I specifically enjoyed the wood processing unit. It was very well managed and organized. Even with less manpower it was very efficient as they had invested in the best machinery to produce products high on quality. They also had a very strong design team which caters the export market.

shiuli - factory visit

Dear sir,

On the 21^st of April we went to visit three factories in Jaipur.

The visit to these factories was interesting. We got to understand the material and its properties or characteristics better. We were able to understand the processes that the raw material passes through to become the final product, much better by the practical exposure given to us.

All the three factories visited were small scale factories. The factories visited were

• Aluminium factory
• Wood factory
• Plastic factory

Our first visit was to an aluminium factory, at Sudarshanpura.

This factory used scraps, wires, bus body parts and recycled products as their raw materials. They made sheets that would be used to make utensils, pressure cooker, bus body parts and wires.

Process in brief:

They collected the scraps, wires and body parts, and dumped it in the Air blast oil furnace. Due to the air pressure within the furnace created by the blower attached to it, and the furnace oil, which is used as a fuel, at a temperature of 650^oC, the aluminium melts. The capacity of the furnace in this factory was 800kgs.

After this the process called the ‘cast iron book mould’ was carried out. In this molten metal sheets were given in a book form with a particular thickness.

Further these sheets would pass through the machine, which would carry, on the process of ‘hot rolling’, this would soften the metal. The sheets would then be carried to another machine in which the cold rolling process would be carried out. It was used to stretch the sheets to a desired length. Finally ‘analing’ is carried out in a furnace in order to release the hardness of the metal sheet. The sheets were further cut into square and circular shapes.

There were seven people employed in this factory. They made sheets that is sold at a whole sale rate. They made aluminium sheets of different thickness to cater to the local market.

Wood Factory

This factory was of Mr. Sameer Wheaton, a product designer, presently working as an design consultant. They made products mainly for export.Here in Jaipur they carried out only one part of the complete process. their main factory was in Delhi.

Various kinds of wood like teak wood, sheesham, saghoan, rose wood along with plywood and sun mica were used to make furniture. Here we saw machinery that is of high quality and very efficient. The health of the workers was taken care as the machine had sawdust suction, the machine had various blades that worked precisely. The process required less man power and yet did the job proficiently. Various electrical, pneumatic and mechanical machines were used in the whole process.

The wood is stacked in a criss cross manner. There are different process carried out like the ‘seizening process’, the planar used was four sided planar, and multiple sided boring machine used for boring.

Wide range of foldable furniture, combination of different materials for making innovative furniture. They worked in stone, metal, leather and bone.

Plastic Factory

After visiting the wood factory we went to another factory at Sudarshanpura.

This factory made pumps that are used in coolers. They used plastic granules of dalerine which is a non-wearing plastic and it can’t be reused; the other types of granules used were polycarbonates and ABS.and nylon 66 which can be used again and again. The temperature used to melt the plastic is 80^oC. The process used was hand molding; they used different moulds for different products. The assembling of these parts was done at the same place.

This factory visit was a good exposure to us. It gave a new dimension to our learning process.

neha - factory visit

Comments on Factory Visit

We visited 4 units on the April 21, 2005, primarily recycled aluminium sheets manufacturing unit, machine making unit, wood processing unit and water pump manufacturer. All the four visits have given us a fair idea about certain manufacturing processes and sufficient background information to explore these processes further.

On our first visit to the aluminium sheet manufacturer, Mr. Rajendra Singh, showed us how scrap metal is collected, from where it was collected, how it is melted in an air blasted oil fired furnace at 650 degree Celsius. The technicalities involved during the melting process were also explained like the use of chlorine and flux. He even showed us where the air was blasted in from and the furnace oil that was used. He even demonstrated how the hot molten metal would be poured from the furnace into the moulds. We were shown book moulds and how other kinds of moulds could be used according to requirement. This was followed by the hot rolling and cold rolling of sheets, where the metal gains compactness. The required thickness of the sheets was determined during the rolling process and can be varied changing the amount of pressure applied. Then the sheets are cut into circular sheets or square sheets. The final process was the annihilation process, where there is strength release and it is done at 400 degrees Celsius.

We then visited another unit belonging to the same people where they manufactured machines, based on the principle of continuous casting of material. This was particularly interesting though difficult to understand. We saw a worker make groves of a big roller that would be used to manufacturer sheets used to make the bus body.

Post lunch, we visited a technically sound wood processing unit. Here, we meet Mr Samir Weaton who was a furniture designer. He gave us a brief but a very comprehensive description on how wood is processed. We were shown how logs of wood were first cut into planks and then seasoned for around 15 days. Seasoning of wood involves putting it in a air tight room with a heater, which heats the wood sufficiently to remove all the excess water. We were then taken around the unit and shown the hi-tech machines like multiple boring machine, 4 sided planar, spindle, router etc. What amazed us the most was the efficiency and precision with which the machines worked. We were also given a glimpse into the room where they tested the shelf life of products, their design studio and the tool shop. We were also explained how they dispose their waste. What was more interesting was the process followed for designing for international buyers and the factors taken into consideration then.

Our last visit was to a water pump manufacturer, who also manufactured the small plastic parts used in the pump. We saw how plastic granules are put into a mould at a particular temperature. This unit was a very small unit where most things were done manually.

On the whole, the trip was very informative.

veenu - factory visit

We went to visit 3 factories on the 21^st of April. These factories were small-scale units. It was a great learning experience where we saw to processes involved in the making of raw material to the final product. The learned the steps involved in procurement of raw material, making of different parts and assembling of these parts.

Aluminium Factory

This factory procures the scrap of waste pressure cooker, bus body, old coins and wire scrapes from the local market. Air blast oil fired furnace is used to melt the aluminium; here cover flux is added to segregate metal and its impurities. The molted metal in then pored into cast iron book moulds and then it goes through hot roller. Cold roller is used to stretch the thick metal sheet into the required thickness. Finally analing is carried out in a furnace in order to release the hardness of the metal sheet. These sheets of aluminium, after being cut into required shapes, are sold to the factories that make pressure cookers, utensils and bus body parts.

Wood Factory

This factory uses wood like saghoan, teek wood, sheesham, rose wood along with plywood and sun mica was used to make furniture. Their work is of high quality and precision is taken into account. Most products are exported and some are made for the local market also. As the machinery are very efficient so less manpower is required and the process is done faster. There were machine had sawdust suction which ensure better health of the workers. They made special blades for different range of styles in the furniture. Various electrical, pneumatic and mechanical machines were used in the whole process. Wide range of foldable furniture, and combination of various materials were used to create innovative furniture. Lots of experimentation was done in stone, metal and different leather.

Plastic Factory

This factory made pumps that are used in coolers. The plastic granules of dalerine which is a non-wearing plastic and which can’t be reused was used here. Nylon 66 which can be reused is also used here. The temperature used to melt the plastic is 80^oC. The process used was hand molding; they used different moulds for different products. The assembling of these parts was done at the same place. The other types of granules used were polycarbonates and ABS.

manoj - factory visit

That's a wonderful day in our design and manufactur learning process.

every day we use so many little-little thing, diffrent-diffren metrail but we do not

know and we do not try,what is the makeing process those thing.

But today i obsearvation a so many thing -

# Manufacturing

# Metarial

# Machineries

# Technologcal process

# Design

# Production

# Quality

# Raw metarial

# Teachnologcal langeauge

# Management

We visited three fecatory(manufacturing place)

# Alumaniam fectory

# Fanutuare(wood) workshop

# Plastic factory

That was a very nice experiences witch i will use in our desing meathodology class.

I appreciating most of the wood workshop of sameer whetan.

Everybody learnt so many things and apply in their design future.

thank you sir

manoj

rajesh - factory visit

hello sir,

very good morning. yesterday april 21, 2005 we went to visit the factories, it was not only a visit but also the process of learning the process .

that was a obsearvation wich we will apply in our next design future.

abut 9.35 a.m. went to a metal factory (AL 2, melting process) basicaly that was a recycaling process of AL 2

2.30 went to a wood workshop of sameer wheaten that was a very very nice experince their management, machinry, and their quality of products was excleant. sameer wheaten said "janarly wood work mai log sochate hai ki ek aad m.m. chalta hai but international standered mai aisa nhi chalta half m.m. matlab half m.m. " it shoes his precission in work.

4 p.m. went to two plastic factory we saw their water pump making process molding and and different kinds of plastic . all the visits are froutfull for us and hopp we will apply in aur design methodology class

thankyou sir

rajesh

factory visit - nandan

hi dinesh

hope you are well. took the students to see alumium
casting rolling melting etc. took them to sameer
wheaton's factory for wood. a state of the art factory
with a customized seasoning unit. WOW!! thank you sir.
as am also a student in all this.

n we ended with plastic units, places operating on
small scale  using hand moulding techniques.

see you on monday. m also going to ahmedabad for
weekend. some work

warm regards
nandan

monday morning

see you all on monday morning.

do email your comments after the factory visits or post the same on the blog.

visualise what changes you would make to the products that you have designed to make them manufacturable. (in sketches)

warm regards.
dinesh

Re: not good

nandan
please get the batch excused from the exhibition or work right through the weekend - friday to sunday too. this phase is important or i might as well not come back on monday. please discuss with cvs and keep me informed.
warm regards.
dinesh

not good

hi dinesh,

how are you? it's not going good here. the students
are showcasing their work at jawahar kala kendra in a
three day exhibition. so, since friday, the day after
you left, they have had the classes suspended. this
will go on till tomorrow.n then i get only thursday
with them for  factory visits, as friday is a holiday
again. n then u are back  on monday. quite
disappointing. so let's see how much we can do in that
one day.

hope you are well

warm regards,

nandan

nandan fotifying for the coming week 

prabal 

anang 

design so far - anang 

vineet 

design so far - vineet 

shweta 

design so far - shweta 

rajani 

design so far - rajani 

disha 

design so far - disha 

design so far - disha 

rajesh 

design so far - rajesh 

ruchi 

design so far - ruchi 

raj vardhan 

design so far - rajvardhan 

learning so far - neha

Design Methodology – Email Assignment

‘Get prepared to get confused’ – thats the brief we were given for our design methodology course. We had started our design methodology course fully prepared to get confused.

Our first week of design methodology has taught us to observe keenly and think right from the first day. The introduction session was quite unlike other classes, where we would introduce ourselves and give a brief about our educational background. Here we were asked to say what our greatest fear was and also repeat our batch-mates fear. To be very honest, this was not something I had really thought about earlier. So the first thing I learnt was to identify my fear. The more important thing was that we learnt more about each other. In order to recall everybody’s fears we had to concentrate when each of us were speaking.

This was followed by an exercise to design 3 varieties of combs for a venture capitalist. So the comb had to be a million dollar idea. Firstly, we had to identify problem areas which we could use as opportunities to develop innovative design for combs. The designs developed by each of us were presented. This presentation was very good fun, we could freely criticize or appreciate our colleagues ideas. I learnt to identify opportunities and more clearly understood the role of innovation in design process.

In the latter half of the day, we were asked to go to the market and buy a product for Rs. 10/-, but the condition was that the product had to be something special, something that would make us happy.

The next morning we were send back to the market to buy the product, because we had not successfully completed the above exercise. Our objective was not very difficult to meet, because Jaipur is a very rich city. Our observations were very focused on interesting thing which fit in our budget. On our return to class, each of us were to display what we had bought, choose any one product and discuss what we found interesting. We were to split into pair and each of us were to play around with the chosen object, while our partner would made atleast 20 observation. It was these observations that would later give us clues to develop our concepts. These observations were also to be presented in class

We concluded the day with a very interesting exercise – making pairs of people and observing how your partner eats ice cream. Initially the action of eating appeared to be very simple but then we realized that we really had to observe very keenly to make valid observations. The observations we made would be incorporated in the suggestions we made to the ice cream manufacturer, regarding the products, the packaging material etc. We learnt to make observation keeping the user as our prime focus, in terms of how the user feels, what problems does he face, what his reactions are etc.

We then saw a very unconventional movie made by CNBC, called Deep Dive, on how an California based company called IDEO uses unconventional way to develop innovate products for varied companies. The most important things I learnt from the movies was to think as wild as you can, as it is only through these wild idea that we can develop new products. Also that one can achieve wonders through team work.

This was followed by a talk on what affordances are. We also demonstrated the process of ‘Bissociation’, where we took a particular and brain stormed about objects we would not associate with it and then thought of way we could connect the two.

We also had a session where we had to thing of really wild product that we had never seen earlier. We had to make a prototype of the product we had conceptualized, by a process that is called QADP – Quick and Dirty Prototyping. We also discussed the various domains involved i.e. the user, buyer, manufacturer and entrepreneur and what are the concerns of each of these domains.

design so far - sudeepa 

vartika 

design so far - vartika 

neha 

design so far - neha 

veenu