Traditional Fireworks of Barpeta Barpeta District, Assam

DesignClinicSchemeofMSMEJuly2014:NASReport:ShirsenduGhoshonBarpetaTraditionalFireworks,BarpetaDistrict,Assam

TraditionalFireworksofBarpetaBarpetaDistrict,Assam

InteractiveNeedAssessmentSurvey&Design

StudyReportforDCSMSME

Micro,SmallandMediumEnterprise(MSME)DesignClinicScheme

July2014

DesignExpertShirsenduGhosh

Fourth Dimension 8986459632,8294140504

[email protected],[email protected]

WithsupportofDistrictIndustry&CommerceCentre,(DICC),Barpeta,Assam&

NIDMSMENorthEastRegionalOffice,Guwahati,Assam


PrefaceWethankNationalInstituteofDesign(NID),AhmedabadandMinistryofMicro,SmallandMediumEnterprises(MSME)forprovidingtheopportunitytocarryoutthisproject.ThisReport intwoparts isprepared inpartial fulfilmentofDesignAwarenessProgrammeunderthe MSME scheme. The main objective of this document is to highlight the status of BarpetaTraditionalFireworkclusterofBarpeta,Assamandmakerecommendationsforthebettermentofthecluster,withfocusondesigninterventionatvariousstages.Thereportalsoattemptstobringoutotherconcernedissueswhichhavebeenmentionedofthereportaftertheinteractivedesignsurvey.The main source of information was from the proprietors of the MSMEs units the primarybeneficiaryoftheprogramme.Alloftheinformationwasgatheredoveraperiodoffivedays(1115July,2014)undertheframeworkofMSMENeedAssessmentSurveyguidelines.Thedesignexpert is thankful toShriDilipKumarBarua,GeneralManagerDICCBarpeta,HimadriDas, Extension Officer, DICC, Barun Burman, Office Assistant, DICC Barpeta, Ms Nilufar Sheikh,Project officer NIDMSME North Easter Region, Gopijit Pathak, Proprietor Barpeta Atisbazi andothermembersfortheirunconditionalcontribution.30July,2014 ShirsenduGhosh,

FourthDimension


Contents

DesignClinicSchemeforMSME..........................................................................4Schemeinformation.........................................................................................4RoleofDesigninImprovingCompetitiveness:................................................4DesignClinicSchemeforMSME.......................................................................5

NeedAssessmentSurvey.....................................................................................5Objectives:........................................................................................................5Methodology:...................................................................................................5ExpectedDeliverables:.....................................................................................5Participants.......................................................................................................5

NeedAssessmentInteractiveSurvey................................................................17ProcessadoptedinconductingtheInteractiveSurvey.................................17

FindingsfromsurveyoffiveMSMEsincludingissuesandsuggestions............18UNIT1:AssamFireworksIndustries...............................................................18UNIT2:ManisunaAtasbaziUdyog.................................................................30UNIT3:LaxmiFireWorks...............................................................................40UNIT4:MonaranjanFireWorks.....................................................................50UNIT5:BarpetaAtasbazi................................................................................51Packaging&LabelsofcompetingfireworkbrandsinretailmarketofNorthEastregion..........63SWOTAnalysisofBarpetaTraditionalFireworkclusters...............................64DirectionsAhead:...........................................................................................68

Designprojectopportunitiesatclusterlevel....................................................70


DesignClinicSchemeforMSMESchemeinformationTheMicro,SmallandMediumEnterprises(MSME)sector isdescribedastheengineofeconomicgrowth forpromotingequitablegrowth.ManycountriestheworldoverhaveestablishedaSMEDevelopmentAgencyasthenodalagencytocoordinateandoverseeallgovernmentinterventionswithrespecttothedevelopmentofthissector.TheMSMEsareavitalpartoftheIndianeconomy.Theycontributetoover45percentofindustrialproductionandaround40percentofthetotalexports.Thereareabout13millionMSMEsinIndia,whichemployabout31millionpeople.ThusMSMEsarethesinglelargestcontributorintermsofemployment generation, besides production and export revenues in the manufacturing sector.PresenceofMSMEsisseeninthevaluechainofalmostallmajorindustrysectorslikeautomotiveindustry,garmentsandtextileindustry,leatherindustryanddrugandpharmaceuticalindustryetc.RoleofDesigninImprovingCompetitiveness:Designisanapproach,processandmethodology.Designisintended,purposeful,contextual,whichisaimedtocreateadvantage,distinctandfuturisticoutcometotheexistingscenario.Designbeingasystemicandholistic innaturehelpsingeneratingmorecreative,higherimpactandsustainablesolutions. Design intervention in business is to create value addition to existing products andservices.Throughdesignprocess,MSMEscanaddvaluetoproducts,services,andintheprocesstotheirfirms.Design,innovationandgrowtharecloselylinked.Innovationanddesignarenotsimplyabout new products or technology. They are also about how to improve/diversify products foreverydayuse,leadingtoreducedcosts,increasedutilityandacceptabilityresultinginnewbusinessopportunities.ItisrecognizedasaninnovativedisciplinethatcanhelpMSMEstosustainandgrowincompetitivemarket.DesignClinicSchemeforDesignExpertise toMSMEs,auniqueandambitiousdesign interventionschemeforthecountry'smicro,smallandmediumscaleenterprises, isaninitiativeofMinistryofMSME,GovernmentofIndialaunchedunderNationalManufacturingCompetitivenessprogramme.ThemainobjectiveoftheDesignClinicSchemeistobringMSMEsectoranddesignexpertisetoacommon platform and to provide expert advice and solutions on real time design problems,resulting in continuous improvement and value addition for existing products and services. Thismodel brings exposure to design thinking and process to the door steps of industry clusters fordesign awareness, improvement, evaluation, analysis and design related intervention andapplication.Designclinicschemewillassistclusterstoopenachannelfordesigninformationinflowfor creative, innovative and futuristic approach towards products, processes, operations,manufacturingandbusinessdesign.The schemewill help generate insight for opportunity identification and design intervention forcompetitive and breakthrough solutions forMSMEs. The objective of Design Clinic scheme is toenhance industry competitiveness and productivity with the help of design intervention andapplicationatvariousfunctionallevels.DesignClinicSchemeisstructuredtoprovidedesignrelatedhelpthroughdesignawarenessseminar,designawarenessprogrammeanddesignprojectstogivedesigninputstoproductsandservicesofMSMEstoenhancecompetitiveness.Theschemeprovidesfinancialassistanceatdifferentstagesforbetterimplementationofschemeanddesignawareness.NationalInstituteofDesign(NID),AhmedabadassiststheMinistryofMSME,GovernmentofIndia,asNodalAgencyforimplementationofthescheme.


DesignClinicSchemeforMSMEFor easy percolation of design thinking and philosophy and maximum benefit for MSME unitsimplementation of theDesign Clinic Scheme is spread into following 3 broad areas. These areashelpinsmoothtransitionofdesigninterventiontoMSMEindustrialandbusinessclusters.1.DesignAwarenessprogramme

a.NeedAssessmentSurveyb.DesignClinicWorkshops

2.DesignAwarenessSeminar3.DesignProjects(handledbyDesignProfessionals/StudentDesigners)NeedAssessmentSurveyObjectives:Theobjectiveofneedassessmentsurveyistogeneratedetailedclusterinformationtounderstandthecoreissuesrelatedto:

RawMaterialatdifferentstagesofmanufacturing Infrastructuresetupandworkstation Skillandtechniques Surfacedesignpatterns,styles,motifsandpaintings Productform,shapeandusage Toolsandtechniquesinuse Capabilityoftheclusterproducingunit PresentMarketstatus Customerexpectationandbehaviour CurrentCompetition Packaging,logisticandstorage Exhibition,displayandmerchandising Licence,Insurance&SafetyIssues

Methodology:

Questionnaire surveyofownersof a sampleofmanufacturingandsalesunits.Discussionwithunitownerandartisans

Processobservationofartisansinaction Findtracesfromearliertechniqueandusageoftoolsandmaterial Selfobservationandanalysis.

ExpectedDeliverables:Thisextensivedesign research is intendedtoprovidequalitativeanddetaildataof thecluster togenerate insights about this craftwhichwouldhelp to address the existing problems and futureopportunityareafordesigninterventionorscopeswhichcanbefurtherworkoutandcanbetakenupduringthedesignclinicworkshopandareastakenupasdesignprojectswithinandoutsidetheclusterscenario.ParticipantsTheNeedAssessmentStudythedesignsurveywasconductedbythe

1. DesignExpert,ShirsenduGhoshinconsultationwith2. FiveownersofBarpetaTraditionalFireworkMSMEunitsinassociation3. DistrictIndustry&CommerceCenterBarpataAssam4. National InstituteofDesign,AhmedabadandMinistryofMicro, Small andMediumScale

EnterpriseNIDMSMENorthEastRegionalOfficeGuwahati,Assam


AssamataGlanceFounded:August15,1947Population:30.94million(2012)Area:78,550kmsCapital:DispurDistricts:23Languages:Assamese,Bengali,Bodo&KarbiLiteracy rate: 64.28% (male 71.93% &femaleliteracyrate56.03%)Assamis a state ofIndiain thenortheastern region located south of theeasternHimalayas, comprisingtheBrahmaputraand theBarakrivervalleys along with theKarbiAnglongandtheNorthCacharHills.Thestate is surroundedby sixof theothersevensister states:ArunachalPradesh,Nagaland, Manipur, Mizoram, TripuraandMeghalaya.GeographicallyAssamandthesestatesareconnectedtotherestofIndiavia a narrow strip of land inWest Bengalcalled theSiliguri Corridoror "Chicken's Neck".AssamsharesinternationalborderswithBhutanandBangladesh.Assambecameapartofthe British India after the British occupied the region following theFirst AngloBurmeseWarof18241826.

Assam can be broadly divided into threedistinctphysicalunits, theBrahmaputraValleyin the north, the Barak Valley in the narrowprotruding south, and the states hilly regionseparatingthetwovalleys.BriefHistoryofAssamThe region of Assam was mentioned by theChinese explorer Chang Kien as having tradelinkswithChinain100B.C.ThePeriplusoftheErythrean Sea and Ptolemys Geography alsoacknowledgetheexistenceofthisstatebeforeChrist. The Australoids or the preDravidiansweretheearliest inhabitantsofthisstate.But,itwere theMongoloidswho entered the landthrough the eastern mountainous passes andoverrun the land long before the time of the

compilationoftheHindureligiousliteratureknownastheVedas.


In the Vedic literature, the state has been mentioned as the land of Kirats withPragjyotishpur as the capital. In the epic Mahabharata, it is mentioned that the Kiratsfoughtagainst thePandavas.HuenTsang, theChinese traveller,visited this region in the7thcentury.Atthatpointoftime,PragjyotishpurwasknownasKamrup,whichwasthenastrong kingdom under King Bhaskaravarman. However, after this there was a gradualdecline of this region and subsequent centurieswerewitness to repeatedonslaughtsbyaboriginalsthatreducedthepowerofthekingdomandledto itsfragmentation. ItwasatimewhennosinglepowercouldholdswayinAssam.

With the advent of the Ahoms, thecenterofpower shifted fromKamrupin Lower Assam to Sibsagar in UpperAssam.The importance of Lower Assamdeclined sharply, except for a shortperiodintheearly16thcenturywhenthe Koch dynasty extended theirwestern limits considerably undertheir illustrious king Naranarayana.TheMughal Empire was at its zenithduring this timeand they took itasa

challengetocrushtheAhoms.Theyattackedthestate17times.Thelastofthewarswasfoughtnear thepresentdaySaraighatBridgeover theriverBrahmaputra inGuwahati. Inthiswar,theAhomsgavetheMughalsacrushingdefeatundertheleadershipoftheablegeneral Lachit Barphukan. Lachit Barphukan achieved immortality for his heroism andmanyanecdotesarenowanintegralpartofthefolkloresofAssam.The next centuries spelled troubles for this kingdom and save for a brief interventionduring the reign of king Rudrasingha, the state went on a gradual decline in the 18thcentury.ThiswasthetimewhentheBurmeseattackedthisstateandannexeditintotheirempire.However,theycouldnotholdswayontheregionforlongandin1826theBritishforcedthemtocedeAssambytheTreatyofYandaboo.With the rest of India, Assam also played animportantroleinthewarofindependence.Itwasdeclareda stateunder theUnionof Indiain 1947. At that time, except Manipur andTripura, thewholeof theNortheast region wascalled Assam. However, due to strongregional distinctions, all of them werecarvedoutas separatestates, startingwithNagaland in1963andendingwithArunachalPradeshin1972.


DistrictsofAssamAssamisdividedinto23districts:Barpeta,Bongaigaon,Cachar,Darrang,Dhemaji,Dhubri,Dibrugarh, Goalpara, Golaghat, Hailakandi, Jorhat, Kamrup, Karbi Anglong, Karimganj,Kokrajhar, Lakhimpur,Marigaon,Nagaon,Nalbari, North CacharHills, Sibsagar, Sonitpur,andTinsukia.EconomyofAssamTeabased industry occupies an important place in Assams economy. The 850odd teagardensinthestateoccupyanareaofabout2.31lakhhectare.Assamisknownforitsrichforestwealthwithvarietiesoffloraandfauna.Coal,petroleumandnaturalgas,limestoneandminorminerals are produced in the state. Coal occurs inDibrugarh, Tinsukia,NorthCachar Hills, Sibsagar, and Lakhimpur districts. Assam is primarily an agriculture state,whichaccountsforthelivelihoodofaboutfourfifthsofthestatespopulation.Morethan70 percent of the workforce is engaged in agriculture and allied activities. Rice is theprimary foodcrop;cashcrops like jute, tea,cotton,oilseeds, sugarcane,potato,etc.,arealso grown in the state. Also grown on a small scale are horticulture crops like orange,banana,pineapple,arecanut,coconut,buava,mango,jackfruit,etc.RiversofAssamAssam has extensive river system consisting of the Brahmaputra, the Kusiyara and theBarakandtheirtributaries.AlltheriversinAssamareliabletofloods,mainlybecausetheyreceiveheavyrainfallwithinashorttime.Theseriversareintheirearlystageofmaturityandareveryactiveagentsoferosion.Theriverwaterscollectatremendousamountofsiltandotherdebrisandraisetheleveloftheriverbeds.Therefore,itbecomesimpossibleforthemainchanneltocopewiththevastvolumeofwaterreceivedduringtherains.EducationinAssamAssam has an overallliteracy rate of 64.28%.While male literacy rateis at 71.93%, the femaleliteracy rate however isonly at 56.03%. Assamhas one of the largestnetworks of highereducation in the entireNorth East. Theinstitutions like theIndian Institute ofTechnology, Guwahati,National Institute ofTechnology, Silchar andGuwahati University areamong the top institutesof the country that


provide quality education to the students. The state has five universities; one deemeduniversity,one instituteofnational importanceandagoodmanynumberofprofessionalcolleges.Arts&CultureofAssamAssam is rich in culture, ethnic groups, languages/dialects spokenand literature. It is known forAssam tea, large and old petroleumresources(thefirstoilreservesofIndiawerediscoveredinAssaminthelate19thcentury),Assamsilkandforitsrichbiodiversity.Assamhas successfully conserved the onehornedIndian rhinocerosfromnear extinction, along with thePygmy hog, tiger and numerousspecies of birds, and it provides one of the last wild habitats fortheAsian elephant. It is becoming an increasingly populardestination for wildlife tourism, and KazirangaandManasarebothWorld Heritage Sites. Assam was also known for itsSaltreeforestsandforestproducts,muchdepletednow.Alandofhighrainfall, Assam is endowed with lush greenery and the mightyriverBrahmaputra, whose tributaries andoxbow lakesprovide theregionwithauniquehydrogeomorphicandaestheticenvironment.The major handicrafts of the state include making furniture from cane and bamboo,handloom weaving, jewellery making, sitalpati (or mat making), brass and bellmetalproducts, pottery,woodwork, and kuhila koth (or fibreweaving). PeopleofAssamuse avast range of handwoven fabricswith intricate designs. Local silk occupies a prominentplaceintheAssamesesociety.Traditionalgarments(ChuriaformenandMekhelaChadorfor women) are used for social and religious events. With growing impact of westernculture, traditionalattireshavegivenway towesternclothesandmajorityof thepeoplecanbeseenintheseclothesonly.FestivalsofAssamRongaliorBohagBihuisthemainfestivalofAssam.ItderivesitsnamefromtheSanskritVishuvam when day and night are rendered equal through the vernal equinox. Peoplewelcome the spring season and pray for a bountiful and rich harvest. This festival iscelebrated in themonthofBohag (midApril), the firstmonthof theAssamesecalendar.TheexactdateintheEnglishcalendarvaries,butthefestivalnormallystartsfromthe13thdayofthemonthofApril.OtherBihusareBhugaliBihu(alsoMaghBihu)andKangaliBihu(alsoKatiBihu).


BarpetaDistrictataGlanceBarpetadistrictisoneofthemajorcitiesinWestern Assam,Indiaand is districtheadquarters. It came into existence in1983 as a separate district in Assam. It islocated 98 kilometres through HajoDaulahal road northwest ofGuwahatistate capital. There are regular busservices available between Barpeta AndGuwahati (Assam State TransportCorporationformISBT,privatebusesfromAdabari and also regular private publicvehiclesfromJhulukbari,Adabari/Hatigaonof Guwahati. Train route is connectedthrough Barpeta Road (18 KM fromBarpeta Town) and airport and port isLokpriya Gopinath Bordoloi InternationalAirportandDhubrirespectivelyBarpeta is located at26.32N 91.0E. It has an average elevation of 35metres (114feet)with subtropical climate,with chillywintersandhothumid summers. It is44kmaway isthegateway toManasNationalPark,oneof the largest forestsofAssamandoneof thefewtiger reservesof India.Thereare threerivers Chaulkhowa,MoraNodi (DeadRiver)andNakhanda,bothofwhicharetributariestoBrahmaputrarunthroughthetown.BarpetaDistrictprofilePopulation2011BarpetadistrictranksfifthinoverallrankingamongthedistrictspopulationsizeinAssam.Percentage to total population of the state is 5.43. In 2011, Barpeta had population of1,693,622.SexRatio inBarpetaasper2011censuswas953per1000malecomparedto2001 census figure of 937. The average national sex ratio in India is 940 as per latestreportsofCensus2011Directorate.In2011census,sexratioforchildrenbelowsixyearis961girlsper 1000boys. SexRatio inurban regionof Barpetadistrict is 959 asper 2011censusdata.InruralareasofBarpetadistrict,sexratiois953femalesper1000males.LiteracyRate2011AverageliteracyrateofBarpetain2011was63.81comparedto56.00of2001.Ifthingsarelooked out at genderwise,male and female literacywere 69.29 and 58.06 respectively.LiteracyrateinruralareasofBarpetadistrictis61.47%aspercensusdata2011.UrbanPopulation2011OutofthetotalBarpetapopulation for2011census,8.70percent(total147,353) lives inurbanregionsofthedistrict.RuralPopulation2011Asper2011census,91.30percentpopulation(total1,546,269)ofBarpetadistrictslivesinruralareasofvillages.


Description 2011 2001

ActualPopulation 1,693,622 1,394,755

Male 867,004 720,069

Female 826,618 674,686

PopulationGrowth 21.43% 19.62%

AreaSq.Km 2,282 2,282

Density/km2 742 521

ProportiontoAssamPopulation 5.43% 5.23%

AverageLiteracy 63.81 56.00

MaleLiteracy 69.29 64.23

FemaleLiteracy 58.06 47.16HistoryofBarpeta

The word Barpeta (b(r)pet/b(r)pi:t (Assamese: ) is derivedfromBarmeaningbigandPetameaningpond.ThusBarpetameans"landofbigponds".Inoldendays,Barpetawas fullofbigponds.Anearby town is Sarupeta, thewordwhichexactly means opposite to the former. In ancient times, Barpeta was partofKamapithadivision ofKamarupa.Medieval invaders continue to callWesternAssamasKamrup. In colonial and postcolonial times, it became part ofKamrup districttill 1983,whennewdistrictofBarpetawascarvedout.Barpeta is also famous for the various temples in thedistrict. It has been a place of great religioussignificance and was known by various names likeTatikuchi, Parabhita, Mathura, Choukhutistan,Nabaranta Sabha, Kamrup etc. It was Koch KingNaranaraya who founded Barnagar (Sarbhog) thepresent district which formed an integral part of theKochHajoandAhomkingdomtilltheBritishtookover.Barpeta is famous for the Satra known as BarpetaNamgharorKirtangharacongregationalprayerhallfoundedbySriMadhabDev,agreatdiscipleofSrimantaSankardev,infifteenthcentury.


TheiconicSattratemplesandthefamous'doi'oryoghurtdistinguishBarpetadistrictfromothers. Barpeta is known for Barpeta Sattra Vaishnavite and Neo Vaishnavite Sattrasscattered all around the town and adjoining areas, important aspect of town's tourismsector.BarpetaSattraisoneofthelargestandpowerfulSattraofAssamattractsdevoteesfromeverynookandcornerofAssam.BarpetaSattraowns22Hatilandi.e.equivalenttoonetown.TheBarpetaresidentspaylandholdingtaxtoBarpetaSattra(trust)andnottoMunicipalitytilldate.All landsaleandpurchaseinBarpetahastohavepermissionoftheSattra.ThisSattraislocated2kmnorthofBarpetatownandfrequentedbylargenumberofdevoteesandvisitorsasitwasaculturalcentre.ItwasherethatPaalNamandBeerNamorThiyaNamwascreatedbyShriMadhabDev.Alargenumberofitemsusedbytheguruincluding Sachipatputhis are still preserved here. Some of the surnames have anassociationwiththerolestheydischargedfortheSattras:

Pathak:TheyreadtheSattraversesknownasputhis Gayan:Singers Bayan:Theyplayedinstruments Sutradhar: Their rolewas to prompt dialogues behind the stagewhichwas to be

narratedbytheartist/performer Ojha:TraditionaldancedramaperformersinSattrapremise Das:SattraDasitaskwastokeepthepremiseclean Hazarika:TheywerefishermenandduringSattracelebrationstheysuppliedfishes

tothepilgrimsanddevotees

Holifestival iscelebratedatBarpetawithpompandgrandeur.ThepeopleofBarpetaareveryhospitableandlivepeacefullymaintainingunityandfraternity.PoliticsBarpeta is a Lok Sabha constituency and it has seven Assembly constituenciesJania,Baghbar, Sorbhog, Sarukhetri, Bhabanipur, Chenga and Barpeta. Syed Abdur Rouf, A.FGolam Osmani and other prominent persons represented the Barpeta constitutionalassembly. Indian presidentFakaruddin Ali Ahmedwas aMember of Parliament from theBarpeta.Amedical college&hospital FakharuddinAliAhmedMedicalCollegehasbeennamedwithformerpresidentofIndia.


ImagesofBarpetatown


HistoryofIndianFireworksIn early 20th century, aMrDasgupta set up aMatch factory in Kolkatawith small semiautomatic Japanesemachines, framesandgadgets imported from Japan.Hemade someexperiments with coloured matches. During that time two enterprising young men, MrShanmugaNadar andMr IyaNadar (cousin brothers), headed for Calcutta. The saw thesmallJapanesematchfactorynexttothelodgetheystayedin.Theybroughtwiththemfewmaterials and attempted to make their first matches in Sivakasi. During this period,colouredmatches and Starmatches were imported from Germany. Books on chemistryhelped them to improve the quality of their products. Having achieved a measure ofsuccess in safetymatches, colouredmatches and startmatches, they ventured in to themakingof sparklers thenthemostpopular insmall fireworks inUKandGermany.Chinawasthenexportingonlyfirecrackersofseveralsizesandrangesbutnootherfireworks.The germinal seed for themaking ofmodern family of fireworksor small fireworkswasplantedintheyear1934whenCentralExciseDutyonMatcheswaspromulgated.UntiltheoutbreakofWorldWar II in1939, therewereonlyhandfulof factories inSivkasi,Trichurand Irimjalakuda in Kerala state. From 1938 to 1944 the import of fireworks andfirecrackerswasobstructedbywar.Theshortagegavea fillip tothe indigenous industry,whichwas in its infancy.During theyear1940, the IndianExplosivesRuleswereenactedwherebyasystemoflicensingwasintroducedformanufacture,possessionandsale.Thuscametobesetupintheyear1940thefirstorganisedfactorywithseveralprecautionsandsafetymeasures.Theshortageinthemarkethelpedthese,thenseasonalfactoriestoworkevenduringoffseasonandbuildupstocks.WithWorldWarIIcomingtoanendandthegatewayforimportofrawmaterialwasreopened,theindigenousindustryenlargeditself.Theexistingfactoriesbroadenedtheirefforts;therecameintoexistenceseveralnewunitsofwhichNationalFireworks,KaliswariFireworksandStandardFireworkswereprominentintheyear1942.Therefactoriesstartedmarketingtheirproductsthroughthelengthandbreadthof India.By theyear1980 thenumberof firework factorieshad risen in189,byendof1986totalnumberoffactorieswere260inTamilNadualone.Otherstatesalsotookupthisproduction.Past15yearshaveseenorganisedfactoriesstartingupinMaharashtra,Gujarat,Karnataka,AndhraPradesh,WestBengalandUttarPradesh.ThisphenomenalgrowthwasduetorequisiterawmaterialssuchasnitratesofBariumandStrontium, Potassium Chlorate, Red Phosphorous, Zinc Oxide, Pyrotechnic Aluminiumpowder,Magnesiumpowderetcbeingproducedindigenouslyandinplentifulquantity.AnimportantfactoristhatfactoriesproducingtheserawmaterialswerenotfromSivkasi,themainfireworkproducingcentre.Anotherfactorcontributingto thespurt inproduction isimportantrawmaterialswereproducedbyfireworkmakersthemselvesatseparatesites.Low rain fall and a dry climate prevailing in Sivkasi area contributed to unabatedproduction.What could havebeen consumed in three hours ofDiwali night came to beproduced in 300 days, almost with overtime jobs during six months of the year. Inmonetarytermstherehasbeenasteady increaseof10%annually,andtodayproductionstands at an outstanding figure of 200 crore of rupees at the market value. About 90percentofIndiasproductionoffireworksisatSivkasi.Therearemorethan800fireworks(licensed and unlicensed) industries in Sivkasi manufacturing around 300 varieties offireworks. An annual business of Rs. 2500 crores (Rs. 8000 cores at the retail end) isestimated.Thelicensedunitsemployabout1.3lakhpeopleandmorethanonelakhpeople


areemployedinunlicensedunits.TheissueofengagementofchildlabourandfirehazardaretwomajorissuesofthefireworkindustriesofSivkasi.FireworksinWestBengalFirecracker/fireworkindustriesofWestBengalisoneofthemajorhouseholdindustriesinIndia.NungivillageisoneofthefamousvillageofWestBengalproducingvariouskindsoffireworks likeflowerpots,Charkhi,colouredtorchetc.Around500unitsarenowworkingbothlegallyandillegally.TheseunitshaveagoodmarketintheNorthEasternregion.FireworksinOdishaIn Padmapur called the Sivkasi of Odisha, its largely unorganised labour whichmanufactures firecrackers,Thiscottage industry isyet toget recognitionasonly four tofive familieswere issued fireworkmakingpermit, despitealmost everyhousehold in thevillagehasbeenintothebusinessforseveralyears.About2500unorganisedlabourersofmorethan500familiesbelongtobothHinduandMuslimcommunitiesofPadmapuranditsadjacent Trilochanpur, Mahajanpur, Purbakachha, Madhyakachha, Campati, Hatikana,Bahadalpatanaand Jagannathpatanamanufacturecrackers toearn their shareofprofits.Beingaseasonaloccupation,childrenskipclassestohelptheirfamilymemberstoaddtofamilyincome.OtherFireworksThere are unrecognised firecracker factories elsewhere including in Khusropur village ofBiharwhichareknownwhenanaccidentisreportedinthemedia.FireworkofBarpeta,AssamFireworkofBarpetadatesback toabout130years locally called 'fotoka'. Late LakshiramPathak of Mojorhati was founder of fireworks industries in Barpeta who started theindustryaftergoingthroughaBengalibookonChinesefireworkspublishedin1885whichgave an idea of crackermaking techniques. The industry was also patronised by QueenVictoriawhowassatisfiedwithworkofLakshiramPathakandawardedhimagoldmedalanddonatedtwobighaoflandatBilortarihatiBarpetatoplyhistrade.In1910,Pathakwasawardeda licence fromtheBritishgovernment tocarryonwithhis trade.AfterPathaksdeathhissonLateNarahariPathakcontinuedthelegacyoftraditionalfireworkproductionprocess.WithinthefamilyotherentrepreneurslikeLateMonoranjanPathakofBrindabanhati, Nalini Pathak and Achinta Pathak of Majorhati, Late Amrendra Pathak, late NirenPathak, Gopjit Pathak and Deepmani Pathak of Bilortarihati all established firework

industries separately. Two grandsons of LateLakshiram Pathak through his son Late AnantaPathak took up fireworkmaking even though theirownfatherhadnot.There are altogether five Pathak families today atMajorihat near Barpeta town. They engage locallabourersandaround30to35potterfamiliesinthetrade.


GenealogyofFireworkclusterinBarpeta

ContinuinginFirework

ThefireworkindustryofBarpetatodaybearsadistinctivemarkofexcellenceandidentity.Customized fireworks aremanufactured as per the needs and objectives of their specialclients,bestsuitedfortheoccasion.Theclientsespeciallybeforetheydecidetoplacetheirorders,thecrackermakerssendrepresentativestotheclientstoplacetheparticularideaand variety of the product. These aspects gave these crackers an extra edge over itscompetitors as the service provided by the crackermakers exclusively for its customers.During Diwali, marriage seasons, festivals or ceremonies, prominent clients who wantspecialpyroshowsonlyhavetoputforwardtheir'needs.But,somewheredowntheline

LateLakshiramPathak

LateAnantaPathak LateManahorPathak LateNarahariPathak Dr.ChaturbhujPathakAge76,RetiredProfinGeology,

residinginGuwahati

GopjitPathakLateNirenPathak DeepmaniPathak

HarideepPathakSettledinGuwahati

DeebakarPathakSettledinGuwahati

LateAmrendrPathak

MsRatnamaniPathak

AchintaPathakAge45,Firework

NirmalPathakAge50,serviceinAgriculturedept,

Barpeta

DijenPathakAge53,servingas

FoodSupplyInspectorPDSin

Karbalong

NaliniPathakAge68,Firework

AjitPathakAge60,Retired,servedFCI,since2yearsstayingin

Barpeta


themuchexpectedgrowthisthesectorisnotbeingachievedduetoacutefinancialcrisisandotherissues.Someofthefireworkproductsmanufacturedthen1. Hile:Abombcylindrical lookingmetalcasingwhichcontainedexplosivemixtureand

soilinside.Duringsilverorgoldenjubleethesebombswereingreatdemand2. Asman Gola: A coconut shell contained the explosive mixture inside and then kept

insideahollowhardpapercasingcylinder.Afterignitingthecoconutshellwillflyinthesky.

3. Fanush:Itisapaperballoonanditwillremainintheskyaslongthefirebelowburns.BarpetasproposedAtosbajiVillageAssamgovernmentunderChiefMinistersdevelopmentfundRupeesSevencrorehasbeensanctioned to District Industries and Commerce Centre alongwith allotment of total 30acresoflandtosetupBarpetaAtosbaziVillage.Afteraroughpatchin2012,the127yearold industry is set tohavea common facility center alongwithother facilities. From theseven crore, the government has sanctioned Rs. 3.5 crore to Assam IndustrialInfrastructure Development Corporation (AIIDC) on March 2013 and Rs. One crore hasbeenreleasedforconstructionofboundarywallandlandfilling.Eachofthefivefirecrackerunits have been allotted two acres land. According to the scheme, all necessaryinfrastructureswillbeprovidedbyAIIDCandhandedovertothefirecrackersunits.Gopjit Pathak along with four others were oriented in Sivakasi. They supply thesefirecrackers to theNortheastwith prices little higher than those fetched by the Sivakasiones.ThisindustryprocuresmostofitsrawmaterialsfromCalcutta.NeedAssessmentInteractiveSurveyProcessadoptedinconductingtheInteractiveSurveyThe DICC Barpeta Office provided a list of SME units engaged in Traditional FireworklocatedinBarpetadistrictofAssam.TheperiodmidJunetomidSeptemberisoffseasonandthereisabsolutelynoproductionduetomonsoon.TheproductionpicksupfrommidSeptemberbeforeDurgaPujaandlasttill April and May. Hence the Design consultant could not photograph the fire workproducts. Secondly due to off seasonmost of the unit workers were also not availableworking intheunitexceptfew.However,namesoftheworkershavebeenrecordedandthosepresentwerephotographed.PresentlytherearefiveSMEunitsandoneunithasstoppedproductionsincelastoneyear.The units do not have a standard DICC registration and explosive licence and arefunctioningfromtheirresidentialunits.


FindingsfromsurveyoffiveMSMEsincludingissuesandsuggestionsUNIT1:AssamFireworksIndustriesAssamFireworksIndustriesAtisbaziBhawan,NearSankardevKalakshetraBilortarihati,Barpeta781301Tel:03665235750,9954797018Email:[email protected]:DeepmaniPathak,Age35SmallScaleIndustryRegistrationno.02/05/06803registeredin1986Unitsetup:Intheyear1885bylateLakshmiPathak(grandfatherofDeepmaniPathak)LateLakhiPathakLateNarihariPathakBanalataPathak(motherofDeepmani)LateAmrendraPathak(elderbrotherexpiredon14June2014)DeepmaniPathakDeepmanihasbeenengagedwiththefireworksincelast20years.Totalsaleslastyear:ApproximatelyRs.80Lakhs.ProductionisbasedonclientordersTotalprofitlastyear:ApproximatelyRs.20LakhsFulltimeworkers:

1. DimpalSutradhar,Age32yearsworkingsincelast18years2. ArupDas,Age23yearsworkingsincelast10years3. GaneshDas,Age36yearsworkingsince12years4. ChinmoyDasage28,workingsince13years5. LokaDas33,workingsince13years6. MrityunjaySutradharage31yearsworkingsince18years

TheaboveworkersarepaidmonthlysalarybetweenRs.5000Rs.8000SevenmonthsbeforeDiwaliadditional15workersare involvedondailywagebasiseachpaidRs.250perdaywithrefreshmentandlunchandabout25workersengagedonweeklybasiswhoarepaidRs.250perdaywithfacilityofmealsandlodge.Thereisaseparateshedforworkerstosleepduringnight.DuringthisperiodtwocooksarehiredforRs.5000andRs.7500each. Inaddition forall12monthsonenightsecurityguard(PradeepPathak) ishiredonamonthlysalaryofRs.8500.

DeepmaniPathak


Imagesofalltheunitartisans

DimpalSutradharAge32 ArupDasAge23 GaneshDasAge36

ChinmoyDasAge28 MritunjaySutradharAge31AkbarAli

ManjitDas NavajitDas


Productrange:Phuljari(FiredterracottacasingFlowerPot)InHindi AnarSlno.

Category/Size Totalannualproduction(innumbers)

Retailrateperpiece(inRs.)

Wholesalerateperpiece(inRs.)

1 SpecialPhuljari(big) 300 1800 12002 SpecialPhuljari 300 1200 8003 MediumPhuljari 1500 500 3004 SmallPhuljari1 5000 50 305 SmallPhuljari2 5000 100 756 SmallPhuljari3 5000 150 100Mata(Sparklers)InHindiPhuljariSlno.

Category Total annual productioninnumbers



1 Matabig 500 150 1002 Matasmall 20,000 5 3AsmanGola(Skybomb/fireballs)Slno.

Category Totalannualproductioninnumbers



1 SmallAsmanGola(15Shots) 200 1200 8002 SmallAsmanGola(singleShot) 500 500 3003 BigAsmanGola(SingleShot) 500 800 5004 BigAsmanGola(60Shots) 100 3000 24005 BigAsmanGola(36Shots 100 2400 18006 BigAsmanGola(24Shots 100 1800 1200LetterGash(Alphabetshapedfirecrackers fixedonbambooframe)Slno.

Category Totalalphabetsproductioninnumbers

Retailandwholesalerateofeachalphabet(inRs.)

1 100orders 1000alphabets 150PattaLori(Crackers)1bundle=1000crackersSlno.




1000bundles 500 3001 Setof100bundles 10,000crackers 4500 35002 Setof50bundles 50000crackers 2250 18003 Setof40bundles 40,000crackers 2000 17004 Setof20bundles 20,000crackers 900 700


BombSlno.


Retailandwholesalerateofeachalphabet(inRs.)

1 Small 500 352 Medium 500 753 Big 300 150(Onlyonorders)There are some large size traditional fire crackers which are performed and displayedexclusively by the trained SME unit staff. The staffmembers carry the fire crackers anddisplay during marriages and celebrations such as inauguration and closing ceremonies,31stDecember,newyear,launchofashop,restaurantorshowroomsetc.Inayeartheunitsuppliesfirecrackerstoabout250marriagesandduringmarriageseasontheyhavetobeprepared to manage and cater to 48 marriages per day. Each of these marriages andcelebrating events place orders which range between Rs. 15,000 to even Rs. 50,000consisting of package of fire crackers Special large flower pots, Matar Gash, CherkhyGash,LetterGash,SunBaziandcombinationsofAsmanGola.Payment&CreditThe client pays advance between 2050 percent when placing order and the remainingbalanceamountiscollectedbytheunitstaffaftertheperformanceisover. In80percentcasestheclientpaysincashonly.RawMaterialsFollowing seven raw materials are procured from Kolkata which are not available inGuwahati

1. Sora Rs.120Kg2. Sulphur Rs.70Kg3. Aluminiumdust Rs.250Kg4. Aluminiumpower Rs.450Kg5. PVCpowder(forfirecolour) Rs.700Kg6. Barium(forfirecolour) Rs.120Kg7. Tanisium(forfirecolour) Rs.300Kg

Combinations in different proportions of the abovematerials different product range offire crackers manufactured. For example bombs require Aluminium power, Sora andSulphor.

1. Casteirondust(Lathemachine) Rs.4070Kg2. Coaldust Rs.20Kg3. Colouredpapertopaste Rs.40(24sheets)

FiredterracottacasingforPhuljari(flowerpots)

1. BigspecialPhuljari Rs.120perpiece2. BigPhuljari Rs.100perpiece3. MediumPhuljari Rs.35perpiece4. SmallPhuljari Rs.20perpiece


MarketingThereareabout5060agents,tradersandshopkeepersspreadacrossindifferentlocationsmainly innortheastern stateswithwhom theunit proprietorhas abusiness tieup. Theretail shop owners and the firework traders deal withmarriage ceremonial items, gifts,cards,Bihufestivalitemsetc.TherearesevenoftheminGuwahati,threeinDibrugarh,onein Shillong, one in Nuagaon, one in Bishwanath Chariali, one in Tezpur, one in NewBongaigaon,oneinKokrajharetc.Mostof these individuals are trustedpeoplewho call theproprietor 10days in advancebeforemarriages,specialcelebrationfunctions,festivals,andDiwalitoplaceorders.Theyarrangetopayanadvanceof3050percenttoconfirmtheorder.Oncetheordersarecompleted,iftheorderisbetweenRs.30,000toRs.50,000ifthereareany free staffs, the proprietor arranges to send two staff with the consignment. Theycannottravelbytrainhencewillhavetotravelbyroad.MinimumRs.50007000isspenton the cost of transportation, board, lodge, extrawages of the two staffmembers. Theconsignment is delivered, may be performed by the staff and they return back aftercollectingthedues.BetweenJunetoAugustboththeproductionandmarketdemand is low. ItpicksuponlyjustbeforeDusherawhentheunitmembershavenotimeeventohavemeals.Therearecontinuousdayandnightproductionshifts.ViewsofUnitProprietor Barpetafirecrackersareofgoodqualityascomparedtootherbrandsinthemarket Entireproductionprocessisverylabourintensivemanualworkthereisnomechanised

productionprocess. ThecostofBarpetafireworkproductsarehigherthanShivkasi Wastepaperisamajorcrisisnoteasilyavailablelocally.InShivkasiit isavailableata

fixedprocuringsourceatacompetitiveprice GeneralwageworkershaveotheravenuestoearnincludingagricultureunlikeShivkasi.

Theentireworkforceisdependentonthefireworkindustry. WagestothelabourishighinBarpeta(Rs.250inadditiontorefreshmentandlunch).In

Shivkasitheentirefamilyof56membersincludingsmallchildrengetinvolvedandearnRs.150200perday.TherethechildrenalsoearnRs.3040perday.

Humidity and moisture content damages the finished product hence the unsoldproducts cannot be stored for next season. Shivkasi has completely dry climate bestsuitedforfirework.

Barpetahasonly5fireworkunitsandascomparedtoShivkasitherearemorethan800unitssupportedbythestategovernmentschemesandguidelines.

So far there have been no support provided onmarketing by the state government.Some fixed retail stalls in Guwahati and other NE state capitals will be of of goodsupport.

There is nopaper cuttingmachine,offset printingunit or bamboocutting, shreddingandsplittingmachines.TheproprietorsawonesuchsemiautomachineinNalbariwithanestimatedcostRs.12Lakhs.


ImageGalleryProductionProcessofCharkhi&SunBazi


ProductionProcessofPhuljari

Fillingexplosivematerialwithoutglovesandsafetyprecautions


ProductionProcessofMataandAsmanGola

Fillingexplosivematerialwithoutsafetygearsandappropriatefillingtools,workstation


CompetitionTheproductpackagingandpresentation isgoodof Shivkasiproducts.Bothproductsandpackaging looks attractive and has safety instruction, logo and brand identity. A SivkasipaperAnarissoldforRs.60andBarpetaAnarforRs.30withmoregunpowderinside.

DesignAuditofUnit1SlNo

Topic Observation PossibleDesignsolutions

1 Product 1. Theterracottaandbamboocasesaremanuallymadesonotuniformofstandardsize

2. SomeoftheproductrangelikeCharkhi,SunBazi,LetterGash,MatarGashetcareavailableinlargesizetobedisplayedinopenandperformedbyunitstaffonly

3. Thereisnogradingprocessorqualitychek

4. Fillingoftheexplosivemixtureinsidethecasesisofnotconsistentquantity.

5. Thefinishedproductsarepastedwithreadymadecolouredpapersonthesurfacewithnolabelling,brandinformation/identityorusageguidance

6. Humidityandmoisturecontentdamagesthefinishedproducthencetheunsoldproductscannotbestoredorusednextseason

1. Semiautomatedmachineswillhelpstandardisedthesizeofthecasings

2. Existinglargesizeproductrangecanberedesignedtosmallerormediumsizeandpackagedtocaterendusertocelebratewithchildrenandfamilymembers

3. Qualitycheckswillhelptodiscardunevensizeandshapes

4. Designcustomizedprintedlabelsforproductcategorywithvisuals,logo,productcodeandinformation

5. Betterqualityofoffsetprintedpaperslogoandinstructionscanbepasted.Markareaforcoveragepriortopastingoflabelstoaparticularlength

6. Theunsoldproductsneedtobepackedinsideaairtightcontainersreducingexposuretohumidityandmoisture

2 Process 1. Theentireproductionprocessislabourintensiveandtimeconsumingleavingroomforinconsistency

2. Thechemicalmaterialsaremanuallymixedandgrinded.Therehavebeencasesofaccidentinthepast

3. Manualtechniqueresultsinanunevenshapeandsizesoftheproduct

4. Thechemicalmasalapowderisfilledandstuffedinsidemanuallywithbarehandsandtools

5. Thereisnodedicatedworkspacetocarryouteachofthetasksbytheworkers.Theysitanywhereandstartworking.

6. Chemicalstorageareaandfinishedgoodstockingareaisnotdistinct

1. Somepartoftheproductionprocesssuchaspaperrolling&cutting,bamboocutting,shredding,splittingwillneedmechanisedprocess

2. Machinedgrinder,mixtureandpowderfillerswillaidefficiencyandconsistency.Workersneedtobeorientedaboutthesafetyhazardsofeachofthechemicalsusedforpreventivemeasures

3. Safetygearssuchasmask,gloves,glassetcneedstobeprovidedtotheworkerswhilefillingthechemicalmixturemanually.

4. Aproperworkstationwithappropriatefacilitiesandventilationwillstreamlinetheproductionprocessandmakeitefficientandsafe


7. Oncethedaystaskisover everythingiswrappedinapolyethylenesheetsfornextdayleavingitexposedtoanyaccident

5. Afterdayswork,theworksiteneedtobecleaned.Orientationandtrainingtotheworkerscanbeginimmediately.

3 Packaging 1. Thefinishedproductsareputintoasecondcorrugatedboxesfilledwithwoodenchips/scrapstransportedto/bythewholesalersorclientwhereitwillbedisplayed

2. Theretailerscarrytheproductsinjuteorplasticbags.

1. Tocaterretailmarket,appropriatepackagingandgraphicdesigninput,willberequiredforeachproductline

2. Specificproductappropriatepackagingwilldirectlyaidconvenience,appeal,productinformation,safetyinstructionsandbranding.

4 Storage 1. Rawmaterialsincludingchemicalsaredumpedinabambooandtinroofopenfromsidesexposedtoallsafetyhazards.

2. Otherrawmaterialsarestoredclosetothedirtfloor,plasticsacks,andbamboobasketswithnodesignatedareas.

3. Finishedfireworkproductsarestoredinthesameworkshedandsomeinsidetheroominaopencartontopofeachotheroronthefloorcausingdamagetothebottommostproduct.

1. Allchemicalsandpowderedrawmaterialneedtobesafelystoredoffthefloorincloseairtightcontainerswithdifferentcolorcodesandalsoclosedroomawayfromfire,electricalconnection.

2. Araisedplatformwithdesignatedareasofstoragefordifferenttypeofmaterialsandtoolsisneeded.

3. Finishedproductsalsotobestackedinsideaclosedandlockedwarehouseonraisedandshelvedplatformsneatlyandcoveredwithplasticsheetsorincustomizedboxes.

5 Layout 1. Thelargeopenareainfrontoftheofficeunitandresidenceisutilisedforproductionandthetwoseparateopenshedsarebehindtheunitforrawmaterial,tools,finishedproductsetc.Theunithasnoboundarywallorlockablegate.

2. Adjacenttotheopenstoreshedarekitchen,eatingspace,retiringshedforworkers,electricalconnections,LPGcylinders.

3. Thesecondshedisutilisedtostoresmallerorunusedtools,bambooframes,unusedflowerpotsetc.

1. Theentirestoragespaceforexplosivechemicals,workstationandfinishedproductscannotcontinueinaresidentialarea.

2. Sequenceofoperationsneedstobestreamlinedfromsourcingandstorageofrawmaterials,production,assemblypackaging&labelling,dispatchneedtobeidentified,sequencedandadaptedtothelayoutofafactoryareaadheringtohighsafetystandards.

6 Workstations,WorkspaceErgonomics

1. Thereisnodedicatedproductionspaceasworkstation.

2. Theworkerscarrytheirtoolsandrequiredquantityofrawmaterialsandchemicalmixtureandassumesasquattingorcrossleggedpositionandworkontheground.

3. Themainworkspaceareasarethe

1. Positionassumedbytheworkersisdifficulttosustainforlongperiodsoftime.Designofaworkspaceallowingworkerstostand,sitonachairorastoolwithanelevatedtablewillhelptheworkerspostureaswellas

2. improveoverallproductivity.


twoshedsbehindtheunitusedtostorechemicals,rawmaterialsandhandtools.Theweighing,grindingandpowderingofthechemicalshappenintheopenshedundersupervisionofunitproprietor.

3. Workersworkingintheshedmixingandgrindingthechemicalsorfillinginthecaseshouldbeprovidedwithprotectivesafetygearssuchasmasks,gloves,glasses.

4. Fillingofexplosivemasalaneedadedicatedareawithadequatelightandventilation

HandTools 1. WoodenUrao(poundingtool),manualgrindingunit,Ironrodsin2sizediameters14and24inch,2feetlongIronsteelrodof2sizediameters16&20mm,Sieve,hacksaw,bamboocutters,axeknife,knife/cutter,scissor,mixingbowl,weighingmachineetc

1. Currentinhousehandtoolsareadequate.Butthisneedstobeautomatedtoincreaseefficiencyandquality.

ResearchandDevelopment

Thereiscurrentlynone 1. Exhaustiveresearchofretailandwholesalemarketsegmentinnortheastandsomeoftheneighbouringeasternstates.

2. Optionsforadvertisinganddistributionandpossiblepartners.

3. Researchonsemiautomatedmachinestoaidproduction

4. Creationofabrandidentityandappropriatepackaging


Storageofrawmaterials,finishedproductsandtools


UNIT2:ManisunaAtasbaziUdyogManisunaAtasbaziUdyogNearSankardevKalakshetraBilortarihati,Barpeta781301Contact:09954172186,09577388275(Ritamani)Registration No. 05/10/03/01/00705 issued on 02 July 1988 from Guwahati underExplosiveActof1884whichwasvalid till1989.Not renewedthereafter.The licencewasissuedtomanufactureandsaleexplosivematerialsunderarticle1(a)(d)ofscheduleIV.Form20(underrule155).Unitoperationalsince:1885NameofProprietor:MariamiPathak,Age43WifeofLateAmrendraPathakage53whoexpiredon14June2014duetohearattack.Herdaughter Ms Ritamani Pathak age 20 studying BA second year has started helping hermotherafterherfathersdemise.MariamiPathak

FulltimeworkersNabajitDas,age28,parttimemanagerSatishNathAge55,workingsincelast15yearsHimanshuDasAge36,workingsince15yearsDevanandNathage36yearsworkingsince12yearsPranjalDasage20yearsworkingsincelast5years.TheygetmonthlysalarybetweenRs.50008000Apartfromtheaboveemployeesthereareabout25dailywageworkerswhoworkfor69monthsearningRs.300duringdaytime(8amto6pm)withmealsandadditionalRs.200fornighttimeworkingfrom6pmto2am

RitamaniPathak


ImagesofalltheunitartisansKeyproductrangeThereare listoftotal36fireworkproductsofferedtotheclients.Listbelowarecommonkeyproductrangeinproduction:1. AsmanGola2. Phuljari(flowerpots)ofallsizes3. PattaLori4. MatarGash5. LetterGash6. CherkhyGash7. MatabothbigandsmallmostlyinDiwaliandmarriages

SathishNath NabajitDas JayantaNath DevanandNath


Marriage season, festivals andDiwali are the threemainevents for saleof fire crackers.DuringmarriagestheSMEunitcaterstoabout150marriagesofAssamese,MarwarisandBengalis in a yearwhich range between Rs. 5000 to Rs. 40,000. Below is the percentilebreakupofannualfireworksalesbytheunit;1 Rs.5000toRs.10,000 20%2 Rs.10,000toRs.20,000 16%3 Rs.20,000toRs.30,000 40%4 Rs.30,000toRs.40,000 12%5 Rs.40,000Rs.50,000 12% Total 1002.Festivals:1 Bihu Rs.10,000toRs.25,000 25%2 GovernmentFunctions Rs. 10,000toRs. 20,000 25%3 Diwali,Mela,Puja,religiousceremonies Rs. 15,000toRs 30,000 50%


TotalsalesinlastDiwali:ApproximatelyRs.10LakhsTotalsaleslastyear:ApproximatelyRs.30LakhsTotalprofitlastyear:ApproximatelyRs8Lakhs.AnnualProductionoffirecrackers1. AsmanGola(Skybomb) Category Totalannual

productioninnumbers



1 SmallAsmanGola 500 200 1802 SmallAsmanGola(15Shot) 400 300 2503 SmallAsmanGola(singleShot) 500 500 3504 BigAsmanGola(SingleShot) 100 600 5005 BigAsmanGola(24Shots) 100 2000 18002. Phuljari(FiredterracottacasingFlowerPot)InHindi AnarSlno.




1 ExtraSmallPhuljari 8000 15 102 SmallPjuljari1* 4000 20 153 SmallPhuljari2 4000 30 254 SmallPhuljari3 3000 50 405 SmallPhuljari4 3000 100 756 SpecialSmallPhuljari 3000 150 1207 MediumPhuljari1* 2500 200 1708 MediumPhuljari2 2000 300 2509 MediumPhuljari3# 2000 500 40010 SpecialMediumPhuljari* 1500 800 70011 LargePhuljari1 1000 1000 80012 LargePhuljari2 500 1200 100013 SpecialLargePhuljari 300 2000 1800 MaximumsaleduringDiwali#Maximumsalesduringmarriages3. PattaLori(Smallfirecrackers)inHindiFatakaSlno.


Retail&wholesalerateperpiece(inRs.)

1 Small 6000 10002 Medium 5000 20003 Big 2000 50004. MatarGash(LighteningTreemadeonlyformarriagesandfestivals)Slno.




1 Black&Whiteflame 1000 10002 Colouredflame 1500 15005. Chirkhey(Singleonlyinbamboo)Slno.



1 Single 2000 15006. LetterGash(Alphabet)Mostlymarriage,DiwaliandFestivalSlno.



1 Assamesealphabets In a year total 1000orders with each sethaving1550alphabets

150peralphabet2 Englishalphabets 120peralphabet

7. Mata(lighteningsparklers/torch)InHindiPhuljariSlno.



1 Small 50,000 Rs.5eachpiece2 Big 3000 Rs.150perpieceViewsofUnitProprietor1. Mostproductionprocessismanualhencethecostoftheproductionincreases2. Fordifferentproductsrequireseparatetoolsandproperinventoryandstoragesystem

oftherawmaterialsandalsofinishedproducts.ForinstanceforPhujaritheironchipsanddustneedtobestoredsafely.

3. SmallMata cannotbe sold in packaging since the cost of theproduct increaseswithpackaging

4. Asman Gola has no packaging, it is wrapped in plastic bags and the product getsdamagedduringtransportation.

5. During the production of Mata (fire sparklers) the fine dust and chemical fumesdamagestherespiratorysystemoftheworker

6. Itisdifficulttomixabout45explosivematerialsmanuallyasemiautomatedmixtureisrequired.

7. The unit procures the earthen flower pot cases from the potters from Gandhinagarvillage.Thesmallerrangeofproductsbecomesexpensiveandalsofragile.

8. Skinning and splitting of bamboo is a problem manually, semiautomated tools willmakeitmoreefficient.

9. Ifthebambooisoldit losesitsflexibleandisofnouse.Thebamboogetsdamagedduringskinningorsplittingprocess.

10. After theAssamdisturbancespossession,manufacturingandsellingofallexplosivematerialsinGuwahatiarebanned.TheunitshavetoprocurefromKolkataorBarpetaRoadbyroadtransport.

11. Since the entire productionprocess ismanual, theBarpeta firework productsmostlythetraditionalandfastmovingitemslikeAsmanGola,Phuljarilackfinishingandlooksrudimentaryforusersinoutsidestates.

12. ThereisnoproperidentityandpackagingofBarpetaproducts.


13. Transportation of the finished products is a major problem since it cannot betransported in trains.Hence transporting in fourwheel vehicles increases the costoftheproductwhichhastobebornebytheMSMEunits.

14. Thereareextortionsbythepoliceandarmyatcheckposts inspiteofpresentingduereceiptsandpapers.

MarketingTheproductsaresoldatwholesalerateinmostofthedistrictsofAssamin1520locationssuchasDibrugarh,Tezpur,Guwahati,Laxmipur,Odalgudi,Kokrajhar,Goalparaetc.Duringfestivals few products are also sold in 810 locations of Delhi and Haryana. Locally it ismostly soldduringmarriagesandDiwali. Theunithasapermit licencebutduringDiwalistatealsoissuestemporarylicences.ModeofpaymentUsuallytheclientpaysabout3050percentadvancewhenplacingordersandthebalanceispaidondelivery.In50percentcasesthemodeofpaymentisincash,25percentthroughbanktransfersand25percentthroughchequeiftheclientisgovernment.RawMaterials50 percent of the raw materials are sourced from Guwahati and Barpeta Road andremaining50percentfromKolkatamostlytheexplosivematerials.ProductionprocessofCharkhiandAsmanGola


Storagesystemofrawmaterials(explosives)andsemifinishedproducts


DesignAuditUnit2SlNo


1 Product 1. Small Mata (sparklers) cannot bepackagedandsoldsincethecostoftheproductincreases

2. The units procure earthen flowerpot cases from the potters makingthe smaller range of productsexpensiveandfragile.

3. Old bamboo is of no use as it getsdamagedduringskinningorsplittingprocess.

4. Skinning, splitting of bamboo andmaking the earthen pots for casingis time consuming and not uniforminsizesasthesearemanuallymade.

5. ProductslikeAsmanGolahasnopackaging,itiswrappedinplasticbagsandsheetsandtheproductgetsdamagedduringtransportation.

1. Semiautomatedpapermachinescanreplacesmallerearthenandbamboocasings.Thiswillmakethecasingscheaper,fasterandalsomakethesizeconsistent.CustomizedpaperrollingmachinesneedstobedevelopedbyMSMEToolRoominGuwahati.

2. ForsomeproductrangesuchasCharkhi,SunBazi,LetterGashetcwherebamboohastobeusedthensplitting,shreddingandcuttingmachinescanbepurchasedordevelopedasperneedfromcaneandbambooinstituteAgartala.

3. Forotherlargesizeproductscanberedesignedtosmallerandmediumsizeorcustomizedpackagingcanbedesignedtoeasetransportedforretailsale

2 Process 1. Entireproductionprocessismanuallabourintensivehencethecostofunitproductcostincreases.

2. Itisdifficulttomixabout45chemicalsandexplosivematerialsmanuallyincorrectconsistencyandproportion.

3. Therearenoinventorylistoftoolsandequipmentsfordifferentfireworkproduction.Setofsametoolsareusedfordifferentpurpose.

4. Explosivechemicals,rawmaterialsandfinishedproductsareobservedwrappedandkeptinanopenshedbutcoveredfromtop.

5. After AISU Assam disturbances in1980 possession, manufacturingandsellingofallexplosivematerialsin Guwahati have been banned bythestate.Theunitsdonothavevalidexplosive licence and also facedifficulty to procure chemicals fromKolkatawhichtakes1012daystimebyroad.

6. With no valid documents, faceextortionsbythepoliceandarmyat

1. Semiautomatedmachinesincludinggrindersandmixturesarerequiredtomaketheexplosivemasalapowderconsistentandproductionprocessefficient.

2. Differentrangeoffireworkproductswillrequireseparatehandtools,machinesandalsoproperinventorymanagement,labellingandstoragesystemincludingforallrawmaterialsandfinishedproducts.ForinstanceforPhujari(flowerpots)ironchipsanddustneedtobestoredseparatelyandsafely.

3. StategovernmentwillhavetoconsiderprovideexplosivelicensetotheunitsandalsotoonelocalentitytotradeexplosivematerialsexclusiveforBarpetafireworkcluster

4. Statewillhavetoissueexplosivelicencetotheunitstomanufactureandsalespecificlistofproductswithinandoutstate.


checkposts even if presentingworkorderreceipts.

7. The units are operatingon a tickingtimebomb.Insurancecompaniesarenotreadyto insuretheunitandtheworkers as it does not fulfil thesafetyguidelines.

5. Allsafetymeasureswillneedtobeadheredbytheunitssuchasmovingoutofaresidentialarea,noelectricalconnection,installationoffireextinguishers,adequatewatersupply,ventilation,workerssafetygears,safestorageofexplosivematerialsetc

3 Packaging 1. Barpetafireworkproductslackbrandidentityandpackaging.Theproductsarekeptincartonboxesofdifferentsizesorwrappedinplasticbagsandtransported.Especiallytheflowerpotsandthelargebambooframecasingproductsgetdamagedduringtransportation.

1. Productappropriatepackagingwillneedtobedesignedforsafetyoftheproduct,brandappeal,productinformation,retailmarketing,safetyinstructionsfortheenduser

4 Storage 1. Allthechemicals,rawmaterials,tools&equipments,finishedfireworkproducts,oldunsoldproductsoflastseason,bambooframes,andemptyflowerpotsarestoredinthesameworkcumstoreshedeitherinplasticsacksoropencartontopofeachother.

2. Thegroundisnotcementedandthesoilismoistandhumid.Someofthearticlesarekeptontemporarybamboowracksabovetheground.

1. Araisedplatformandmetalwrackwithdesignatedareasforstorageofchemicals,rawmaterials,tools,finishedproductstobeproperlystackedinsideaclosedandlockedstoreroomawayfromfire,LPG,inflammablematerials&electricconnection.

5 Layout 1. Thelargeopenareainfrontoftheofficeunitandresidenceisutilisedforproductionandthetwoseparateopenshedsarebehindtheunitforrawmaterial,tools,finishedproductsetc.Theunithasnoboundarywallorlockablegate.

2. Adjacenttotheopenstoreshedarekitchen,eatingspace,retiringroomforworkers,electricalconnections,LPGcylinders.

3. Thesecondshedisutilisedtostoresmallerorunusedtools,bambooframes,unusedflowerpotsetc.

1. Theentirestoragespaceforexplosivechemicals,workstationandfinishedproductscannotcontinueinaresidentialarea.

2. Sequenceofoperationsneedstobestreamlinedfromsourcingandstorageofrawmaterials,production,assemblypackaging&labelling,dispatchneedtobeidentified,sequencedandadaptedtothelayoutofafactoryareaadheringtohighsafetystandards.

6 Workstations,WorkspaceandErgonomics

1. Whenfillingexplosivemasalainsidethe Mata (fire sparklers) the dustadequatelydamagestherespiratorysystemoftheworker.

2. Theunitdoesnothaveanydedicatedspaceasworkstation,storage,inventoryoffinishedproducts,toolsetc.Theworkers

1. The explosive masala needs tobe filled in a closed anddedicated area with adequatelight,ventilationandsafetygearsfortheworkershealth.

2. Itisdifficulttosustainlonghoursof continuous work in thesquattingorcross legposition.A


findanyemptyspacearoundandworkingroupssittingeitherinsquattingpositionorcrosslegs.

3. Theyusebarehandstofilltheexplosivemasalainthecases.

4. Thereisonlyoneshedusedtostorechemicals,rawmaterialsandhandtools.Theweighing,grindingandpowderingofthechemicalshappenintheopenarea.

properelevatedtableandsittingarrangement need to bedesigned to allow workers toeitherstandorsitonastool.Thiswill ergonomically ease theworkingpostureoftheworker

3. Thecorrectposturewillalsohelpimproveoverallproductivity.

HandTools 1. Poundingtool,manualgrindingunit,Ironrodsin2sizediameters14and24inch,2feetlongIronsteelrodof2sizediameters16&20mm,Sieve,hacksaw,bamboocutters,axeknife,knife/cutter,scissor,mixingbowl,weighingmachineetcarethecommontoolsusedbytheunit

1. Currentinhousehandtoolsareadequate.Butprocessneedstobeautomatedtoincreaseefficiencyandqualityofthefinishedproducts.


Thereiscurrentlynone 1. Research requiredonavailabilityof semiautomated machinessuppliers in India or abroad andaccordingly design customizedmachinetools

2. Retail and wholesale marketresearch to understand thecustomer segment in north eastand some of the neighbouringeasternstates.


UNIT3:LaxmiFireWorksLaxmiFireWorksMojarhati,LNRoadP.O.Barpeta,Barpeta781301,AssamTel:03665236276,09954322321,09435024849NameofProprietors:NaliniPathak,age68&AchintaPathakage45Registration/Licence no. 348 (K) 79 issued in 1979 by Deputy Commissioner of thenKamrupdistrict under ExplosiveAct. (Therewere threedistricts under Kamrup Barpeta,Nalbari and Guwahati.) After ULFA disturbances, issue of explosive licence was stoppedfrom1980inGuwahati.TheheadofficeofExplosivedepartmentunderministryofhomesisatNagpurwhichissueslicenceforpetrol,diesel,LPG,fireworksetcpossessionandsale.Fulltimeworkers:BarbelDas,age32beenengagedsince5yearsKunakanPathak,age27beenengagedsince8yearsNilakantDas,age50beenengagedsince8yearsAjitDas,age38beenengagedsince3yearsHarideoPathak,age40notrelatedbutbeenengagedwiththeunitsincechildhoodIn addition there are 15 workers who are engaged for 34 months on per day wagesrangingbetweenRs.150200.Theirprimarytaskistomixthemixtureasprovidedtothem,paste old newspaper and coloured marble papers on the fire crackers, skin and splitbambooandothermanuallabourwork.

NaliniPathak


ImagesofalltheunitartisansKeyProductrangePhuljari(FiredterracottacasingFlowerPot)InHindiAnarSlno.




1 SmallPhuljari 1500 100 802 MediumPhuljari 1500 500 450 Onlyonorders 3 SpecialLargePhuljari 100 1500 13004 LargePhuljari 100 1000 800Productioncostofmaking25smallPhuljariSlno

Rawmaterials Marketrate Requiredquantity Totalcost1 Sulphur Rs.80perKg 250grams Rs.202 SaltPetri Rs.150perKg 1000grams Rs.383 Charcoal Rs.100perKg 250grams Rs.254 CasteIrondust Rs.50perKg 250grams Rs.135 Terracotta

case/containerRs.15perpiece Rs.375

6 Marblepaperandadhesive

Rs.5perpiece Rs.125

7 Twodailywagelaboursfor2days

Rs. 200 wage +Rs.30food

Rs.460

Rs.1060

Perpiececost:Rs.4250Profitmargin:15%i.eRs.6Wholesaleprice:Rs.75andperpieceretailpriceRs.100Gash(Tree)varietySlno.



1 White&blackflame 100 Rs.12002 Coloured(red+Green)flames 50 Rs.1500

AjitDasNeelkantaDasBabelDas PunakantaPathak


3 SotowalBazi(Cherkhy) 100 Rs. 15004 LetterGash(Alphabet) 100orderswithminimum15

alphabets(Total1500alphabets)

Rs. 200peralphabet

Mata(LightningSparklers)PhuljariSlno.




1 SmallPhuljari 8000 Rs. 400 for 100piece

Rs. 350 for 100piece

2 LargeMata(Sticksize) 100 400perpiece 350perpieceLastyeartotalsaleswasRs.5lakhsandprofitmarginwasRs.1lakhsViewsofUnitProprietor:ComparisonwithSivkasifireworkunits1. In Sivkasi there are more than 800 registered and unregistered firework units as

comparedtofiveinBarpetaAssam,hencetheyhavetheadvantageonquantityacrossthecountry.

2. All Sivkasi products have small varieties with good attractive coloured labels andpackaging,henceare transportedwellacross thecountry.Thecustomersdirectlyusethe product.Whereas Barpeta fireworks are mostly large in size and transported inbags,boxesorcartonscarriedby12unitstaff.

3. TheSivkasiproductshavegoodpackagingandinstructions.4. Thechemical formulasofSivkasiandBarpetaaresamebutmajordifference Sivkasi

products last for two yearsas theyusealuminiumand silverdustbut inBarpeta theunitsusecastirondustwhichgetsaffectedafteroneyear.

5. InSivkasi, the localDICofficehasa fullfledged training centreoffers regular trainingmodules on technical and technological issues by experienced engineers and subjectexperts.

6. WeatherinSivkasiishotandtherenoagriculturelandhencefireworkactivityisthekeysource of livelihood. Labour is easily available at competitivewages. A family of 56memberswithtwoadultsand34childrenearnRs.150200perday.

7. Product wise Sivkasi fire rockets have been banned in many places as the burntresidue damages when falls on the ground. As compared to those rockets BarpetaAsmanGolaissafer.Theentirecasingstaysbackinsameplaceonthegroundandtheexplosivematerialsgetsburntinthesky.

8. Barpetahasno licence supplier for explosivematerials. The local government shouldprovidelicencetostartaunitlocally.ItisexpensivetosourceexplosivematerialsfromKolkata.

9. Locally in Barpeta town there is one licence retailer selling all varieties of fireworksalongwithgiftsandstationaryKanaiBulaiBhandar

RequirementofRawmaterialsSlno

Rawmaterials Source Rate Annualrequirement

1 Aluminiumpowder Kolkata Rs.500Kg 30Kg2 Toncia(forcolourflame) Kolkata Rs. 500Kg 5Kg3 DhokaAluminiumDust(forcolour Kolkata Rs.400Kg 4Kg


flame)4 PVCPowder(forcolourflame) Kolkata Rs. 700Kg 4Kg5 Gala Kolkata Rs. 1200Kg 1Kg6 SilverPowder(forwhiteflame) Kolkata Rs. 400Kg 10Kg6 Terracotta earthen pots of

differentsizesBarpeta Rs.15&Rs.100 200pieces

7 Bamboo(forSatowalBazi,Charkhi,Gash&LetterGashproducts)

Barpeta Rs.150for1bambooof2530feet

100bamboos

8 Jute Barpeta Rs.25Kg 1quintal9 Colouredpaper Barpeta Rs.40Dista

1Dista24sheets1Rim20Dista

7Rimsor140Dista or 4360sheets

10 Charcoal Barpeta Rs. 100Kg 200KgsPackagingfortransportationSlno


1 CorrugatedoldCartonboxes Barpeta Rs.10goodqualityRs.6mediumquality

25cartons

2 Woodchips Barpeta Rs. 35for 1Sack(4Kgs) 30sacks/120Kgs3 Plasticsheettowrapthe

cartonBarpeta Rs. 100Kg

(10meterby9meter)20Kgs

4 Jutestring(Sutli) Barpeta Rs.75Kg 20KgTransportationcostThecartonswillbecarriedbytwoworkersfromtheunittothedestinationbyroad.Wagesfor2workers:Rs.400x2x2days Rs.1600Ifnighthaltextracharge:Rs.400x2persons Rs.800Food:Rs.100x2x2days Rs.400Transportationcost:Rs.200x2persons Rs.400Profileofclients80percentoftheclientsarefromwithinAssamandfewinborderingnortheast.Remaining20 percent clients are from outside Assam who usually order for special functions,ceremoniesandmarriageswhichhastobeminimumRs.20,000order.Paymentterms2540percentadvanceatthetimeofplacingordersBalancepaymentafterdeliveryofproductsModeofpayment Cashpayment80percent Chequepayment15percent Banktransfer5percent


Paymentschedule1. Whole sale retailers or direct customers within Assam in Guwahati, Dibrugarh,

TinsukhiyaetcpayonthesamedaywhengoodsaredeliveredbytheSMEunitstaff2. Iftheclientisknownandtrustedthepaymentisdelayedby26days3. Government departments such as tourism take about a month and pay in cheque

mostlyProductionProcessofPhuljari

Handsexposedtoexplosivechemicals,nousageofsafetygearsandinappropriatehandtools


Imagesoffewsemifinishedfireworkproducts

TopimageisCharkhi

TopandleftsideimagesofSunBazi


SmallMata(Sparklers) MediumMata(Sparklers)

LargeMata(Sparklers)

Bomb

MediumPhuljari(FlowerPot)


Storagesystemandhandtools


DesignAuditofUnit3SlNo


1 Product 1. Theunitusescastirondustinflowerpotswhichgetsaffectedduehumidandmoistureafteroneyear.

2. Theunitmanufacturesfireworkproductsmostlyonorderswhicharelargeinsize.Hencethereislimitationtotransporttheproductsindependentlyacrossthestateandregion.

3. Theproductsoftheunitdonothaveanysurfacegraphicsorattractivevisualappeal/colourssinceitdoesnotdealwithretailmarket.

4. Theunithasnoclueatwhatpricefinallytheproductisultimatelysoldbytheretailertoanenduser.

1. Procurementofchemicalsisbottleneck.Sivkasiproductsusealuminiumandsilverdustinsteadofirondustsoitlastfor2years.

2. Thesizeofsomeofthelargeproductscanbereducedtocaterretailmarketwithsuitablepackagingandbranding.Itcanbetransportedwithoutanyescort.Sivkasiproductshavesmallervarietieswithattractivecolouredlabelsandpackaging.Theproductstravelacrossthecountryduetopackaging.Theproductscompeteonsmallmarginsandquantity.

2 Process 1. Theproductionprocessisnotstreamlined.Theunitdoesnothaveregularproductionacrosstheyear.ProductionstartsusuallywhenwholesaleordersstartbeforeDiwaliorduringfestivalsandmarriageseasons.Foranyoffseasontheunitgetsproductsfromotherunitstofulfilitsorders.

2. Leftoverchemicalmixtureiskeptinplasticbagsandputtodryinthesunbeforeusingitfororders.Theexistingquantitymaynotfulfilcompleteorder.Manualfillingprocessisnotconsistentwhenithastocatertodemandsinlimitedtime

3. Oncefilled,thecasingsaresealedandpastedwithcolouredpapers.Theproductfinishingvisuallylooksrudimentary.

1. Thereisagapbetweendemandandproductioncapacity.Theunitneedstoestimateitsactualproductioncapacityintermsoflastfewyearssaleandplanforassuredworkforce,toolsandrawmaterials.

2. Priortoordersbetterplanningandpreparationssuchreadywithestimatedrawmaterials,chemicals,availabilityoflabourswillhelpensureuninterruptedproductionwillhelpefficiencyoftheunit.

3. Bothrawmaterialsandfinishedfireworkproductswillrequireproperinventorymanagement,labelling&storagesystem.

4. Semiautomatedmachinesandappropriatelabellingandpackagingwillimproveproductfinishing.

3 Packaging 1. Thefinishedproductsarepackedinassortedcartonboxesfromthemarket,bearingbrandnamesofothercompaniesandthenproductsare

1. Asimpleandinexpensivepackaging,bearingnameofunitwillneedtobedevelopedandalltheunitownerswillalsorequire


transportedtowholesalers.2. Thefinishedproductsandchemicalpowdersarekeptincartonboxesorinplasticsacksorwrappedinplasticsheets.Theunsoldproductsandleftoverchemicalsarekeptasitis.

someguidanceonthis.2. Productappropriatepackaging

willneedtobedesignedforsafetyoftheproduct,brandappeal,productinformation,retailmarketing,safetyinstructionsfortheenduser

4 Storage 1. Theunithastwoshedstostoreonesmallroominsidetheproprietorsresidencewithcompoundwallandlockablegateandthesecondshedabout500metersawaywithtemporaryfenceandgate.

2. Alltheexpensivechemicalsandtools&equipmentsarekeptinsidetheroomandallrawmaterials,finishedfireworkproducts,oldunsoldproductsoflastseason,bambooframes,emptyflowerpotsarestoredinthesecondshed.

3. Thegroundinthesecondshedisnotcementedandthesoilismoistandhumid.Someofthearticlesarekeptontemporarybamboowracksabovetheground.

1. Boththestorageshedsarenotpermissibleasperexplosivesafetynormsastheunitisoperatingmiddleofresidentialarea.Thefirststoreroominsidethehouseoftheproprietoraswellthetemporarystorageshedlittleawaywillinvitetroubleinfuture.

2. TheunitshouldplantoshifttothenewFireworkvillageallottedbythestategovernment.

3. Araisedplatformwithmetalrackindesignatedareaswillneedtobeusedforstorageofchemicals,rawmaterials,tools,finishedproducts.

5 Layout 1. Theopenareainfrontoftheresidenceoftheunitsproprietorisutilisedforproductionandthesecondtemporaryshedisusedtostorerawmaterial,mixing,grinding,keepbambooframes,finishedproductsbeforedelivery,packagingetc.

1. Thepresentstoragespaceforexplosivechemicals,workstationandfinishedproductswillneedtobeshiftedtotheproposedfireworkvillageexcepttheclientinterfacecancontinuefromthepresentlocation..

2. Alltheunitoperationsneedstobestreamlinedsourcingandstorageofrawmaterials,production,packaging&labelling,dispatchtobeadaptedasperasmallscaleindustrylayoutfollowingsafetyguidelines.

6 Workstations,WorkspaceandErgonomics

1. Theworkersareusebarehandstofilltheexplosivemasalainthecases.

2. Theunitdoesnotseemtohaveadequatehandtoolsforalltheworkersaffectingsimulationofanassemblylineproductionsystem.

1. Theunitneedstohaveadedicatedandclosedareawithadequatelight,ventilation,handtoolsandsafetygearsforalltheworkers.

2. Aproperworkstationneedtoplannedwithelevatedtable,sittingarrangementandtoolsforworkerstoworkcomfortably.

HandTools 1. Poundingtool,manualgrindingunit,Ironrodsin2sizediameters14

1. Currentinhousehandtoolsareadequate.Butthisneedstobe


and24inch,2feetlongIronsteelrodof2sizediameters16&20mm,Sieve,hacksaw,bamboocutters,axeknife,knife/cutter,scissor,mixingbowl,weighingmachineetcarethecommontoolsusedbytheunit

automatedtoincreaseefficiencyandqualityofthefinishedproducts.


Thereiscurrentlynone 1. Aretailmarketresearchtounderstandthecustomersegment

2. ResearchonavailabilityofsemiautomatedmachinesandsuppliersinIndiaorabroad

UNIT4:MonaranjanFireWorksMonaranjanFireWorksBrindawanhati,BarpetaTel:09707805695,09957494329NameoftheProprietors:HimanshuPathakage35RamanimohanPathak,age48ModhusudanPathak,age50Registrationno.Old25(9)54TheexplosivelicencewasissuedfromtheofficeofInspectorofExplosiveinIndia.Theunithas the licence to manufacture and sell fireworks and gun powder in quantity notexceeding200 Ibs.The licencehasbeenrenewedeveryyear from1963,1964andtill31March1971.Thereafterthe licencewasreissuedbyDeputyCommissionerBarpetaon12November2013withoneyearvaliditytill31March2014withlicenceNumber3316/282/14andfileNo.BAE/101/2013

LateManaranjanPathak

RamanimohanPathak MadhusudanPathak HimanshuPathak


TheunitwasstartedbyLateAgariPathakandthenoperatedbyhisson lateMonaranjanPathakforabout50years.LateMonaranjanstoppedactiveengagementwithhisfireworkunitwhenhewasnotkeepingwell.Heexpiredtwoyearsbackattheageof84.Amonghisfour sonsModhusudanPathak andRamanimohanPathak continuedwith the activity forfewyears.WhileModhusudanmanagedtheproductionandRamanimohaninterfacedwithclients.Howeversincelastoneyeartheunitisnotoperational.TheyplantostartthefireworkactivitywithinvolvementoftheirthirdandyoungerbrotherHimnahsuPathakbeforeDiwaliinitiallywithlimitedordersandinvestments.HimanshuisaBhartal dancer and has visited several places in India with his troop to perform oninvitation. He also runs a dance school in the name of Shankar Sangeet Vidyalaya.Himanshu mentioned he will shift his focus to make the family firework legacy to aprospering enterprise. Monaranjan FireWorks plans to shift the production unit to theFireworkvillageinBilorterihatiBarpeta.DuringtheNeedAssessmentSurveytherewasnoproductionintheunit.UNIT5:BarpetaAtasbaziBarpetaAtasbaziNearSankardevaKalakshatraBilorterihati,Barpeta,AssamTel:09954888882,08811899880NameofProprietor:GopjitPathakRegistrationNo:1. MunicipalityTradeLicencenumber139/2011122. EM PartI No. 18051101513 issued on 26 December 2011 (capacity incase of

manufacturecodeis35006)3. Original Explosive licence No. 05/10/03/01/00705 was issued on 02 July 1988 from

Guwahati under ExplosiveAct of 1884whichwas valid till 1989whichwas issued toLateAmrendraPathakwhentheyalloperatedunderoneunit.Thislicencewasissuedtomanufactureandsaleexplosivematerialsunderarticle1(a)(d)ofscheduleIV.Form20 (under rule 155). Since last two years Barpeta Atasbazi is operating as separateenterpriseanddoesnothaveitsownExplosivelicence.

TheSMEunitisoperationalsince2011TotalsaleslastyearTotalsaleslastyear:ApproximatelyRs.80LakhsTotalsalesinlastDiwali:ApproximatelyRs30LakhsTotalprofitmargininlastyear:Approximately10lakhs.


Fulltimeworkers1. MoonDas,age21workingsince4years2. BipulDas,age20workingsince4years3. PadmalasanDasage21workingsince4years4. PunkuDas,age20workingsince6years5. NarayanDas,age30workingsince6years6. SantyBanage35workingsince4years7. DhaneswarPathakage42workingsince4years8. RabenDasage25workingsince4years9. DhruvjyotiHazarikaage33workingsince4years10. AchintaDasage35workingsince2years11. TutumaniDasage37workingsince1year12. AbhinashOjha,age35workingsince2years13. MinalJtotiPathakage36yearsworkingsince4years14. NavjeetDasage32yearsworkingsince5years15. BuljitDasage32workingsince4years16. ChampaniPathakage33workingsince6yearsTheaboveworkersareengagedonmonthlysalarybetweenRs.5000Rs.8000.MinalJyotiPathakandBuljitDas supportonmarketing, colletingof dues fromclientsetc.AbhinashOjhahelpsinofficework.AbhinashandBuljitgetamonthlysalaryofRs.15,000.Inadditiontotheabovethereareabout30dailywageworkersengagedoncontractandparttimebasis.

MoonDas BipulDas PadmalasanDas

PinkuDas NarayanDas


ProductionProcess

Workingwithoutsafetygearsandinappropriateworksspace,facilityandbodypostures


Storagesystemofsemifinishedproductsandexplosivematerials


ListofTools&EquipmentsusedbythefireworkMSMEs

Grindingunitforexplosivechemicals

Hacksawtocutbamboo

PoundingunittopowderchemicalsIronrodstofillexplosive

Sievetofilter

Electronicweighingunit

Daotosplitbamboo

PlierstocutwireandScissorstocutthreadandpapers

Hammer


KeyProductrange1. AsmanGola(Skybomb/fireballs)Slno.




1 SmallAsmanGola(15Shots) 500 1200 8002 MediumAsmanGola(1

Shot)2000 500 350

2. Phuljari(Flowerpots)AnnarSlno.




1 SpecialPhuljari 200 1800 1000

Rightside Steelrodstofillchemicals,TopMixingplates,LeftSteelrodsandBottomIronplates


2 Special2Phuljari 400 1200 7003 BigPhuljari 3000 600 3004 MediumPhuljari 5000 500 2503. Mata(Sparklers)Slno.




1 Big 500 150 752 Medium 5000 30 183 Small 10,00,00 5 34. PattaKaLori(LoosecrackersfromSivkasiassembledinBarpeta)Slno.




1 Bundleof1000PattaKaLoricrackers

1000bundles(1bundlehas1000crackers)

450 350

5. PaperBlast(Coloured)FiredinallpurposesSlno.




1 PaperBlast 1000 300 1256. ColourSmoke(FiredduringHolifestival)1 ColourSmoke 600 300 1507. AbirBlast(FiredduringHolifestival)1 AbirBlast 500 300 150

LetterGash

MediumsizePhuljari(Flowerpots)


8. LetterGash(Alphabets)Slno.



1 Normalalphabetsize 10,000 150peralphabet2 Specialalphabetsize

(onlyforfestivals)1000 250peralphabet

9. MatarGash(LighteningTree)1 Plain (black & white

electricalflame)1000 1500

2 Colouredflame 200 180010. Cherkhy&SunBazi1 Cherkhy 50 15002 SunBazi 50 200011. Fanoos(Paperballoononbambooframe)1 16FeetdiameterFanush 200 50012. Protimurti(LogodecorationlikeAlphabetfiredinceremonies)1 Protimurti 20 4000ProcurementofRawmaterialsAll rawmaterialswereavailable inGuwahati till 1983. In 1980AssamAndolanagitationstartedbyAISU and the state government bannedmanufacture or sale of any explosivematerialsintheopenmarket.SincethentheunitsareprocuringfromKolkata.Thereare56wholesaletraders inBaraBazar inKolkatabuttheBarpetaSMEunitshavebeensourcingrawmaterialsfromonetradernamedExcelTraderssincelast1520years.They call the trader to place order and deposit about 2540 percent of the purchaseamount in his account through bank transfer. The raw materials are packed andtransportedonroadwhichreachestheunitowners in710daystime.Ondeliveryofthegoodsandreceiptofthebuiltythebalanceamounthastobepaidincash.Theproprietorsharedthegovernmentshouldpermita licenceholdertosellchemicals inBarpeta.Thiswilleaselotoftheirtrouble.RequirementofrawmaterialsSlno


1 Aluminiumpowder Kolkata Rs. 450Kg 150Kg2 Aluminiumdust(localmarket) Barpeta Rs. 150Kg 100Kg3 Aluminiumdust Kolkata Rs. 240Kg 50Kg4 Barium (For brightness of the

flame)Kolkata Rs.120Kg 2000Kg

5 PVCPowder(forcolouredflames)Earlier Potassium Chloride powder was usedbutithasriskofcatchingfiredueanyheat

Kolkata Rs.650Kg 100Kg

6 Toncia(forcolouredflame) Kolkata Rs.400Kg 50Kg7 SaltPetri(Forignitingspark) Kolkata Rs. 150Kg 2000Kg8 Sulphur(Forignition) Kolkata Rs.60Kg 1000Kg


9 Charcoal(localmarket) Barpeta Rs. 25Kg 700Kg10 JutestringSutli(localmarket) Barpeta Rs. 65Kg 1000Kg11 JutePolta Barpeta Rs. 20Kg 20Kg12 MarblePaper (1Rim20Dista&1

Dista24sheetsofpaper)Barpeta Rs. 750 1Rim

300Rims

13 OldNewsPaper Barpeta Rs.20Kg 500Kg14 CottonThread(1packet10rolls&

1roll100meters)Barpeta Rs.60Packet 300Packet

30000metersRequirementofHandToolsinafireworkunitwith15workersSlno

ListofHandTools RequiredNumbers

Rateperunit

1 TraditionalwoodenUrao(Okhli)forgrindingandmixing.Jackfruitwoodlastsandcostmore

4 Rs.20004000

2 Manualgrindingunitinstoneforfinepowder 3 Rs.12003 Ironrodsin2sizediameters14and24inchforpressing

explosivemixtureinsidethecasing50 Rs.50

4 2feetlongIronsteelrodof2diameters 16&20mmforpressingexplosivemixtureinsidebamboocase

20 Rs.70

5 Sieve(Chalini)of3differentmeshsizes(fine,medium&large)

30 Rs.30

6 Tablewithmarbletopforlabellingthefirepotswithnewspaperormarblepaper

1 Rs.500marble

7 Hacksawtocutbamboo 6 Rs.120andRs.7fornewblade

8 DaoAxeknifeinsmallandbigvarietytosplitbamboo 6 Rs.3009 Steelfineedgeknife/cuttertocutpaper 10 Rs.10010 Scissortocutjuteandcottonthreads 2 Rs.20011 Karahimixingbowl 1 Rs.35012 Electronicweighingmachine 1 Rs.10,000


DesignAuditofUnit5

SlNo


1 Product 1. TheunitmanufacturessomenewproductrangenotobservedwithotherunitssuchasFanoos(paperballoononbambooframe),Protimurti(Logodesigns),ColourSmoke,AbirBlastetc.

2. Theunitismakingeffortonproductinnovationswithcombinationsofsize,shapesandchemicalmixtures.

3. Theproductsaregradedasperthequalityandfinishandtherejectsaresoldatlowerrates.

4. Theunitmanufacturesfireworkproductsbothforretailandwholesaleorders.TheproprietorhasadisplayunitinBarpetatownofsampleproducts,imagealbumandalsovideofilmrecordedinthenight.

5. Theproprietorhasagoodbusinesssenseandrespondstomarketdemandswithnewrangeofproducts.

1. Designcustomizedprintedlabelsforproductcategorywithvisuals,logo,productcodeandinformation

2. Existinglargesizeproductrangecanberedesignedtosmallersizeandpackagedtoreducethecost.

3. ProcurementofchemicalsfromKolkataisbottleneckinproduction.

4. Semiautomatedmachineswillhelpstandardizesizeofthecasingsinpaperrollsorbamboo

5. Theworkersoftheunitwillneedsometrainingonfinishing,safetyprecautions,cateringtoretailmarket.

2 Process 1. Thisistheonlyunitwhichhasshiftedandoperatingfromthenewfireworkvillage.Theproprietorhasconstructedatemporaryshedforproduction.

2. Thechemicalmixtureismanuallygrindedinpoundingunit

Traditional Fireworks of Barpeta Barpeta District, Assam

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Transcript of Traditional Fireworks of Barpeta Barpeta District, Assam