Shanti Creation Kamar To La Blacksmith Cluster

Blacksmith Cluster
Kamartola, Assam Interactive design study

Cluster Level report, 2013
submitted by : SUKANYA BOR SAIKIA
Contents
Acknowledgements 3
National Institute of Design > Foreword 4

Design Clinic Scheme for MSMEs >
Design Awareness Programme >
Shanti Creations >
Assam…State of diversity> a. Brief & Introduction 12

Blacksmith Industry : An Overview>
Objective of the study>
Study methods implemented>
Scope of the study>
Detail of Location/District > b. Cluster Level Report 27

Economy>
Demographic distribution of Units >
Cluster History >
Business Operations : Raw Materials and production Scenario >
Tools and equipments >
Status of Design at cluster >
Product & process Specialization >
SWOT MATRIX >
Black smithy process in Kamartola Village >
Unit Description > c. Unitwise Design Audit 65

Study and Scope for existing scenario > Report (From Unit Survey)
Identifying Gaps in the System >
Intervention > d. Soft and Hard Design 97

Conclusion > Intervention
2
Sukanya Bor Saikia | Interactive design study report | Kamartola Blacksmith Cluster | 2013
Acknowledgements
Firstly, we would like to thank National Institute of Design (NID) and its following members of the North East zone Team of Design Clinic Scheme for
MSMEs ,who gave us an opportunity to first of all select us as a consulting design resource to work with their esteemed team of Design Clinic Scheme and
then placing me to work with Udyog Vikas Kendra. They played a great role in the successful completion of the Need Assessment survey report. Hence we
would like to give my gratitude to Mr. Pradyumna Vyas (Director), Mr. Shashank Mehta (DCS for MSMEs, Head, NID), Mr. Ashok Mondal (East and North
East Zone co-ordinator, DCS for MSMEs, NID), Mrs Sheikh Nilofar and the entire DCS for MSMEs team.
A special thanks to SHANTI CREATION, for providing me the opportunity and platform to work with their highly qualified team. We would like to thank
Mrs. Manashi Borah, for supporting me throughout the need assessment survey and making the report. Also would like to thank SHANTI CREATION by
giving me knowledge about the particular field of Blacksmith Cluster and providing me with their valuable feedback which would be very useful in my near
future and further in my life.
Thanks to the lovely people and artisans of Kamartola, Hajo, Assam.
Last but not the least I would like to thank my family for being my support throughout the period of making this report.
3
Foreword
National Institute of Design >
Design Clinic Scheme for MSMEs >
Design Awareness Programme >
SHANTI CREATION >
4
The National Institute of Design (NID) is internationally acclaimed as
one of the foremost multi-disciplinary institutions in the field of
design education and research. The Business Week, USA has listed
NID as one of the top 25 European & Asian programmes in the world.
The institute functions as an autonomous body under the
department of Industrial Policy & Promotion, Ministry of Commerce
& Industry, and Government of India. NID is recognised by the Dept.
of Scientific & Industrial Research (DSIR) under Ministry of Science &
Technology, Government of India, as a scientific and industrial design
research organisation.
NID has been a pioneer in industrial design education after Bauhaus
and Ulm in Germany and is known for its pursuit of design excellence
to make Designed in India, Made for the World a reality. NID’s
graduates have made a mark in key sectors of commerce, industry
and social development by taking role of catalysts and through
thought leadership.
National Institute of Design
5
Design clinic scheme was initiated under MSME’s unique and ambitious design intervention scheme for the country’s micro, small and medium scale
enterprises. It is a Government of India, Ministry of MSME initiative launched under National Manufacturing Competitive Programme. DCS was initiated to
increase awareness about the value of design and establish design learning in MSMEs. This programme was introduced to increase competitiveness of MSME
products and services through design. To create a sustainable design ecosystem for the MSME sector through continuous learning and skill development
promoting the use of design by MSME for developing better products and services that are market led.
Key principles: Adopting a rigorous, yet applicant friendly process. Promoting and disseminating design concepts in regional or local languages that can be
understood by the MSMEs. Establishing benefits without overwhelming the MSMEs. Establishing systematic processes for design and product development in
MSMEs.
Design Awareness Seminar: The design sensitisation seminar is aimed to create a platform for MSME units to improve the manufacturing competitiveness. The
seminar will help MSME participants to interact with design experts/speakers to understand design methodology and benefits of design to MSME in their
business, product, process, service and operations. To take design to a higher level of manufacturing functions, it is very important to develop and
understanding of the design scenario and environment at an early stage of conception.
Design Awareness Programme: Is focused on exploring industrial functions and activities to develop a holistic map of MSME clusters and units. The design
expert/s will generate design information about products, market scenario, technology, communication, research and development, and various industrial
functions along with human factor study for ergonomics, safety, convenience, learning and skill up gradation through design research. The programme will also
provide design remedies for identified opportunities through the design clinic workshop. The design awareness programme is conducted in two stages.
- Need Assessment Survey
- Design Clinic Workshop
6
Design Projects: Design projects are identified during the need assessment survey
and discussed during the design clinic workshop. Project which require intensive
design observation and interventions can be taken up as design projects with the
help of design experts. The project can be related to design intervention in area of
product/process /strategic areas where design can help in generating solutions and
value for individual or group of MSMEs.
Role of Design in Improving Competitiveness: Design is an approach, process and

methodology. Design is indented, purposeful, contextual, which is aimed to
create advantage, distinction and futuristic outcome as a result. Design is
systemic and holistic in nature, therefore helps in generating more creative,
impactful and sustainable solutions. In manufacturing, design is commonly
associated with industrial product design – specifically the ‘aesthetics and
appearance’ of a product at a surface level interaction.
However, the application of design is much broader, for example designing for
functional appeal, ease of manufacture, consumption and sustainable. Designing
may also be done for reliability or quality or business processes. Service designs
are primarily to cater to customer’s experience of the delivered product and
service.
The larger purpose of design is to do things in a better manner, to improve a

situation and to make a positive difference. The role of design in business is to
create value. A company can use the design process to add value to products,
services, and the organisation. A well-designed product, service, or organisation
is always more valuable. Design, innovation and growth are linked. Innovation
and design are not simply about new products or technology. They are also
about how to improve products for everyday use, leading to reduced costs,
increased usability and new business opportunities. Design is recognised as an
innovative discipline that can help MSMEs to sustain and grow in an increasingly
competitive market.
7
Design Awareness Programme
The design awareness programme, DAP, is focused to develop a holistic map of MSME clusters and units by exploring through industrial functions and
activities. The design expert/s will generate design information about products, market scenario, technology, communication, research & development, and
various industrial functions along with human factor study for ergonomics, safety, convenience, learning and skill up gradation through design research.
Also the programme will provide design remedies for identifi ed opportunities through design clinic workshop. The workshop will help participants to
understand the holistic scenario of cluster and benefi t them with the support of design expert/s, for design intervention in opportunity areas explored
during the programme.
The activities of design awareness programme are targeted around following areas of design information collection and remedial solutions. Design Expert
will visit the identifi ed /selected MSME units located in cluster region and interact with them to develop a design understanding of cluster. During the
interaction design will provide inputs to MSMEs about product improvements, best practices and creative problem solving approach based on contextual
scenario. In the process s/he will identify underlying opportunities with the help of explorative design research of clusters and participating units. This
activity is an intensive design research for understanding the present scenario and opportunities for the design intervention. Also it will help improve MSME
through Interactive learning, guidance and training during the visit.
This activity will be a detailed research thorough visits and interaction with people within the MSME work environment. It will also help designer to
generate information about the cluster units, their products, manufacturing processes, market scenario followed by identifying opportunity areas for
design interventions. The research would be taken up by design expert/s for generation of design insights through various processes. of exploration,
interaction and data collection. Design expert/s will take part in developing macro perspective by studying cluster scenario and micro point of view by
exploring through MSME units operations. As an outcome of interactive design research, expert/s will identify opportunity areas at cluster as well as units
level for design interventions and design project/s in the future course of design clinic scheme The research methodology for design study survey will
include activities through observation, interaction, photography, interviews and qualitative/ quantitative design data collection. The survey will help in
developing detailed map of cluster and units for identifi cation of patterns and exploring opportunity areas for design intervention at various levels of
product and human interactions.
8
Artisans at work in Blacksmith Cluster, Kamartola, Assam
9
OBJECTIVE : To promote Designing and Marketing of Rural Product which reflects Rural Weavers and Artisans and JLG’S to develop their
economic and social benefit.
SHANTI CREATION is a Non Govt. organisation that was created in the year 2008. It is situated in Bishnu Rabha Path, Beltola, Guwahati, Assam. In continuance of
its objectives either by itself or in collaboration with other cooperative, financial, government, development and banking organisations or corporate bodies, the
“SHANTI CREATION” shall do the some of the following activities :
1. To promote activities for the educational & socio-economic development of the unemployed youth specially rural & urban youths.
2. To facilitate marginalized community in accessing formal, non formal, vocational education etc, especially targeting the most deprived vulnerable children
and woman.
3. To work for Skill up gradation to small scale industries and to Rural People
4. To inculcate legal awareness among the poor and vulnerable section of the society in regard to their right.
5. To organize legal Awareness Camp, Free Medical Camp, Blood Donation Camp, Health Awareness Camp about HIV/AIDS, Cancer etc.
6. To work for the poor and marginalized by enabling to access safe drinking water and hygiene and sanitation.
7. Encouraging all marketing efforts to boost sales generation in the different cluster such as participating in Exhibition, sales event held at local level and
outside the state, order generation of buyers and direct marketing by forming a marketing team with selected members of the cluster.
8. To fight for environment protection by facilitating awareness generation on environment degradation and work for preservation of eco system by
implementing forestation projects and programme.
9. Registration and renewal at regular activity under the Joint Director of Foreign Trade Import-Export Certificate (IEC).
10. To take steps for Agriculture, Horticulture, Animal husbandry for the development of rural poor people and thereby encourage them to take-up livelihood
independently.
10
Activity Report of SHANTI CREATION since 2011 :
•Improve Handloom Technology Total : 5 Program

: No of Beneficiary - 150
•Pattern Making and Garment Construction : 6 Program

: No of Beneficiary -200
•Formation of Joint Liability Group Total : 70
•Credit Linkage with Banks : 40
•Cotton and Silk yarn dyeing program with chemicals and vegetables : 5 program
: No of beneficiary -150
•Pattern Making and Garment Construction
•Textile Design development and yarn dyeing
•Rural Product Marketing to Sale the product of Rural Weaver
•Participation in Exhibition about : 5
•Technical Consultant on 5 ESDP Program Sponsored by IIE, Guwahati
•2 no of Design Clinic Workshop under Ministry of MSME, Govt. of India in Collaboration with NID, Ahmedabad
11
a. Brief & Introduction
Assam…State of diversity>
Blacksmith Industry : An Overview>
Objective of the study>
Study methods implemented>
Scope of the study>
12
Assam…State of diversity
13
Assam GEOGRAPHY
Brahmaputra, the life-line of Assam is an antecedent river, older than the Himalayas. The
river with steep gorges and rapids in Arunachal Pradesh entering Assam, becomes a
braided river with tributaries, creates a flood plain (Brahmaputra Valley: 50–60 mi/80–100
km wide, 600 mi/1000 km long). The hills of Karbi Anglong, North Cachar and those close
FACT FILE to Guwahati (also Khasi-Garo Hills) are originally parts of the South Indian Plateau
system. In the south, the Barak originating in the Barail Range (Assam-Nagaland border)
AREA 78, 550 sq. km flows through the Cachar district with a 40–50 km wide valley and enters Bangladesh
CAPITAL Dispur with the name Surma.
ATTAINED STATEHOOD August 15, 1947 Assam is endowed with petroleum, natural gas, coal, limestone and other minor minerals
.
POPULATION (2011 census) 31,169,272 such as magnetic quartizite, kaolin, sillimanites, clay and feldspar. Discovered in 1889, all
DISTRICTS 27 the major petroleum-gas reserves are in Upper Assam.
LANGUAGES Assamese,Bengali, Bodo, Hindi, English, etc. Located south of the eastern Himalayas, Assam comprises the Brahmaputra & the Barak
LEGISLATURE Unicameral river valleys and the Karbi Anglong & the North Cachar Hills with an area of 30,285 Square
CLIMATE Summer Maximum 38 degrees Celsius miles (78,438 Square km). Assam currently is almost equivalent to the size of Ireland or
Minimum 20 degrees Celsius Austria. Assam is surrounded by the rest of the Seven sisters state: Arunachal Pradesh,
Winter Maximum 25 degrees Celsius Nagaland, Manipur, Mizoram, Tripura and Meghalaya sharin International Border with
Minimum 10 degrees Celsius Bhutan & Bangladesh. Assam is known for Assam tea, Petroleum, resources, Assam silk &
for its rich biodiversity.
14
Guwahati City (gateway to northeast)
DEMOGRAPHICS
Assam’s population was estimated at 28.67 million in 2006 and at 30.57

million by 2011, 34.18 million by 2021 and 35.60 million by 2026. Assam has
many ethnic groups and the People of India project has studied 115 of
these. Out of which 79 (69%) identify themselves Template: Explanation
needed regionally, 22 (19%) locally, and 3 trans-nationally. The earliest
settlers were Austro-Asiatic, followed by Tibeto-Burman, Indo-Aryan
speakers, and Tai–Kadai speakers. Forty-five languages are spoken by
different communities, including three major language families: Austro-
Asiatic , Sino-Tibetan and Indo-European.
There are 23 notified Scheduled Tribes (ST) in Assam with the Bodos
(40.9 per cent) making half of the total ST population (around 13 per
cent) of the state. The other STs (both plains and hills) include Miri,
Karbi, Rabha, Kachari, Lalung, Barman in Cachar, Borokachar, Deori,
Hajai, Mech, Dimasa, Hajong, Singhphho, Khampti and Garo, Chakma,
Hmar, Khasi, Jaintia, Synteng, Pnar, War, Bhoi, Lyngngam, and Kuki.
ECONOMY
Economy of Assam today represents a unique juxtaposition of

backwardness amidst plenty. Despite its rich natural resources, and
supplying of up to 25% of India’s petroleum needs, growth rate of
Assam’s income has not kept pace with that of India’s; differences
increased rapidly since 1970s. Agriculture : Assam’s biggest contribution
to the world is tea. Assam is a major producer of crude oil and it
accounts for about 15% of India’s crude output. Tourism : Assam is the
central state in the North-East Region of India and serves as the
gateway to the rest of the Seven Sister States. For the purposes of
tourism there are wildlife preserves like the Kaziranga National Park,
Manas National Park, Pobitora Sanctuary among others.
15
CULTURE
Assamese culture is traditionally a hybrid one developed due to assimilation of ethno-cultural
groups in the past. Various elements like Tamulpan (the areca nut and betel leaves), Sorai and
Gamosa are being used to represent beliefs, feelings, pride, identity, etc. The major milestones in
evolution of Assamese culture are: 1. Assimilation in the Kamarupa Kingdom for almost 700 years
(under the Varmans for 300 years, Salastambhas and Palas for each 200 years).
2. Establishment of the Ahom dynasty in the 13th century AD and assimilation for next 600 years.
3. Assimilation in the Koch Kingdom (15th–16th century AD) of western Assam and Kachari
Kingdom (12th–18th century AD) of central and southern Assam.
4. Vaishnava Movement led by Srimanta Shankardeva (Xonkordeu) in the 15th century and its
contribution provided another dimension to Assamese culture. of social institutions such as
namghar and sattra (the Vaishnav Monasteries).
Bihu(Rongali, Bohag, Kati) is the most important and common and celebrated all over Assam.
Durga Puja is another festival celebrated with great enthusiasm. Muslims celebrate two Eids (Eid ul-
Fitr and Eid al-Adha)
Bihu (Tongali, Bohag, Kati) is the most important, common festival which is celebrated all over Assam. Durga Puja is another festival celebrated with great
enthusiasm.
CLIMATE Muslims celebrate two Eids (Eid-Ul-Fitr and Eid-al-Adha) .
With the “Tropical Monsoon Rainforest Climate”, Assam is temperate (summer max. at 95–100 °F or 35–38°C and winter min. at 43–46 °F or 6–8 °C) and
experiences heavy rainfall and high humidity. The climate is characterized by heavy monsoon downpours reducing summer temperatures and affecting
foggy nights and mornings in winters. Thunderstorms known as Bordoicila are frequent during the afternoons. Spring (Mar–Apr) and Autumn (Sept–Oct)
are usually pleasant with moderate rainfall and temperature.
16
FLORA AND FAUNA
Assam is one of the richest biodiversity zones in the world and consists of tropical rainforests, deciduous forests, riverine grasslands, bamboo orchards
and numerous wetland ecosystems. The Kaziranga, home of the rare Indian Rhinoceros and Manas are two UNESCO World Heritage Sites in Assam. Some
other endangered species with significant population in Assam are the tiger, elephant, Hoolock gibbon, Jerdon’s Babbler etc. For the State Bird, the White-
winged Wood Duck, Assam is a globally important area. The state has the largest population of the Wild Water Buffalo in the world. The state also has the
highest diversity of birds in India with around 820 species, with 946 subspecies. The region is prone to natural disasters with annual floods and frequent
mild earthquakes. Strong earthquakes are rare; three of which were recorded in 1869, 1897 (8.1 on the Richter scale); and in 1950 (8.6).
17
LANGUAGES
Assamese and Bodo are the major languages spoken while Bengali holds official status in the three districts in the Barak Valley and is the second most
widely spoken language of the state (27%). Dimasa is a one of the oldest language spoken in North East India particularly in Assam. Other native
languages of Tibeto-Burman origin and related to Bodo-Kachari are DEORI Mising, Karbi, Rabha, Tiwa, etc. A total of six Tai language were spoken in
Assam : Tai Phake, Tai Aiton, Khamti, Khamyang, Ahom, Turung. Bengali is the official language in Barak Valley and the widely spoken language there
is Sylheti, a dialect of Bengali.
RELIGIONS
According to the 2001 census, there were 17,296, 455 Hindus, 8,240, 611 Muslims, 986,589 Christians, 22,519 Sikhs, 51,029 Buddhists, 23,957 Jains and
22,999 belonging to other religious communities like Khamti, Phake, Aiton etc communities.
18
TRADITIONAL CRAFTS
Assam has a rich tradition of crafts; presently, Cane and bamboo

craft, bell metal and brass craft, silk and cotton weaving, jute
products making craft toy and mask making, pottery and
terracotta work, wood craft, jewellery making, musical
instruments making, etc. remained as major traditions.
Historically, Assam also excelled in making boats, traditional guns
and gunpowder, ivory crafts, colours and paints, articles of lac,
agarwood products, traditional building materials, utilities from
iron, etc.
Utilities and symbolic articles such as Sorai and Bota made from
bell metal and brass are found in every Assamese household. Hajo
and Sarthebari are the most important centres of traditional bell-
metal and brass crafts. Assam is the home of several types of silks,
the most prestigious are: Muga – the natural golden silk, Pat – a
creamy-bright-silver coloured silk and Eri – a variety used for
manufacturing warm clothes for winter. Assam possesses unique
crafts of toy and mask making mostly concentrated in the
Vaishnav Monasteries, pottery and terracotta work in lower
Assam districts and wood craft, iron craft, jewellery, etc. in many
places across the region.
19
20
Blacksmith working pic
20
a.1. Blacksmith Industry : an Overview
A blacksmith is a person who creates objects from wrought
iron or steel by forging the metal; that is, by using tools to hammer, bend, and
cut (compare to whitesmith). Blacksmiths produce objects such as gates,
grilles, railings, light fixtures, furniture, sculpture, tools, agricultural
implements, decorative and religious items, cooking utensils, and weapons.
ORIGIN OF THE TERM
The term "blacksmith" comes from the activity of "forging" iron or the "black"
metal - so named due to the color of the metal after being heated (a key part
of the blacksmithing process). The term "forging" means to shape metal by
heating and hammering. "Smith" is from the Proto-German "smithaz" meaning
"skilled worker.“
Blacksmiths work primarily with wrought iron and steel. The "black" in
"blacksmith" refers to the black fire scale, a layer of oxides that forms on the
surface of the metal during heating. The word "smith" derives from an old word,
"smite" (to hit). Thus, a blacksmith is a person who hits black metal.
Blacksmiths work by heating pieces of wrought iron or steel, until the metal
becomes soft enough to be shaped with hand tools, such as a
hammer, anvil and chisel. Heating is accomplished by the use of a forge fueled by
propane, natural gas, coal, charcoal, coke or oil.
The techniques of smithing may be roughly divided into forging (sometimes called
"sculpting"), welding, heat treating, and finishing.
21
22
HISTORY, RELIGION & MYTHOLOGY
MYTHOLOGY IRON AGE

In Hindu mythology, Tvastar also known as Vishvakarma is the blacksmith Concurrent with the advent of alphabetic characters in the Iron Age,
of the devas. Hephaestus (Latin: Vulcan) was the blacksmith of the gods humans became aware of the metal iron. In earlier ages, iron's qualities,
in Greek and Roman mythology. In Celtic mythology, the role of Smith is in contrast to those of bronze, were not generally understood though.
held by eponymous (their names do mean 'smith') characters Iron artifacts, composed of meteoric iron, have the chemical
: Goibhniu (Irish myths of the Tuatha Dé Danann cycle) composition containing up to 40% nickel. Despite being subject to rust,
or Gofannon (Welsh myths/ the Mabinogion ). The Anglo-Saxon Wayland iron replaced bronze as soon as iron-wielding hordes could invade Bronze
Smith, known in Old Norse as Völundr, is a heroic blacksmith in Germanic Age societies and literally slice through their obsolete bronze defenses.
mythology. Iron is a stronger and tougher metal than bronze, and iron ores are found
nearly everywhere. Copper and Tin deposits, by contrast, are scattered
BEFORE IRON AGE and few, and expensive to exploit.
During the Chalcolithic era and the Bronze Age, humans in the Mideast MEDIEVAL PERIOD
learned how to smelt, melt, cast, rivet, and (to a limited extent ) forge
copper and bronze. Bronze is sufficiently corrosion-resistant In the medieval period, blacksmithing was considered part of the set
that artifacts of bronze may last thousands of years relatively unscathed. of seven mechanical arts. Prior to the industrial revolution, a“villagesmithy"
Accordingly, museums frequently preserve more examples of Bronze was a staple of every town. Factories and mass-production reduced the
Age metal-work than examples of artifacts from the much younger Iron demand for blacksmith-made tools and hardware.
Age.
22
20th CENTURY
During the 20th century various gases (natural gas, acetylene, etc.) have also come
to be used as fuels for blacksmithing. While these are fine for blacksmithing iron,
special care must be taken when using them to blacksmith steel. Each time a piece
of steel is heated, there is a tendency for the carbon content to leave the steel
(decarburization).
A renewed interest in blacksmithing occurred as part of the trend in "do-it-yourself"

and "self-sufficiency" that occurred during the 1970s. Currently there are many
books, organizations and individuals working to help educate the public about
blacksmithing, including local groups of smiths who have formed clubs, with some
of those smiths demonstrating at historical sites and living history events. Some
modern blacksmiths who produce decorative metalwork refer to themselves as
artist-blacksmiths.
While developed nations saw a decline and re-awakening of interest in

blacksmithing, in many developing nations blacksmiths continued doing what
blacksmiths have been doing for 3500 years: making and repairing iron and steel
tools and hardware for people in their local area.
For example artisans in a developing nation like India are still using Iron bought
from the wastes and left over from the Railway Industry an use them to make
knives and other household utility items. Everything is done manually.
23
a.2. Objective of the study
The diagnostic study on the Blacksmith cluster of Hajo’s Kamartola village has been undertaken ,keeping in view about the following objectives:
Identifying the socio-economic condition of the cluster

Outlining the present business environment of the cluster
Identifying the problems faced by the cluster
Identifying infrastructural and financial support required for the overall development of the cluster
24
a.3. Study methods implemented
The present diagnostic study has been carried out covering the entire
Kamartola Village in the Kamrup district of Assam. Based on the laid down
objectives, both primary and secondary data have been used and analyzed in
the study. The study has been divided into five stages :
1) In the second stage as per the requirement of the study, primary data
has been collected using purposive sampling through intensive
interactions/interviews with concerned cluster actors as well as with
various stakeholders. For collecting the primary data, structured
discussion formats have been devised for collecting village-level and
artisan-level information. Interviews have been carried out with the
cluster units involved in manufacturing jute products.
2) The secondary data have been gathered from various government
publications Census Report, Annual Reports of various government
departments.
3) Through exhaustive desk research the overall status of the Blacksmith
industry has come out based on research. Besides, the overall design of
the survey has also been worked out.
4) Analysis of data and information collected by applying various standard
design tools. Studying the present scenario and identifying the problems
and gaps in the existing business operations.
5) In the final stage suitable interventions have been devised to bridge the
identified critical gaps. Developing proper cluster vision and strategy
formulation in the form of an Action Plan comprising both soft and hard
interventions. Considering the village population were chosen for
detailed design research out of all the Kamartola village.
The solution given can be implemented to other villages also.
25
a.4. Scope of the study
The study would will help to get basic information about the cluster including the exact location of the cluster, age of the cluster, cluster products,
existing technology used, present workstation, number of micro and small units together along with the average investment, employment level, level of
technology, turn-over, exports and institutional supports available in the cluster.
The demography of the cluster will also be assessed. The proper intervention plan will be worked out in different areas like marketing, technology
upgradation, credit, institutional capacity building etc. after making a need based analysis. It would also provide a means for assessing the feasibility of
interventions, enhancing cooperation among the cluster actors and most importantly involve all the units irrespective of their size of business operation
in the cluster development programme.
26
b. Cluster Level Report
Detail of Location/District >

Economy>
Demographic distribution of Units >
Cluster History >
Business Operations : Raw Materials and production Scenario >
Tools and equipments >
Status of Design at cluster >
Product & process Specialization >
SWOT MATRIX >
Black smithy process in Kamartola Village >
27
b.1. Detail of Location/District
Kamrup District Overview
STATE Assam
ADMINISTRATIVE DIVISION Lower Assam
AREA 6882 sq km
POPULATION (2011) 35,96,292
URBAN DEMOGRAPHICS Literacy : 70.95%
Sex Ratio : 914
MODERN SCENARIO
Kamrup district consists of wide plains through which the mighty river Brahmaputra
makes its way flowing a steady course from east to west. The demographic pattern
of Kamrup District is a heterogenous one. However, there exist a perceptible degree
of mutual love, respect and inter-religious tolerance amongst them.
The District is bounded by Udalguri and Baska district in the north, Meghalaya in the
south, Darrang and Kamrup Metropolitan District in the east and Goalpara and
Nalbari District in the west.
Kamrup district has been steadily decreasing in size for decades. During British India
at some point Kamrup was divided into two big districts for administrative reasons
one added to Assam and other to Bengal which includes Cooch
Behar and Jalpaiguri. In 1983 Barpeta district was split from Kamrup. Nalbari district
was then similarly split off on 14 August 1985. On 3 February 2003 Kamrup
Metropolitan district was formed to cover the urban core of the district, and 1 June
2004 saw the formation of Baksa district which was formed from parts of three
districts, including Kamrup. The headquarters of district was at Guwahati. The
population is rural and suburban with major urban agglomeration in Guwahati, the
largest city of region.
28
GEOGRAPHY AND ENVIRONMENT
Kamrup district occupies an area of 4,345 square kilometres

(1,678 sq mi),comparatively equivalent to Australia's Kangaroo
Island. The Brahmaputra, which divides the district into two nearly
equal portions, is navigable by river steamers throughout the year, and
receives several tributaries navigable by large native boats in the rainy
season. The chief of these are the Manas, Chaul Khoya and Barnadi on
the north, and the Kulsi and Dibru on the south bank.
In 1989 Kamrup district became home to the Dipor Bil Wildlife

Sanctuary, which has an area of 4.1 km2 (1.6 sq mi).
DEMOGRAPHICS
According to the 2011 census Kamrup district has a population of 1,517,202,

roughly equal to the West African country of Gabon or the US state
of Hawaii. Kamrup has a sex ratio of 946 females for every 1000 males, and
a literacy rate of 72.81%.
The district has followers of Hinduism, Islam, Christianity, Buddhism and
Animism. The ancient temples of Kamakhya and Hajo attracts many pilgrims
from all quarters. Major language spoken natively is Kamrupi with pockets of
Amri, a Tibeto-Burman language related with Karbi, with 1,25,000 speakers
ECONOMY
The staple crop of the district is rice, of which there are three crops. The
indigenous manufactures are confined to the weaving of silk and cotton
cloths for home use, and to the making of brass cups and plates. The
chief exports are rice, oil seeds, timber and cotton; the imports are fine
rice, salt, piece goods, sugar, betel nuts, coconuts and hardware. A
section of the Assam-Bengal railway starts from Guwahati, and a branch
of the Eastern Bengal railway has recently been opened to the opposite
bank of the river. A metalled road runs due south from Guwahati
to Shillong.
29
b.2. Economy
Although the rural economy of Kamrup district is agrarian in nature however, the
tertiary sector is dominant in terms of its income share and employment and livelihood
generation. The sector contributes 66 percent of the total income in the Gross District
Domestic Product while secondary sector contributes 20 percent. The primary sector
contribution is estimated to be 14 percent. The per capita Gross District Domestic
Product of Kamrup estimated at Rs.22292 is the highest among the districts of the
state.
The industrial base of the district is agro based. The district has 676 (23 percent of State
total) industrial units registered which comprise of food products and beverages,
manufacture of wood and wood products. The district has a total number of 14,776 SSI
units which is almost 30 percent of the State total. The largest concentration of
industry is in and around Guwahati due to availability of various infrastructure facilities
and proximity to the main commercial and trading centres in the N.E. Region.
The district is covered under District Rural Industries Project (DRIP) of NABARD from
the year 2000-2001. The main objective of DRIP is to create sustainable employment
avenues in rural areas through enhanced credit flow to RNFS with complementary
promotional support. The industries having major concentration around Guwahati
include engineering, agro-based and chemical industries. The forest based industries
are concentrated in Palasbari, Sualkuchi, Hajo and North Guwahati. Sualkuchi and North
Guwahati are also famous for handloom and handicraft activities. The existing RNFS
activities in the district are classified under three broad heads as manufacturing and
processing, trade, transport and service. The data from District Industries & Commerce
Center, Kamrup shows the various categories of Industries already set up in district and
where high growth potential exist.
30
34
b.3. Demographic distribution of Units
The famous Madhav Mandir in Hajo
HAJO
Hajo is a town in India situated in the Kamrup district of Assam. It is in the
state/region of Assam. The population is between 10,000 and 20,000. Hajo is an
ancient pilgrimage centre for three religions: Hindus, Buddhists, and Muslims. It
lies on the banks of the Brahmaputra River, 24 km from the city of Guwahati in
the Kamrup district of Assam, India. The area is dotted with a number of ancient
temples as well as other sacred artifacts. The Hayagriva Madhava Mandir is the
most famous temple of Hajo. Lesser known temples of Hajo like that
of Ganesha was constructed during the reign of Ahom King Pramatta Singha in
1744 AD. The Kedareswara Temple, a Shiva temple, has inscription on the temple
showing that it is of Rajeswar Singha period.
Geographical Information for Hajo
Place name : Hajo

Latitude : 26° 15' 51" N
Longitude : 91° 36' 52" E
Feature description : Town
Region : Kamrup
Area/state : Assam
Population range of place: is between 10,000 and 20,000
Country : India
Village Name : Bangaltola
Habitation Name : Kamartola
31
b.4. Cluster History
The Cluster was created in the year 2012 by Shanti Creation supported by
Ministry of District Industries Commision. There are around 100 artisans in the
cluster which is situated in the Kamartola Village in Hajo of Kamrup District of
Assam. Almost all the artisans have their own working shed in the premises of
their own houses. Some of the worksheds are situated on a different area near
the village and every twice a week there is a vegetable market Haat in the
same area.
All the artisans of the cluster are men. Apart from Blacksmithing, they are
mainly engaged as farmers and have their own farms and grow crops like
potato, rice etc. In off season or few member of each and every family
belonging to the cluster produces products which are slod in the local market,
nearby city market and trade fairs.They earn around Rs 1500- Rs 2000 per
month.
The Raw materials they use are Carbon Steel collected from the scrap of large
vehicle parts. The other raw material is wood which they collect from trees and
branches. And finally the coal is procured from a nearby market. Due to the
fact that raw materials used in the production of various knives and products
in the clusters are easily available the amount of production of the cluster is
good. But the materials are not long lasting and gets rusted easily due to lack
of treatment of the iron. The annual production of the cluster is as per the
need of the customers and the orders given by the middle men. There
products are being sold in the Local Market of Kamartola, Hajo, Guwahati and
in various Exhibitions in Guwahati. Till now a lot many not a single program
and training session have been conducted in the cluster. Identifying the cluster
by Shanti creations and DICC would make the cluster people self reliable and
finding a way out to earn and have a good livelihood of their and made them
entrepreneurs.
32
47
KAMARTOLA VILLAGE
33
About Kamartola
Kamartola is a Village situated in the town Hajo of Assam. Kamartola is the habitation name of
the village Bangartola. The place has been named Kamartola because of the specific reason that
it is famous for its Blacksmith work in entire Assam. ‘Kamar’ in Assamese language means a kind
of Work specifically done by artisans by using iron as a material.
Kamartola is a small Village situated around 5

kms away from the main town of Hajo. The
basic source of income of the people residing
in the village is either by black smithy or by
farming of various crops like Potato, Rice,
paddy etc. The artisans of the village has to
work everyday to earn their living.
There is no extra income outsourced. The

products made in the cluster are mostly sold
in the local market or nearby market like that
of Guwahati, trade fairs and Local fairs or
festivals within the Village.
The people of the Village are very

hardworking and forward thinking and are
also quiet eager to learn new things in their
life.
34
TRANSPORTATION : GUWAHATI-HAJO-GUWAHATI
Hajo is just 25 km from Guwahati, serves as an important rail head for travel and is well connected to all the parts of the country. There are many modes of
transport available to the town of Hajo, buses, flights or trains in order to reach the place. Hajo is well connected to the nearby cities of Tezpur and
Guwahati. Though, flights cannot be taken directly to the town of Hajo, but they can however be taken to the nearby city of Guwahati.
Many major roads run through the town of Hajo, and a road that runs from Guwahati to Nalbari is a major road in the region. The road that leads from
Guwahati to Barpeta can also be taken to the town of Hajo.
35
No. of Villages covered : 1
Kamartola Village
Support by : Tools Used :

Ministry of MSMEs, Hand operated pump,
Shanti Creation Metal & Wooden
Hammer,
Products Produced : Total no. of working Chisel,
Barpetia Dau (Long Units: 100 Iron Tongs of various
straight cutting knife sizes and rounded
with flat nose) mouth,
Seedha Dau (Long File,
straight cutting knife) Hand Saw
Deggar Bhim (Anvil)
Pati Bothi (Bird shaped Nieri ( A ‘T’ shaped Iron
peeling/cutting knife) object for hammering)
Katari (Knife) Punching Tool
Jungar (A product with Self made cutter
maning pointed mouths)
Type of Industry: Technology Used :
Dighal Dau (Long cutting
Micro Scale Industry Hand operated pump,
knife)
Forging,
Drawing,
Annual Production :
Bending,
As per need or order
Upsetting,
Punching,
Combining,
Welding,
Finishing
Market:
Trade Fairs Earning:
Local Market Rs 1000/1500 pm
Raw Material: Iron,
Wood extracted from
wood twigs of trees,
Coal,
Water
36
37
Black smithy process throughout the world
Blacksmiths work primarily with wrought iron and steel. The "black" in "blacksmith" refers to the black fire scale, a layer of oxides that forms on the surface
of the metal during heating. The word "smith" derives from an old word, "smite" (to hit). Thus, a blacksmith is a person who hits black metal.
Blacksmiths work by heating pieces of wrought iron or steel, until the metal becomes soft enough to be shaped with hand tools, such as a
hammer, anvil and chisel. Heating is accomplished by the use of a forge fueled by propane, natural gas, coal, charcoal, coke or oil. The techniques
of smithing may be roughly divided into forging (sometimes called "sculpting"), welding, heat treating, and finishing.
37
HEATING : Blacksmiths work by heating pieces of wrought iron or steel in a forge until the
metal becomes soft enough to be shaped with tools such as a hammer. Heating is
accomplished by the use of a forge fueled by propane, natural gas, coal, charcoal, or coke.
Colour is important for indicating the temperature and workability of the metal: As iron is
heated to increasing temperatures, it first glows red, then orange, yellow, and finally white.
Blacksmiths work in dim, low-light conditions because they have to see the colour achieved
at ideal heat for most forging, which is the bright yellow-orange colour appropriately known
as a "forging heat".
FORGING : A process in which metal is shaped by hammering. In this the iron is hammered
into shape. Even punching and cutting operations (except when trimming waste) by smiths
will usually re-arrange metal around the hole, rather than drilling it out as swarf. There are
seven basic operations or techniques employed in forging: drawing down, shrinking (a type
of upsetting), bending, upsetting, swaging, punching and forge welding. These operations
generally employ hammer and anvil at a minimum, but smiths will also make use of other
tools and techniques to accommodate odd-sized or repetitive jobs.
DRAWING: Drawing lengthens the metal by reducing one or both of the other two
dimensions. As the depth is reduced, the width narrowed, or the piece is both lengthened
or "drawn out.“ As an example of drawing, a smith making a chisel might flatten a square
bar of steel, lengthening the metal, reducing its depth but keeping its width consistent.
Drawing does not have to be uniform. A taper can result as in making a wedge or a
woodworking chisel blade. If tapered in two dimensions, a point results. Drawing can be
accomplished with a variety of tools and methods. Two typical methods using only hammer
and anvil would be hammering on the anvil horn, and hammering on the anvil face using the
cross peen of a hammer. Another method for drawing is to use a tool called a fuller, or the
peen of the hammer, to hasten the drawing out of a thick piece of metal. (The technique is
called fullering from the tool.)
38
BENDING : Heating iron to a "forging heat" allows bending as if it were a soft, ductile metal,
like copper or silver. Bending can be done with the hammer over the horn or edge of the
anvil or by inserting a bending fork into the Hardy Hole (the square hole in the top of the
anvil), placing the work piece between the tines of the fork, and bending the material to the
desired angle. Bends can be dressed and tightened, or widened, by hammering them over
the appropriately shaped part of the anvil.
UPSETTIING: Upsetting is the process of making metal thicker in one dimension through
shortening in the other. One form is to heat the end of a rod and then hammer on it as one
would drive a nail: the rod gets shorter, and the hot part widens. An alternative to hammering
on the hot end is to place the hot end on the anvil and hammer on the cold end.
PUNCHING : Punching may be done to create a decorative pattern, or to make a hole. For
example, in preparation for making a hammerhead, a smith would punch a hole in a heavy bar
or rod for the hammer handle. Punching is not limited to depressions and holes. It also includes
cutting, slitting, and drifting—all done with a chisel.
COMBINING PROCESSES : The five basic forging processes are often combined to produce and
refine the shapes necessary for finished products. For example, to fashion a cross-peen hammer
head, a smith would start with a bar roughly the diameter of the hammer face: the handle hole
would be punched and drifted (widened by inserting or passing a larger tool through it), the
head would be cut (punched, but with a wedge), the peen would be drawn to a wedge, and the
face would be dressed by upsetting.
As with making a chisel, since it is lengthened by drawing it would also tend to spread in width.
A smith would therefore frequently turn the chisel-to-be on its side and hammer it back down—
upsetting it—to check the spread and keep the metal at the correct width.
39
WELDING: Welding is the joining of the same or similar kind of metal.
A modern blacksmith has a range of options and tools to accomplish this. The basic types of
welding commonly employed in a modern workshop include traditional forge welding as well as
modern methods, including oxyacetylene and arc welding.
In forge welding the pieces to be joined are heated to what is generally referred to as "welding
heat". For mild steel most smiths judge this temperature by color: the metal will glow an intense
yellow or white. At this temperature the steel is near molten.
Any foreign material in the weld, such as the oxides or "scale" that typically form in the fire, can
weaken it and potentially cause it to fail. He will first clean the parts to be joined with a wire
brush, then put them in the fire to heat. With a mix of drawing and upsetting the faces will be
shaped so that when finally brought together the centre of the weld will connect first and the
connection will spread outward under the hammer blows, pushing the flux (if used) and foreign
material out.
FINISHING : Depending on the intended use of the piece a blacksmith may finish it in a number
of ways:
A simple jig (a tool) that the smith might only use a few times in the shop may get the minimum
of finishing: a rap on the anvil to break off scale and a brushing with a wire brush.
Files can be employed to bring a piece to final shape, remove burrs and sharp edges, and
smooth the surface.
Heat treatment and case-hardening to achieve the desired hardness.
The wire brush either as a hand tool or power tool can further smooth, brighten and polish
surface.
Grinding stones, abrasive paper, and emery wheels can further shape, smooth and polish the
surface.
There are a range of treatments and finishes to inhibit oxidation of the metal and enhance or
change the appearance of the piece. An experienced smith selects the finish based on the metal
and intended use of the item. Finishes include but are not limited to: paint,
varnish, bluing, browning, oil, and wax.
40
b.5. Business Operations : Raw Materials and production Scenario
CARBON STEEL
About
Carbon steel is steel where the main interstitial alloying constituent is carbon in the
range of 0.12-2.0%. The term "carbon steel" may also be used in reference to steel
which is not stainless steel; in this use carbon steel may include alloy steels. As the
carbon percentage content rises, steel has the ability to become harder and
stronger through heat treating, however it becomes less ductile. Regardless of the
heat treatment, a higher carbon content reduces weld ability. In carbon steels, the
higher carbon content lowers the melting point.
Types
Carbon steel is broken down into four classes based on carbon content:
1.Mild and low carbon steel

Mild steel, also called plain-carbon steel, is the most common form of steel
because its price is relatively low while it provides material properties that are
acceptable for many applications, more so than iron. Low carbon steel contains
approximately 0.05–0.3% carbon and mild steel contains 0.3–0.6% carbon; making it
malleable and ductile. Mild steel has a relatively low tensile strength, but it is cheap
and malleable; surface hardness can be increased through carburizing.
2.Higher carbon steels

Carbon steels which can successfully undergo heat-treatment have a carbon
content in the range of 0.30–1.70% by weight. Trace impurities of various
other elements can have a significant effect on the quality of the resulting steel.
Medium carbon steel : Approximately 0.30–0.59% carbon content. Balances

ductility and strength and has good wear resistance; used
for large parts, forging and automotive components.
41
High carbon steel : Approximately 0.6–0.99% carbon content. Very strong, used for springs and high-
strength wires.
Ultra-high carbon steel : Approximately 1.0–2.0% carbon content. Steels that can be tempered to Scrap of Ultra
great hardness. Used for special purposes like (non-industrial-purpose) knives,
axles or punches. Most steels with more than 1.2% carbon content are made
high Carbon
using powder metallurgy. Note that steel with a carbon content above 2.0% is steel used in
considered cast iron.
the cluster
The Ultra high carbon steel that the artisans use are mostly scrap
parts of a truck, specially the spring system in the trucks.
PRICE
PRICE of Ultra high carbon steel Scrap = Rs 40-45 /- per kg
The Ultra high carbon steel procured by a blacksmith to make products in Kamartola are bought from a
scrap dealer in a place called Buripara. These scraps are generally extracted from the truck parts. Since
contains high amount of carbon content i.e.. aapproximately 1.0–2.0% carbon content, therefore Ultra
high carbon steel becomes the best possible material to be used for making the knifes and deggars etc.
The raw material is malleable and can be beaten and drawn due to it apt carbon content present in it.
Apart from Ultra high carbon steel the artisans also use wrought iron
and this can be identified by the fact that the knives get rusted easily.
42
WOOD
The wood is either self cut from trees by the artisans or are bought from local market.
The handle used in the products produced in the cluster are wooden twigs, branches
and cylindrical pieces cut out of large logs. There no particular wood that are being
used, due to which the life of the handles are very less. Every user that buys such a
product generally has to replace the handles in every twice a month.
The handle made out of the branches are very fragile and of low quality.
PRICE
PRICE of logs = Rs 500 per piece of log
PRICE
PRICE of coal bought from Saravbhatti = Rs 20/- per kg
COAL
The material to heat up steel for forgin, beating etc is heated by using coal and firing it
up with a blower.
About
Coal (from the Old English term col, which has meant "mineral of fossilized carbon"
since the 13th century) is a combustible black or brownish-black sedimentary
rock usually occurring in rock strata in layers or veins called coal beds or coal seams.
Coal is extracted from the ground by coal mining, either underground by shaft mining,
or at ground level by open pit mining extraction.Throughout history, coal has been a
useful resource. It is primarily burned for the production of electricity and/or heat, and
is also used for industrial purposes, such as refining metals. A fossil fuel, coal forms
when dead plant matter is converted into peat, which in turn is converted into lignite,
then sub-bituminous coal, after that bituminous coal, and lastly anthracite. This
involves biological and geological processes that take place over a long period.
43
b.6. Tools and equipments
Till now the artisans of the cluster are making products without any machinery and hence they rely on the techniques of forging, drawing, bending,
upsetting, punching, combining, welding and finishing . They have not been given any trainings as of till now, but there is a great need of proper training
sessions to be held and provided in the cluster. Following are the tools used by the cluster artisans of Kamartola Village :
HAND MADE BENDING TOOL
METAL HAMMER
HAND MADE CHISEL
DIFFERENT KIND OF TONGS
44
HAND MADE PUNCHING TOOL
HAND SAW FILE
SMALL ANVIL LARGE ANVIL

45
LARGE HAMMER PIRA (SMALL SEAT TO SIT AND WORK_
SMALL WOODEN SURFACE TO SHAPE UP THINGS TOOLBOX

46
QUENCH BASIN
47
LEVER
CHIMNEY OF THE PUMP
THE PUMP
MOUTH OF THE FURNACE

THE JOINERY OF THE
LEVER AND PUMP
WEIGHT PUT THAT HANGS WITH

THE LEVER END WHICH HOLD
THE LEVERUP IN THE AIR
48
b.7. Status of Design at cluster
There are only few kind of products which has been developed in the
cluster. The cluster artisans have been working on this particular art and
craft from many decades from now. But very little change or no change
at all have been come over the designs that they have coming up with
since ages.
The bent tooth design of knives is a traditional design of Assam and is

prominent in all the blacksmith cluster throughout the region. Though it
is unique and the only design that has been practiced and made in
Assam, but due to the fact that the raw materials used are very poor in
quality, It does not last longer and people are not ready to pay much
amount of money to the artisans or even the sellers.
But if we look at the usability aspect, the products like Dau(long and big
knife) and Deggar (very long, sharp and curved knife)proved to be
useful in doing many household chores like cutting grass to cutting tree,
cutting large objects. But though the products made by the artisans are
use in variety of work, but they does not last long and gets rusted even
by a single drop of water, specially the ones made from poor metal. The
handles of the products are not ergonomic and are not properly
finished and due to this, the user finds it difficult to use the knives.
49
b.8. Product & process Specialization
CLUSTER PRODUCTS
50
KASI (Grass cutter)
BON KATA (Grass cutter)
BARPETIA DAU
DAU (Long, big and strong

knife)
51
AXE KOTARI (Knives)
PATI BOTHI : A cutting and peeling tool with a

stand BARPETIA DAU
Wooden Stand
52
DIGHAL DAU
SEEDHA DAU DEGGAR
TRISHUL (Trident)
CHISEL KOTARI (knife) UNFINISHED PATI BOTHI
53
b.9. SWOT MATRIX
SWOT Analysis/Matrix is a structure planning method used to
evaluate the strengths, Weaknesses, Opportunities and threats
involved in a project or in a business venture. A SWOT analysis
can be carried out for a product, place or person.
54
Internal Assessment of the Organisation
STRENGHT WEEKNESS
> Raw material availability. > Infrastructure facility is not well developed.
> Traditionally skilled workers. > Unhealthy competition among the units.
> Existence of sufficient production capacity. >Design and quality of product is not suitable for export
> Existence of a strong co-operative society. > Inadequate R&D
>Availability of Human Resources. > Out dated technologies and machineries
>Hard working artisans. >Marketing process is not well organized
SWOT ANALYSIS
OPPORTUNITY THREAT
> Intervention of financial institution, technical institution. > High competition with other cluster unit outside the region.
> Product development and design. > Products designed are well polished in other cluster, pose a
>Introduction of modern technology in order to upgrade the threat to the cluster products.
skills and quality of the products. > Changing market trends/tastes.
> Scope for creating showroom by the SHGs or cluster units. > Poor finishing techniques.
>Introduction of market promotional measures.
> Participation in national level seminars.
External Assessment of the Environment

55
b.10. Black smithy process in Kamartola Village
Describing the entire procedure of Kamartola Blacksmith Cluster, wherein all the necessary steps are mentioned and described via the research and survey
conducted among the cluster artisans. This would gives a proper idea that how and from where the raw materials are being bought and finally molded into
a product. Everything would be in a pictorial view.
56
Blacksmith products making process Kamartola Village, Hajo, Assam
RAW MATERIALS
PROCESS
FINAL OUTCOME
57
c.2. Existing process Description and chart
58
Raw materials Stored
Buripara Ultra high Carbon steel
Brought from Local market Wood

Kamartola Village
Cut from trees
Coal
Brought from Product Development
Saravbhatti
Raw materials
Used when
Ultra high Carbon steel Wood Coal Stored
required
Drawing Forging Heating Cutting

Cutting
Bending Upsetting Combining Welding Guwahati

Shaping Market/shops
Beating of the rings to Finishing

fit in the knife handle Local
Finishing
Mrket/shops
Finished Rings
Local Small
Combining Finished parts of wood Products Sold to
Fairs
and Carbon steel
59
STEP I STEP II : WOOD and COAL
WOOD
RAW MATERIAL Raw Material brought from Local Market to WOOD
PROCUREMENT Kamartola Village by the artisans. Wood is properly cut from
the branches into handles
shapes, though the finishing
is done later on.
ULTRA HIGH CARBON STEEL

Raw Material brought from Buripara to
Kamartola Village by the artisans.
COAL
The Coal is used for producing

heat for heating, forging,
beating, bending etc processes.
COAL
Raw Material cut from tree or brought Rest of the coal which is not in
from Saravbhatti to Kamartola Village by use are kept below the work
the artisans. shed either in open or inside a
polybag.
60
STEP III (STEEL) ULTRA HIGH CARBON STEEL
The long strips of carbon
steel are cut into desired
pieces for making knives
and other products
STEP IV
(CARBON
STEEL KNIFE)
1. HEATING : The part is heated till it 2. FORGING : After heating, the forged 3. HEATING : The heating process is
reaches the desired temperature part is beaten with great force with two continued until a desired shaped is
and colour. blacksmiths on either side of the anvil. achieved.
4. FORGING 2 : Until a desired shape 5. UPSETTING : The shape is beaten 6. UPSETTING : The final desired 7. FINISHING : The finally
is achieved forging is continued. at one end which results in a tapered shape is put into a quench basin to achieved part is filed.
shape of the knife. cool down the temperature for
further finishing.
61
STEP IV (CARBON STEEL KNIFE) 8. FINISHING : The finished part kept and stacked aside for further joining with other parts of the knife
62
STEP V (STEEL RINGS)
1. Cutting small strips and applying the methods of drawing, 2. The desired rings to be joined later on.
beating, bending and welding them to get small rings.
STEP VI (WOODEN HANDLES)
1. The cut wooden pieces from the branches are finished 2. The rings produced in STEP V are joint with the
upto an extent. handles
63
STEP VII (JOINING THE PARTS)
Joining the Carbon steel finished knives with
+ the handles. The positive knife part is put

inside the negative hole in the handle and
then pressed from the outside.
STEP VIII (FINAL TOUCH UP)
FILING
64
c. Unitwise Design Audit
Report (From Unit Survey)
Unit Description >
Study and Scope for existing scenario >
Identifying Gaps in the System >
65
c.1. Unit Description
66
Sl. No. Name Place & phone no.
1. Satyanath Das Kamartola Village, Hajo, Assam :

+918254011402
2. Uddhab Das Kamartola Village, Hajo, Assam
3. Basanta Das Kamartola Village, Hajo, Assam
4. Sarat Medhi Kamartola Village, Hajo, Assam
5. Ananta Das Kamartola Village, Hajo, Assam
6. Mahesh Deka Kamartola Village, Hajo, Assam
7. Bubul Das Kamartola Village, Hajo, Assam
8. Ponameshwar Das Kamartola Village, Hajo, Assam :

+919678395413
9. Badan Chandra Das Kamartola Village, Hajo, Assam
10. Pabitra Das Kamartola Village, Hajo, Assam
11. Tailkhya Medhi Kamartola Village, Hajo, Assam
12. Basudev Das Kamartola Village, Hajo, Assam
13. Suresh Das Kamartola Village, Hajo, Assam :
+919954843439
14. Dinesh Bharali Kamartola Village, Hajo, Assam
15. Mamat Das Kamartola Village, Hajo, Assam :
+919854660496
16. Hemanta Das Kamartola Village, Hajo, Assam
17. Pankaj Mahanta Kamartola Village, Hajo, Assam
18. Pabin Das Kamartola Village, Hajo, Assam
67
c.2. Study and Scope for existing scenario
68
69
a. Description/study and scope for existing Products, redesign, new product development and product diversification
Issue and concerns :
1. Since there is a good demand for sustainable products all over the world, but the designs, particularly in the cluster till now, has not went beyond what
has been developed since ages and are of very limited variety.
2. National - international market linkages are not yet developed and strengthened sufficiently to get continuous order and better remuneration.
3. The existing products consist of only few repetitive designs and with no contemporary or new colours or designs.
4. On orders the artisans can’t afford buying raw materials and only procure them after receiving any kind of less cash advance.
5. The products are of the same quality even if the traders/customers are different.
6. Some products, made by the artisans are inspired randomly or from existing products made in other parts of Assam, and other states.
7. Most of the existing products does not have such good finishing which decreases the life cycle of the products.
8. Except one or two artisans almost all the artisans in the cluster make similar products on order basis only.
9. Very Poor Raw material quality.
10. The finishing in the products is not up to the mark.
11. There is no product diversification at all in terms of aesthetics and quality.
12. No body anatomy is considered while designing products.
13. No inspirational engravings or other things are being practiced till now in the cluster.
14. The product made are not in much demand as similar kinds of products are being made in other part of Assam also.
69
15. The lack of Quality Certification makes it very difficult for the artisans/agents to win trust of customers, especially outside the state.
16. When the products get wet, they are easily attacked by rust. There has not been any such step taken forward to protect the products from outer
damage, i.e. no treatment process has been developed yet.
17. The deformity in the handles and poorly finished knives are easily visible on the product which make its less attractive and not for international market.
Poor raw material quality leads to poor Too large handle compared to No product Diversification. Similar products shown above The odd shape of the head
finishing. the knife. No body anatomy and are made in all the units in the cluster. of ‘Kotari’Knife lead the
ergonomics considered during user to cut their fingers
designing the products. most of the time.
Attached by rust
before producing in
the market. This Deformed poorly
shows that the raw finished handles
material quality is very does not have
poor and not safe for any particular
the buyer as they shape of it own.
might consume some
of them while cutting
vegetable, fruit etc.
70
Solutions and opportunities :
1. The Raw materials procured can be of better quality to improve perceptual quality of existing product by proper linkage via the organisation handling
the cluster.
2. Possibility of another range of product in cutting tools itself, so that the basic idea of knife makers are not gone from the cluster. Other new age
products like with the help of proper technology and machineries, can be easily developed and would bring in much higher remuneration to the
makers. The products can then cater to the needs of a different target group who are more design and are quality conscious.
3. The existing products can be made more contemporary and relevant, less labour intensive.
4. The elements from the existing traditional designs of assam, eg. : designs in traditional assamese dress, nature inspired designs etc. can be used and
engraved in new product development and diversification and to give the products a local identity of itself.
5. Local craft can be combined with the Blacksmith products to get diversified products, like combining bamboo for making handles instead of wooden,
6. Increasing the life span of the metal by treating with various agents or by using better steel.
7. The elements from existing traditional products can be used to introduce lifestyle products such as foldable knife, cutlery, and other nick knacks for
contemporary homes leading to scope of wider customers.
71
b. Scope for research and development direction for future initiatives
1. There is no as such hardcore technology used in the making Blacksmith products by the artisans and the process to make it are also outdated and quiet
time consuming.
2. The artisans and other cluster people also don’t have enough resources as well as funds to get introduced to new technology.
3. They do not have enough funds, time and expertise to carry out research and development on a regular basis to find out the market trends in national
or international market.
4. The quality of products is compromised due to insufficient delivery time and lack of man power and technology which would have facilitated and
increased the speed of work without compromising on quality.
5. They are not geared to thinking in terms of conducting research and development in this area which is seen more as a local prevalent traditional craft.
6. The cluster does not have a proper schedule of work or time and each unit works individually though being in a group, therefore there are no separate
departments to handle specific job.
No technology implemented while Does not have any working techniques due Lack of technology and working shed The excessive burning of coal without
finishing the products to fund problems. Everything is done with makes it difficult for the artisans to any proper exhaustive system leads to
whatever resources available on the spot, work single handedly and need sticking of impure materials on the
though it might be difficult to use. accompany always. roof, which is very hazardous artisan’s
health.
72
Technology:
1. Improvisation in machinery, tooling, process through R&D activities.
2. Investigating the properties of Jute in order to make the best use of the same while developing products.
3. A Common Facility Centre (CFC) can be set up with modern technology.
4. Exchange of technology ideas can be initiated through CFC.
5. Research in the area of proper furnace, working table to cut the products, proper heighted Anvil etc.
Marketing:
1. Research in terms of consumer trends and competition in the local, National and international market.
2. Creating an online portal or website to sell the products to the unreachable.
73
c. Existing status and opportunity for visual identity, branding and communication design
1. The artisans mostly does not have any pictures of their creations in any kind of format be it photographs or other.
2. There is absolutely no visual identity for the clusters as they rarely sell the products directly to the final consumers.
3. There is no proper documentation/ catalogue of the traditional products made in Kamartola Blacksmith cluster.
4. The products till date has never been advertised, hence people indifferent cities and places of India and around the world are unaware of the craft.
5. Mostly the people in the cluster are unaware of the latest trends, also they work individually and make the designs which has been taught to them by
someone else, therefore they don’t get much opportunity to share ideas of how to promote their products to reach out to maximum consumers.
6. Even while selling them off to the consumers, the products are not properly packed and labelled.
No visual identity and no tags for the identification of No proper stacking and display of the products One of the outdated display techniques used in
their products. while selling off to the customers. Kamartola Blacksmith Cluster to show the kinds
of knives developed in the cluster.
74
1. The idea of having a common visual identity and branding for the cluster was well accepted. However it was felt that it should go in sync with
initiatives like online selling portal/website, advertisement, packaging design, branding etc.
2. There is a big scope in developing visual identity for the cluster units, branding and communication design to connect them to the market directly and
get them more exposure.
3. Along with product diversification, a product catalogue is a must and also presence of products online will be of great help to reach larger audience.
4. A comprehensive documentation of Kamatola Blacksmith cluster along with the catalogue will be a great source of information for the people outside
Assam and to understand benefits of completely hand made products.
5. The concept of common brand building like will help them to create an identity for themselves.
6. Promoting the concept of ‘100% HANDCRAFTED’ amongst Kamartola Village cluster artisans.
75
d. Scope for technology, modernization and design collaborations.
Issues & concerns:
1. The disadvantages of the products include poor raw material quality, poor finishing and knives when subjected to water gets rusted.
2. Due to lack of technology, products can not be finished properly.
3. The tools used by the artisans are either outdated with no real modern technology available to them.
4. There is no automatic facility of cutting the metal, any beating technology, or automatic finishing technology/tools/machineries like buffering etc in the
cluster, and artisans have to do it all by hand.
5. Even in case of bulk orders for the same products, its made by hand, which leaves them with no time to experiment and create new designs.
6. There is a reluctance and resistance to modernization and adoption of new designs on the produced products.
7. The products get destroyed during the storage of the semi-finished or finished products.
8. The amount of waste generated is not utilised in any way.
9. The kind of knives the artisans haven been making tends to break on the joinery part mostly the wooden handles breaks and people have to make the
handles again.
10. Very difficult for the artisans to work in summers due to the fact that the open furnace gets too heated up.
11. Since the furnace os open most of the heat escapes into the air giving less than half of the heat produced out of burning coal for the production of the
knives
76
Huge and age old furnace and pumping equipments really need The poorly constructed quench basin is far away from the sitting
some real and good intervention. area where the hammering and shaping is done, this is why the
artisans have to hammer the metal again and again until in the
end it is dipped on the water.
No safety precaution being taken while the process of making No safety gloves worn.
the products.
77
Solution/opportunities:
1. It is a high time to introduce them to processes and agents for treating the raw materials so that the life cycle of the products increases and the
consumer does not have any issues related to Jute products.
2. Buying good quality raw materials via proper dealers through financial help would definitely raise up the cluster above its present status.
3. Using good quality wood and changing the way the knives that have been made by the artisans, which can be achieved by increasing the length of the
carbon steel cutting part that is joint to the wooden handles.
4. Introduction of finishing techniques as well as components that can help in enhancing the quality perception as well as life of the product.
5. A few changes in machineries and mechanisms, won’t change the concept of the ‘100% HANDCRAFTED’.
6. Separate units of Cutting, heating, forging, drawing, bending, upsetting, combining, welding and finishing can be set up in the common facilitation
centre.
7. The introduction to the CFC will give them an opportunity to explore beyond the traditional technique of polishing or weaving. They can be introduced
to which can increase speed of work by many folds especially for bulk order.
8. Developing innovative packaging for the knives from other materials available in nearby areas like the silk of famous Sualkuchi silk industry with proper
lining or jute from Jute industry of Dhubri which can be used as an eco-friendly substitute for plastic and paper packaging.
78
e. The scope for operations and process innovation from design perspective
Issues & concerns:
1. Manual process of filing, buffering and rest finishing, is done which is not uniform and looks untidy.
2. The present process of making knives is time consuming.
3. Process of forging, beating etc can be very time consuming and exhausting. The process can take up to many hours even days or weeks.
4. Artisans use unknown wood from local jungle, which is inferior in quality and does not last longer.
Finishing is done manually, in fact all the processes are done The wood used is of low quality and the above picture show
manually with outdated tools the quality of finishing also and outcome of the end product.
79
1. Various kinds of making knives can be explored and developed.
2. The productivity can be increased by the introduction of appropriate and new age tools and machineries.
3. A Material Bank can be opened up near the village like in Hajo town of Kamrup district which is easy to access from the capital city of Assam and other
places as well and is near the cluster also.
4. The Raw material Bank can bring the raw materials and in bulk, and thus saving time in making these findings.
5. Finding out a better method of treating the Raw material.
80
f. Design opportunity in workstation and tooling design
Issues & concerns:
1. There is no proper lighting system for working in night hours, rely generally on natural light.
2. There are no such modern tools used in the cluster.
3. The artisans sit in inappropriate and tiresome working positions to make the positions
4. There is no place to work as a group, everyone works individually as per the need of the market.
5. In case of no electricity artisans work in candle light for long hours, which can be painful for eyes and leading to eyesight problems. Its a major area of
concern in the cluster.
6. The amount of heat and dust produced during the entire procedure of knife making is very harmful for the artisans as they do not were any kind of
safety equipments or devices in order to save themselves from inhaling harmful gases of coal and burning there hands during the process of making
the products.
7. There is high amount of risk for the artisans to get hurt by the process of cutting, beating, forging etc processes without using any kind of precaution.
8. Very less artisans can afford working inside with decent facility, but maximum artisans work in sheds outside inhaling fumes.
9. The products are kept with no proper arrangement or storage, leads to damage.
10. The work process is really slow due to hand made nature of the process.
81
Utterly cluttered and unorganised Work shed.
The Workshop is very dark and artisans have to work in such

The work shed is made up of bamboo and hay, and it is difficult to a dark place that threats there eyesight.
protect the inner materials and belongings from rain and sunlight.
82
1. There is an urgent need of CFC and a proper place to store the Jute products with each artisan owning there own room or shelf to store their products
2. The new tools for cutting, finishing, polishing etc or other treatment agents etc. can be introduced at common facilitation centre.
3. Introduction to proper machineries and tools etc could improve productivity.
4. Organized work stations at CFC.
5. Solar lights can be introduced so that they could work in the evening hours.
6. Proper gloves, eye protection glasses, helmet to wear during the dyeing process, treatment processes.
7. Seating need to be improved along with tables to work upon in the CFC.
83
g. Details of market and competition study for design advantage and distinction
Issues & Concerns :
1. Customers/ Traders are not ready to pay higher prices for the products due to the fact that they would get Blacksmith products from any shop or part
of Assam.
2. There is a serious competition from other Blacksmith clusters in Assam, north east and other Indian clusters .
3. Decrease in profit margins due to exploitation by the traders.
4. Lack of group discussions and awareness to new trends in the market and individualistic approach to sell the products is a weak link in the cluster.
5. No consideration of modularity, stackability for transportation purpose in traditional products.
Poor finishing and no ergonomic considerations used while Poor finishing quality using knife as a permanent tool for
making the products finishing , not even sand paper.
84
1. The retail market can also be explored - Tie-ups with retail chains could help in marketing-distribution of small fast moving items.
2. Product diversification using traditional techniques and motifs will give them distinctive advantage as these designs will not be manufactured
elsewhere.
3. They can introduce new accessories in the cluster like knife packagin, which could give them a bigger market share.
4. They could reach out to larger markets other then delhi like the ones which admires local crafts and biodegradable products and can target such user
groups with new product developments.
5. Training to the artisans on how to sell their products from online portals.
6. Creating and online selling experience for the customers by the Organisation.
85
h. Study for the need of training and skill up‐gradation.
1. Less focus on Design Training.
2. Even in cutting or finishing the products, the neatness of the craft is poor.
3. Due to lack of exposure and technology artisans have been practicing same processes and copying the designs from other clusters.
4. There is no system in place through which the cluster can effectively make use of the BDS (Business Development Services) providers. Even though
diverse BDS resources the present locally, they face several limitations in the absence of effective institutional framework and therefore do not have a
well-defined presence.
Poor finishing. Good

skill upgradation
programme highly
recommended
Consumes a lot of time while blowing air New product developed but without any
into the coal to produce fire and heat. aesthetic sense and improper finishing
86
1. A common training centre which could provide training on skill enhancement, quality control and product development can be established in order to
train more people in practising this craft.
2. A major need of a Master craftsmen to train the craftsmen.
3. Master artisans could be sent to participate at National or international level workshops.
4. A skill upgradation course/ curriculum can be introduced with expert guidance.
5. Self organised workshops where the artisans should express their skills and knowledge apart traditional practices, leading to sharing and development
of new ideas
6. Institutional linkages & Capacity Building and as well as the local BDS also need more training and exposure.
87
i. Description of ergonomic and environment factors in MSME premise.
1. Traditionally blacksmith is having sitting workstation for their work which is ergonomically very poor design.
2. Time taken for movement of hands from furnace to quench basin is also more that is why they have to do more hammering and repeat it again and
again until the shape will be made.
3. Productivity and efficiency is less due to poor design as far as ergonomics is concerned, they have muscular problems.
4. No proper place to keep the tools at place.
5. The semi-finished products, finished products, tools and raw materials, everything lie one above the other with any proper systematic arrangements
under the shed.
No proper infrastructure leads to decreased amount of production of products The anvil is too small and placed too low, due to this the artisans has to sit on
an awkward and tiring position and hammer the materials entire day long.
88
There is not no proper ergonomic table or surface where the artisan Picture says it all!!
can properly file and finish each and every part of the product. All
they have to do is bend and work in and unergonomic posture.
The sitting tool where the artisans sit and work would cause Everything starting from tools to product to anvil to sitting are is on the same
backache and back problems place and does not provide the artisans ample amount of space to work.
89
Human factor integration and Arrangement of the workplace
1. Workstation design in terms of physical dimension, including seating can solve lots of problem of end user.
2. The aim should be to minimize the risk of operator discomfort and related muscular-skeletal problems such as back and shoulder complaints.
3. Workstation layout, should such that specifically the positioning of equipment on and around the workstation to ensure that it is visible and within
easy reach of the operators who will use it.
4. Rhythm is essential to the smooth and automatic performance of a repetitive operation. The work should be arranged to permit easy and natural
rhythm whenever possible.
5. Work should be arranged so that eye movements are confined to a comfortable area, without the need for frequent changes of focus.
6. Tools and materials should be pre-positioned to reduce searching.
7. “Drop deliveries” or ejectors should be used wherever possible, so that the operative does not have to use his or her hands to dispose of the finished
work.
8. Provisions should be made for adequate lighting and a chair of the type and height to permit good posture should be provided. The height of the
workplace and seat should be arranged to allow alternate attending and sitting.
Design of tools and equipment
1. The hand should be relieved of all work of “holding” the work piece where this can be done by a jig, fixture or foot operated device
2. Two or more tools should be combined wherever possible.
3. Handles should be so designed that as much surface of the hand as possible can come into contact with the handle. This is especially necessary when
considerable forces have to be used on the handle.
90
j. Packaging and logistics related design opportunities
1. There is no real concept of packaging at the cluster level.
2. No unique identity for the Kamartola Blacksmith products, packaging for products from all clusters is the same.
3. Products are kept either in a shed, or kept in a plastic bags or mostly openly outside, leads to breakage and wear and tear of the surface of the finished
or semi-finished products.
4. There is also chances of theft during commuting from city to other.
5. No insurance cover.
1. New packaging design can be introduced such as pouches or knife carriers using and blending traditional Assamese textiles with Jute, silk or leather
type material to pack the products.
2. These packaging solutions will give a visual and unique identity to the products made in Assam.
3. Packaging can be taken care of in terms of moisture content even in extreme cases when the products are shipped while exporting.
4. To make the artisans aware of the packaging process by training sessions and teach them how cushioning and proper packaging could save the
products and avoid damage while the shipping process.
5. New and cost effective form of packaging needs to be introduced.
6. If packaging is improved, it would create a good presence and in turn will boost the business and help in competing.
7. Proper Bar coding on the packaging.
91
k. Exhibition /Display design opportunities.
1. A shop with great visible display on every district or in the leading cities in the country could attract good amount of customers to the cluster
2. The artisans can participate in more trade fairs at state, national and international level.
3. They can perform a road show of their products with the help of a leading organisation like Shanti Creation.
4. At cluster/ village level a small display area/showroom can be created.
5. Products can be displayed at art centres, museums etc. in various cities.
6. Setting up records.
International Tradefair, reaching out the Organising own Handicraft tradefair Breaking/Making records Knives at a showroom with proper
international market packaging, display and price tags
92
l. Study of infrastructure setup from design perspective
1. Traditionally blacksmith is having sitting workstation for their work which is ergonomically very poor design.
2. No in house display area for the products.
3. Often there is not sufficient space to dry and stock raw material as well as storing unfinished and finished work.
1. A common work place for the artisans in the village or a CFC.
2. A proper display area can make it attractive for consumers.
3. A common facility centre can be provided for setting up colouring/dyeing unit as well as for
finishing work machineries.
4. If not machinery a common space can be provided to dry and stock raw material as well as store
unfinished and finished work separately. This will also ensure that drying happens naturally over
a period of time.
93
m. Scopes for design intervention for benefit of MSME units
1. Scope of Diversification of products which can only be developed by intense training, more exposure to other markets, technology intervention and
good quality accessories.
2. A greater and better cooperation and understanding between the artisans and the traders/middlemen.
3. A Common Facilitation Centre will tremendously increase the scope of communication between various artisans and thus lead to sharing of knowledge
and skills.
4. Also there could be a need of communication between Karmartola Blacksmith cluster and other Blacksmith production units of India and that of
International standards.
5. Interactive sessions with the artisans and the management community.
SOME SERIOUS COMPETITORS
Koftgiri knives from Rajasthan, India Koftgiri Work Native American knife
94
c.3. Identifying Gaps in the System
Noting down the major loopholes in the a system and

applying detailed intervention accordingly Describing the
"value chain," which demonstrates why even support
activities, such as an employee training program, can affect GAP
the organization's performance and its return on
investment.
GAP
GAP
95
High Raw Material Procurement Cost
The Raw material requirement is met by local metal
dealers/supplier. Though dealers are local but the raw No machineries:
materials are of poor grade and quality. The units are not using any kind of machines that are
limiting the scope of full production capacity. The modern
machines required for introducing the latest designs for the
items are not available.
Weak Linkage :
The units have not been able to develop a proper
linkage with the existing financial institutions and
other government agencies. Easy availability of Lack of proper working place:
credit is still a far way to go. There is no separate working place with proper seating
GAPS IN arrangements, tools taking in consideration of the
ergonomic consideration of the artisans for the units to
Lack of proper management system of the

THE carry out the entire manufacturing process. No proper
place to work in groups for sharing ideas. They are using
SYSTEM
their front yards for the same purpose creating a very
cluster units:
congestive space. Also they are not having any separate
The units are lacking in modern and
godown facility to keep the raw materials and the finished
improved management skills which do not
items. This is not enabling them to raise the production
enable the units to perform in an organized
level.
manner.
Lack of social capital: Under developed Marketing System

At present only one co-operative society is operative in At present the products are mostly order based from
the cluster but the functioning of the society needs to the local shop owners. Though they are recently
be enhanced. The strong co-operation among the getting orders from some other North Eastern
cluster units can be a positive factor in furthering the states, this segment is very few. They are yet to enter
social capacity building process. the market outside North East. Export promotion
activities have not been undertaken
96
d. Soft and Hard Design
Intervention
Intervention >
Conclusion >
97
d.1. Intervention
Absence of better management practice is somewhat hampering the
units to face the new emerging business environment. This calls for
the introduction of modern management techniques like
SOFT INTERVENTION benchmarking, human resource management techniques etc.
Requirement/s:
• Engaging management experts
• Providing training to the owners of the units on better management
As has been seen the use of traditional tools is hampering the production skills
process, there is a need of arranging for the modern machineries
and other equipments necessary for carrying out the production process
smoothly. The linkage should be developed with the financial institutions
to go for introducing the required machineries.
Requirement/s:
• Linkages with the financial institution
• To train up the employees on the use of modern machineries The under developed market system is a major gap in the cluster. The
intervention is required in the marketing process so that the units can
get better price for their products as well as can widen their market
reach
Requirement/s:
Product diversification is a major area of intervention. Development • Participation in national and international level exhibitions
of new products is expected to help meet the emerging and diversified • Engaging Market Consultant
demands from the different segments of customers and to capture the • Bringing out a Product Catalogue
new markets as well as to have a better hold on the existing markets.
Requirement/s:
• Product Categorization
• Design and Technical Intervention
• Engaging Technologist
• Skill Building of Artisans in Diversified Product Lines
98
Research &
development :
Technical upgradation Market: consumer
Market linkages: Outside state research, branding
showroom, and packaging
National/International Fairs
Skill development
programmes and
schemes
HARD INTERVENTION
Training &
Raw material Workshop Centre
Procurement Centre Product
development and
diversification
COMMON FACILITY
CENTRE Kamartola
Blacksmith Cluster, Assam
Ergonomic
Workstation and
Finishing Centre & tool design
Heating furnace
NGO support
National/
Process innovation International
market linkages
Weaving Community Branding &

communication
Packaging innovation
99
d.2. Conclusion
The visit to Kamartola village, Hajo, Assam was a memorable and a great learning experience for me. It gave me the various insights regarding
development and issues concerned towards the artisans, specially those working in micro scale industry level.
Since Blacksmithing products making is one of the most important handicrafts in Assam, therefore, for me it had become a very important task to study
the traditional craft of Assam which is developed in such a place where any kind of business development strategies and mindset is NIL. There were many
findings that I developed during my extensive study in the cluster. One of the major findings in the cluster were that of the fact that everything that was
made in each and every unit, actually did not make much of a difference in the monthly income of an artisan/craftsperson. Due to poor finishing because of
poor infrastructure, the products were not up to the mark for national or international standards. The price of a product that we pay when we buy from a
retail store was much higher than what we were told in the cluster. This meant that the artisans in the cluster were exploited to a great extent. One of the
major factors were that the artisans could not get direct linkage to the market or they did not had proper knowledge of costing. The agents who are able
to give products on maximum credit basis are favoured by the retailers. Because of this trend, the agents need to put in their own money for new orders
which is not feasible.
Regarding production, the artisans without any doubt are very skilled and hardworking. Due to the fact that the orders that they get are not so high
demand. The work shed is completely unhygienic and cluttered. Sitting position is too tiresome while making the products. Even the raw materials
specially the branches for the knife handles decreases the life cycle of the knife. But their is still hope and sufficient scope of us and other govt.
organisation to help out the cluster in terms of providing proper training, skills, machinery, CFC, market linkages and industry visits.
With a combination of design, traditions and advance skills this cluster can make its own trademark in crafts sector, with their own identity. Developing
new designs keeping the essence intact, with such prospects still there are a lot of scope of development and growth as mentioned in the detailed study
carried out.
As everything a handcrafted while making the product, hence the entire process becomes very slow. With the introduction of a proper equipped CFC, the
cluster can go far ahead than its competitors.
The most important thing that I noticed was that of product diversification and waste management in the cluster. Till now the cluster artisans have been
making only products which revolves around around few designs of knives and cutting tools. Apart from these products there is a huge scope of
developing far more and different kinds of products with new designs on it. The artisans must try to make a mark of its own by its products.
Last but not the least, if a treatment process along with a proper branding is applied in the cluster, then the cluster would become the most unique cluster
with respect to other places.
100
mobile : +91 9435707663 / 0361-2305105
email : sukanya.borsaikia@gmail.com
address : House no. - 16, Dharmeshwar taro Path, Krishnapur,
Beltola, Guwahati-781028, Assam
101
Blacksmith Cluster
Kamartola, Assam
Design Clinic Workshop | Band 5

27/05/2013 – 31/05/2013
submitted by : SUKANYA BOR SAIKIA
Organised by Shanti Creation
Workshop Schedule
Sl. No. Date 9.45 A.M Sessions(10.00 AM to 1.00 PM) Sessions(2.00 PM to 4 PM)
Day 1 27/05/2013 Registration Session 1: Inauguration, felicitation of the Chief guest BREAK Session 2 : Presentation by Sukanya Bor Saikia on
With Speech by Mr. Anup Kr. Baruah, GM, DICC and guest of showcasing the blacksmith products made
Attendance honour Mr Mali, Founder ex-Director of Indian Institute throughout the world
of Entrpreneurship
Day 2 28/05/2013 Attendance Session 1 : Tools and Technology usage and BREAK Session 2 : Wood Carving and finishing Workshop :
implementation and Finishing Methods/technologies : by Lila Gogoi, Handicraft Designer
by Sukanya Bor Saikia
Day 3 29/05/2013 Attendance Session 1 : Product Diversification and making process BREAK Session 2 : Involvement of new technology
with addition of new materials and design: by Sukanya intervention in Blacksmith Industry:
Bor Saikia by Sukanya Bor Saikia
Day 4 30/05/2013 Attendance Session 1 : Metal Carving Workshop : BREAK Session 2 : Concept of Packaging and Branding for
by Mridu Pawan Medhi, BE Mechanical sustainable marketing : by Sukanya Bor Saikia
Day 5 31/05/2013 Attendance Session 1 : Loan and Credit linkage with financial BREAK Session 2 : End of the program with remedial
organization : by Anupam Dutta, Faculty SIRD, Assam solutions, Evaluation and Conclusion Ceremony
/Feed Back Form
2
Sukanya Bor Saikia | Design Clinic Workshop| Band 5 |Kamartola Blacksmith Cluster | 2013
Topics covered during five days
1. Presentation by Sukanya Bor Saikia on showcasing the blacksmith products made throughout the world
2. Tools and Technology usage and implementation and Finishing Methods/technologies
3. Wood Carving and finishing Workshop
4. Product Diversification and making process with addition of new materials and design
5. Involvement of new technology intervention in Blacksmith Industry
6. Metal Carving Workshop
7. Concept of Packaging and Branding for sustainable marketing
8. Loan and Credit linkage with financial organization
3
Registration with Attendance
4
Day 1 : Session 1: Inauguration, felicitation of the Chief guest : Speech by Mr. Anup Kr. Baruah, GM, DICC
and guest of honor Mr. Mali, Founder ex-Director of Indian Institute of Entrepreneurship
From left : Sukanya Bor Saikia (Industrial Guest of honor Mr. Mali being felicitated
Designer), Mr. Mali (Founder & ex-Director
of IIE), Mr. Anup Kr. Baruah (GM,DICC)
The Workshop Venue at Sri Sri Gopiballab Satra,

Kamartola, Kamrup , Assam
5
6
Day 1 : Session 2 : Presentation by Sukanya Bor Saikia on showcasing the blacksmith products made
throughout the world
7
Different Blacksmith knives made thoughout the world
8
Different Blacksmith knives made thoughout the world
9
Other Blacksmith products
10
Day 2 : Session 1 : Tools and Technology usage and implementation and Finishing Methods/technologies : by
Sukanya Bor Saikia
Machines like : Hand held automatic On the desk from Left : Lila Gogoi and
Battery operated drill, Hand held Sukanya Bor Saikia
Buffer, Hand held sanding machine
etc were produced and discussed in
front of the artisans to make them
aware of machine usage.
The Machines
11
12
Giving demonstration about various machines and how it works
LEFT : Giving presentation and showing various machineries : RIGHT : Showing how to hold and work.
13
TOOLS & TECHNOLOGY
Opportunity Area
Observation : > Most of the existing products does not have such good finishing which decreases the life cycle of the products.
> The deformity in the handles and poorly finished knives are easily visible on the product which make its less attractive and not for
international market.
> There is no automatic facility of cutting the metal, any beating technology, or automatic finishing technology/tools/machineries like
buffering etc in the cluster, and artisans have to do it all by hand.
> Even in case of bulk orders for the same products, its made by hand, which leaves them with no time to experiment and create new designs.
> The products get destroyed during the storage of the semi-finished or finished products.
> The tools used by the artisans are either outdated with no real modern technology available to them.
> No safety precaution being taken while the process of making the products.
Remedial Solutions
3. The introduction to the CFC will give them an opportunity to explore beyond the traditional technique of polishing or weaving. They can be
introduced to which can increase speed of work by many folds especially for bulk order.
4. A few changes in machineries and mechanisms, won’t change the concept of the ‘100% HANDCRAFTED’.
5. Separate units of Cutting, heating, forging, drawing, bending, upsetting, combining, welding and finishing can be set up in the common facilitation
centre.
14
Finishing Techniques
Mirror Finish Engraving and writing
Metal Finish Brushing Metals : Creates a uniform, parallel grain surface

texture to smooth out a product’s exterior. An abrasive belt or
wire brush is usually employed to achieve this effect.
15
Industrial Machineries that can be incorporated in the CFC
Brushing machine Bench Grinder
Rs 3591 Drill Bits

Rs 4938
Contents: 1, 1.5, 2, 2.5,
3, 3.5, 4, 4.5, 5, 5.5, 6,
6.5, 7, 7.5, 8, 8.5, 9,
9.5, 10mm.
Bench Grinder cum brushing machine
16
Buff Polishing : Creates a smooth, non-textured finish. Buff polishing machine
uses a cloth wheel to buff the product’s surface, resulting in a high, glossy
sheen. The process is often used for decorative products that benefit from
lustre and smoothness.
A great way to buff any metallic, painted, or varnished surface. Buffing uses a
buffer that is powered by an electric motor, making the job far more effortless
and time consuming that buffing by hand
Rs 10,500
Rs 19,000
17
Day 2 : Session 2 : Wood Carving and finishing Workshop : by Lila Gogoi, Handicraft Designer
18
19
Day 3 : Session 1 : Product Diversification and making process with addition of new materials and design:
by Sukanya Bor Saikia
20
MATERIAL OPTIMIZATION
Opportunity Area
Observation : > Very Poor Raw material quality.
> The lack of Quality Certification makes it very difficult for the artisans/agents to win trust of customers, especially outside the state.
> When the products get wet, they are easily attacked by rust. There has not been any such step taken forward to protect the products from
outer damage, i.e. no treatment process has been developed yet.
Remedial Solutions
1. The Raw materials procured can be of better quality to improve perceptual quality of existing product by proper linkage via the organisation handling
the cluster.
2. Increasing the life span of the metal by treating with various agents or by using better steel.
3. Quality Certification will makes it easy for the artisans/agents to win trust of customers, especially outside the state.
21
SCOPE OF DEVELOPMENT
Opportunity Area
Observation : > Kamartola is quite a remote village of Assam where the clusters only produce knives and few other products.
> The artisans and other cluster people also don’t have enough resources as well as funds to get introduced to new technology.
> The cluster does not have a proper schedule of work or time and each unit works individually though being in a group, therefore there
are no separate departments to handle specific job.
> They are not geared to thinking in terms of conducting research and development in this area which is seen more as a local prevalent
traditional craft.
Remedial Solutions
Technology:
1. Improvisation in machinery, tooling, process through R&D activities.
2. Investigating the properties of Jute in order to make the best use of the same while developing products.
3. A Common Facility Centre (CFC) can be set up with modern technology.
4. Exchange of technology ideas can be initiated through CFC.
5. Research in the area of proper furnace, working table to cut the products, proper heighted Anvil etc.
Marketing:
1. Research in terms of consumer trends and competition in the local, National and international market.
2. Creating an online portal or website to sell the products to the unreachable.
22
Techniques to make knives
23
Demonstration of the designs shown to the artisans on the work shed with proper dimensions and measurements.
24
Designs being shown and drawn on paper to be developed at the cluster.
25
The artisans involvement and suggestion of developing products.
26
Day 4 : Session 1 : Metal Carving Workshop
27
PRODUCT DEVELOPMENT
Opportunity Area
Observation : > The existing products consist of only few repetitive designs and with no contemporary or new colours or designs.
> Some products, made by the artisans are inspired randomly or from existing products made in other parts of Assam, and other states.
> The artisans in the cluster make similar products on order basis only.
> No inspirational engravings or other things are being practiced till now in the cluster.
> No body anatomy is considered while designing products.
> There is no product diversification at all in terms of aesthetics and quality.
> The deformity in the handles and poorly finished knives are easily visible on the product which make its less attractive and not for
international market.
Remedial Solutions
1. Possibility of another range of product in cutting tools itself, so that the basic idea of knife makers are not gone from the cluster. Other new age
products like with the help of proper technology and machineries, can be easily developed and would bring in much higher remuneration to the
makers. The products can then cater to the needs of a different target group who are more design and are quality conscious.
2. The existing products can be made more contemporary and relevant, less labour intensive by inclusion of machineries in the cluster.
3. The elements from the existing traditional designs of assam, eg. : designs in traditional assamese dress, nature inspired designs etc. can be used
and engraved in new product development and diversification and to give the products a local identity of itself.
4. Local craft can be combined with the Blacksmith products to get diversified products, like combining bamboo for making handles instead of
wooden.
5. The elements from existing traditional products can be used to introduce lifestyle products such as foldable knife, cutlery, and other nick knacks
for contemporary homes leading to scope of wider customers.
28
Koftgiri Work
Koftgiri knives from Rajasthan, India
29
30
31
Day 4 : Session 2 : Concept of Packaging and Branding for sustainable marketing : by Sukanya Bor
Saikia
32
Packaging
33
Packaging
34
Day 5 : Session 1 : Loan and Credit linkage with financial organization : by Anupam Dutta, Faculty SIRD, Assam
35
WAREHOUSING
Opportunity Area
Observation : > No proper lighting system for working in night hours, rely generally on natural light.
> The artisans sit in inappropriate and tiresome working positions to make the positions
> There is no place to work as a group, everyone works individually as per the need of the market.
> The amount of heat and dust produced during the entire procedure of knife making is very harmful for the artisans as they do not were
any kind of safety equipments or devices in order to save themselves from inhaling harmful gases of coal and burning there hands
during the process of making the products.
> There is high amount of risk for the artisans to get hurt by the process of cutting, beating, forging etc processes without using any kind
of precaution.
> The products are kept with no proper arrangement or storage, leads to damage.
> The work process is really slow due to hand made nature of the process.
Remedial Solutions
1. A Material Bank can be opened up near the village like in Hajo town of Kamrup district which is easy to access from the capital city of Assam and other
places as well and is near the cluster also.
2. There is an urgent need of CFC with organised workstations and a proper place to store the Jute products with each artisan owning there own
room or shelf to store their products.
3. Solar lights can be introduced so that they could work in the evening hours.
4. Proper gloves, eye protection glasses, helmet to wear during the dyeing process, treatment processes.
5. Seating need to be improved along with tables to work upon in the CFC.
36
Day 5 :Session 2 : End of the program with remedial solutions, Evaluation and Conclusion Ceremony /Feed
Back Form
Feedback form fill up and submission.
37
PROJECT OPPORTUNITIES
WORKPLACE LAYOUT AND SIMPLIFICATION OF MOVEMENTS
1. If similar work is being done by each hand, there should be a separate supply of materials or parts for each hand.
2. If the eyes are used to select material, as far as possible the material should be kept in an area where the eyes can locate it without there being any
need to turn the head.
3. Use semi-circular arrangements.
4. Design the workplace using ergonomic principles.
5. The nature and the shape of the material influence its position in the layout.
6. Hand tools should be picked up with the least possible disturbance to the rhythm and symmetry of movements. As far as possible the operator should
be able to pick up or put down a tool as the hand moves from one part of the work to the n4ext, without making a special journey. Natural movements
are curved, not straight: tools should be placed on the arc of movements of any material which has to be slid along the surface of the bench.
ARRANGEMENT OF WORKPLACE
1. Definite and fixed stations should be provided for all tools and materials to permit habit formations.
2. Tools and materials should be pre-positioned to reduce searching.
3. Gravity feed, bins and containers should be used to deliver the materials as close to the point of use as possible.
4. Tools, materials and controls should be located within the maximum working area and as near to the worker as possible.
5. Materials and tools should be arranged to permit the best sequence of motions.
6. “Drop deliveries” or ejectors should be used wherever possible, so that the operative does not have to use
7. his or her hands to dispose of the finished work.
8. Provisions should be made for adequate lighting and a chair of the type and height to permit good posture should be provided. The height of the
workplace and seat should be arranged to allow alternate attending and sitting.
38
PROJECT OPPORTUNITIES
DESIGN OF TOOLS AND EQUIPMENTS
1. The hand should be relieved of all work of “holding” the work piece where this can be done by a jig, fixture or foot operated device.
2. Two or more tools should be combined wherever possible.
3. Handles should be so designed that as much surface of the hand as possible can come into contact with the handle. This is especially necessary when
considerable forces have to be used on the handle.
OTHERS
1. To develop good communication strategies and implementation in a planned manner for the cluster.
2. Formation of Design & Training collaborative and associations can help them recognition and to be taken seriously by the traders and the middlemen.
3. Regular participation in trade fairs, national and international exhibitions will give them exposure, so that they are updated with the present and the
latest happenings.
4. Exposure visits to various organizations, craft councils and tie-ups with design experts will act as facilitator in their development.
CONCLUSION
To achieve better efficiency of performance, more human comfort and to reduce musculoskeletal injury, it is necessary to design the hand tools and
equipment keeping in consideration the operator’s capabilities and limitations. The design of equipment is always a compromise between the
operator’s biological needs, which are determined by the ergonomics guidelines, and physical requirements of the equipment.
1. Integrating human factors into design projects as a means to bridge the gap between designers and end users.
2. There is great scope of improving workstation of Rural Blacksmiths and their hand tools and equipment based on scientific application of
anthropometric data of Blacksmiths.
39
PRODUCTS MADE DURING THE FIVE DAY WORKSHOP
40
41
42
43
44
45
mobile : +91 9435707663 / 0361-2305105
email : sukanya.borsaikia@gmail.com
address : House no. - 16, Dharmeshwar taro Path, Krishnapur, 46
Beltola, Guwahati-781028, Assam
Kamartola Blacksmith Cluster
Sukanya Bor Saikia
Industrial Designer
Shanti Creations, National Institute of Design, Ministry of MSMEs
Kind of knives made throughout the world
Folding knife
cannon-spanish-style-clasp-knife
Knives made out of a large screw
Carving
Koftgiri Work
Koftgiri knives from Rajasthan, India

Other Products
Finishing techniques
Mirror Finish
Engraving and layering
Metal finish
Metal polishing techniques to be used in Kamartola products
Metal Plating machines use a chemical bath to coat or alter the surface of a substrate
with a thin layer of metal, such as nickel
Brushing Metals : Creates a uniform, parallel grain
surface texture to smooth out a product’s
exterior. An abrasive belt or wire brush is usually
employed to achieve this effect.
For grinding and sharpening.
Bench Grinder
Rs 4938
Drill Bits
Rs 3591
Contents: 1,
1.5, 2, 2.5, 3,
3.5, 4, 4.5, 5,
5.5, 6, 6.5, 7,
7.5, 8, 8.5, 9,
9.5, 10mm.
Buff Polishing : Creates a smooth, non-textured finish. Buff polishing machine uses a
cloth wheel to buff the product’s surface, resulting in a high, glossy sheen. The
process is often used for decorative products that benefit from lustre and
smoothness.
A great way to buff any metallic, painted, or varnished surface. Buffing uses a buffer
that is powered by an electric motor, making the job far more effortless and time
consuming that buffing by hand
Rs 10,500
Rs 19,000
Techniques
Packaging

Shanti Creation Kamar To La Blacksmith Cluster

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Shanti Creation Kamar To La Blacksmith Cluster

Uploaded by

Copyright:

Available Formats

Blacksmith Cluster

Kamartola, Assam Interactive design study

National Institute of Design > Foreword 4

Assam…State of diversity> a. Brief & Introduction 12

Detail of Location/District > b. Cluster Level Report 27

Unit Description > c. Unitwise Design Audit 65

Intervention > d. Soft and Hard Design 97

Thanks to the lovely people and artisans of Kamartola, Hajo, Assam.

National Institute of Design

Role of Design in Improving Competitiveness: Design is an approach, process and

The larger purpose of design is to do things in a better manner, to improve a

•Improve Handloom Technology Total : 5 Program

•Pattern Making and Garment Construction : 6 Program

•Formation of Joint Liability Group Total : 70

•Credit Linkage with Banks : 40

•Textile Design development and yarn dyeing

•Rural Product Marketing to Sale the product of Rural Weaver

•Participation in Exhibition about : 5

•Technical Consultant on 5 ESDP Program Sponsored by IIE, Guwahati

Assam’s population was estimated at 28.67 million in 2006 and at 30.57

Economy of Assam today represents a unique juxtaposition of

Assam has a rich tradition of crafts; presently, Cane and bamboo

ORIGIN OF THE TERM

MYTHOLOGY IRON AGE

A renewed interest in blacksmithing occurred as part of the trend in "do-it-yourself"

While developed nations saw a decline and re-awakening of interest in

Identifying the socio-economic condition of the cluster

The solution given can be implemented to other villages also.

Detail of Location/District >

Kamrup district occupies an area of 4,345 square kilometres

In 1989 Kamrup district became home to the Dipor Bil Wildlife

According to the 2011 census Kamrup district has a population of 1,517,202,

Geographical Information for Hajo

Place name : Hajo

Kamartola is a small Village situated around 5

There is no extra income outsourced. The

The people of the Village are very

Support by : Tools Used :

1.Mild and low carbon steel

2.Higher carbon steels

Medium carbon steel : Approximately 0.30–0.59% carbon content. Balances

HAND MADE CHISEL

DIFFERENT KIND OF TONGS

SMALL ANVIL LARGE ANVIL

SMALL WOODEN SURFACE TO SHAPE UP THINGS TOOLBOX

MOUTH OF THE FURNACE

WEIGHT PUT THAT HANGS WITH

The bent tooth design of knives is a traditional design of Assam and is

BON KATA (Grass cutter)

DAU (Long, big and strong

PATI BOTHI : A cutting and peeling tool with a

External Assessment of the Environment

Brought from Local market Wood

Cut from trees

Drawing Forging Heating Cutting

Bending Upsetting Combining Welding Guwahati

Beating of the rings to Finishing

ULTRA HIGH CARBON STEEL

The Coal is used for producing

STEP VI (WOODEN HANDLES)

Joining the Carbon steel finished knives with

+ the handles. The positive knife part is put