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PRE-FEASIBILITY REPORT For

Setting Up Common Facility Center (CFC)

COPPER COATED METAL BELL CRAFT,

BHUJ, GUJARAT

Under

Handicraft Mega Cluster Mission (HMCM)

Of

Ministry of Textile Govt. of India.

May2017

Prepared by:

MSME-TOOL ROOM

(Ministry of MSME, Govt. of India.)

Sanwer Road Industrial Area, Indore (M.P.)

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CONTENTS

Sr. No.

Particular Page No.

1. Introduction 5

2. Proposed Manufacturing Process 16

3. Civil Constructions Required 29

4. Final Implication 32

5. Conclusions 36

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ACKNOWLEDGEMENT

The team of Indo-German Tool Room express Thanks to Mr. Pradeep

Kumar CEO, Handicrafts Mega Cluster Mission (HMCM) New Delhi for giving an opportunity to IGTR to work on the project of Copper Coated Metal Bell craft.

Thanks to Mr. Ranbir Singh consultant of Handicraft-Mega Cluster Mission (HMCM) New Delhi for providing his continues support during the stockholder meeting and visiting the different units of manufacturer of Copper Coated Metal Bells.

We also thanks to Ms. Juhi Pandey Director and Mr. Ghatit Laheru Deputy Director of Kachchh Heritage Art & Craft Music Information & Resources (KHAMIR) Ajrakhpur for providing necessary information of stockholders for this project.

(Ashok Kumar)

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Objective of the Project

To access the present way of manufacturing of the metal bell.

To study and propose the up graded technology for manufacturing process to make it more competitive in the market.

Setting up the common facility center by equipping upgrading their manufacturing process, latest machinery and equipments.

Installation and commissioning of approved machines.

Training of artisans on machine and equipments set-up in common facility center.

Three months duration Hand holding support.

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1. Introduction

Kutch is an east while princely state of India. It is the largest district of the state of Gujarat and the second largest district in India. The land is virtually "an island", resembling a tortoise, surrounded by seawater.

Copper-coated iron bells from Kutch in Gujarat were made traditionally in sindh, now in Pakistan. The art has been passed down over the generations. At that time, the bells made were exchanged for wheat, vegetables, milk pots and pans or clothes. It was a natural means to social and financial independence. These bells were used at entrances to homes and were also hung around the necks of grazing animals like cows and goats. Locally, they still serve the same Purpose.

Kutch is the land of crafts. It has crafts in its sand since generations. Bell making is a similar traditional craft of Kutch. These bells are made from waste iron sheets from different products. These bells were initially made for the cattle cows, buffalo, etc. But years ago the local market for these bells declined due to drought in that area. But after few years the elders of the village zura found a new market opportunity for bells outside Kutch. These bells are made completely by hand and through a new inverse process involving a lot of craft skills. Upon completion this bell has its own hand crafted look and a sweet melodies around produced by Metal Bell Craft pieces.

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The craft is divided into various steps starting from marking the parts to combining them and coating them with copper in the bhatti (Furnace) and finally producing the sound by inserting the Metal Bell Craft prong. The process of welding is also included further for using these bells in them. The unique feature of this bell is that the sound is different every time and is each and every bell and the sound and pitch can be increased or decreased by hammering. This craft has travelled from the necks of the cattle to the walls of big homes and the people of zura village and working day and night to increase the popularity of their work and skill nationally as well as internationally.

1.1 Regions of Production

Zura, the hub of copper coated bell making craft is a small dusty village situated in Bhuj, taluka (district) Gujarat 23-24N-69:39E approximately 30 km away from Bhuj, Gujarat. It has a population of 5000. The village has one primary school and four anganwadi. The village is situated near Jhura hills which are a source for many raw materials that are being used in crafts. The main occupation of the people is farming. Besides the craft of making copper coated bells, people also do leather work, Metal Bell Craft, shawl weaving, soof embroidery, bandhej work, etc.

Copper bells are now being made only in two villages in Bhuj, Gujarat. These are Nirona and Zura.

Craftsman in Zura was blacksmithing copper bells. Small bells to use for wind chimes and large bells used for animals to wear.

Live and let live’ is a policy which is followed here. It was a household specialized in making of copper bells. The bells are actually made of scrap sheet metal, but given a copper tinge in the end. Although the making is crude, the sound quality is excellent and that is what one uses to judge the skill of the workmen. Yet again, we were carefully seated and the whole process was demonstrated over chhaas.

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Further, we were escorted to a family who dealt in lacquer work. The simplicity of the process is ingenious.

Most of the bell making is done in Kutch, Gujarat by the lohars of the muslim community. The entire family is involved in the process, though women only do the mud coating on the bells before they are put into the oven. Men perform the technical and critical tasks of shaping the bells and setting their sound.

1.2 Raw Materials

Scrap iron sheets of 1-2 mm thickness are brought from the local market situated in Bhuj, Gujarat. There are many scrap vendors in new station road area of Bhuj, Gujarat. Mostly they purchase sheets that are evenly flat and have no budges or rough protrusions. No other treatment is provided to the sheet, other than hammering so that the sheets get properly flattened and is left with not even the slightest of lumps. Scrap iron means the sheets that are procured from old refrigeration, air-conditions, chimneys, etc. These scrap iron sheets are available in the market at a cost of Rs. 30-40 per kg. If they purchase fresh iron sheets they are available for Rs 60 per kg. But usually they use the scrap iron sheets which are economical to them. It has another benefit also. These scrap iron sheets are being reused and reworked upon to manufacture something that is of great value to the market. The iron sheets do not require any further processing. They are directly used for making iron bells.

The bell is made of CRCA (Cold Rolled Cold Annealed) and coated primarily with copper, along with a few other metals. They are made from scrap iron sheets which are repeatedly beaten to join together and to give them the required shape. The metal parts are neatly joined by skill hands by a locking system without any kind of welding.

Then they are coated with powdered copper with the help of mud paste and then heated in a furnace to fix the powdered copper on the surface of the bells. Once cooled and ready, a Metal Bell Craft piece is attached to the centre of the bell for that characteristic sound which is beautifully sonorous. Denting of the bell to get the perfect pitch is also done by hand, by repeated beating with a hammer. It

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takes a lot of expertise and very careful and sensitive use of sound as well as touch.

Bell making in Kutch (Bhuj, Gujarat) is a wonderfully sustainable craft as the raw material is metal scrap which is purchased from junk yards and the only use of energy is in the furnace for preparing them. Even the waste generated is miniscule, comprising of small metal scrap and burnt mud.

Nowadays, this craft is gaining popularity as decorative items not just because they have a beautiful sound, but also because those sounds remind us of being close to the earth, the villages and our roots.

1.3 Tools Varieties of tools and raw materials are used for Bell metal making. Easily pliable iron sheets are used as a basic raw material for production of Bell metal. Metal is collected from the nearby industry of the Bhuj, area. The sound of bell metal mainly depends on shape and size of body of the bell. Different sizes from 1 to 14 of metal bells are prepared according to the customer demand.

Raw Materials used: Iron and copper Sheets:

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Sheets are used to make the bell.

Kirad tree Metal Bell Craft:

Metal Bell Craft is used to make the clapper.

Brass, Iron, Copper and Zinc Powder:

These are used to apply on the bell before heating.

Tool Used

Cutter (Thekapani):

Cutter is used to cut the metal sheet.

Hammer (Hathodi)

Hammer is used to shape the metal sheet into bell.

Kiln (Bhatti):

Kiln is used to heat the bell.

Raw Cotton (Kappas) and Mud:

These are mixed together and the mixture is covered on the bell before heating.

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Holder (sansee):

It is used to hold the bell and place it in the kiln.

Grinding & Buffing:

Grinding machine is used for grinding the copper bells, once they are finished to give them smooth edges. The craftsman sharp their tools with this grinding machine.

Welding Blow Torch:

It is used for joining the two iron pieces of frames used for holding and decorating. The frames that are made out of the wires and joined together with the help of torch. Welding wires are used to weld iron pieces. As soon as the metal turns red while heating, the welding is applied.

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1.4 Making of the Craft

The making of a copper bell can be divided into three parts:

1.4.1 Main Cylindrical Hollow

The body of bell is made by shaping rectangular strips of iron plates into a cylindrical hollow. The length and width of the iron strip used depends on the size of the bell to be crafted. The stone on which the iron strips are shaped is also special. Holes of various sizes are made in it to fit the iron strips for bells of various sizes.

1.4.2 Semi-circular Hollow

The cylindrical body is topped with a semi-circular shaped, half-orange hollow crown, which is made from a small iron strip. The dome-like top looks like the inside of a bowl and is welded perfectly with the cylindrical body of the bell.

1.4.3 Loop

The clasp loop at the top of the bell (through which is passed the rope or twine from which the bells hangs) is attached. A very narrow iron strip is shaped like a horseshoe; both its ends are then pushed in through the bell top to the inside of the bell both the ends are twisted together and locked, creating a thin circular or oval loop of which half is atop the bell, and the other half inside the bell. The textured and burnished copper coating is created through several stages, each involving a distinct process. The uncoated iron bell is first dipped in a solution of mud and water (mostly women do this particular part of the process) and then the bell is rolled in the mix of brass and copper powder. This metallic powder sticks to the bell as it is covered with a wet mud solution. Bits of cotton are soaked in the mud and water solution, after which they are stretched into dense pancake-like shapes. The bell, with brass and copper powder clinging to it, is wrapped in the cotton pancake and baked in a bhatti for 30-45 minutes. The length of time that the bell is kept in a bhatti depends on the size of the bell, with the smallest size being baked for half an hour to 45 minutes and the largest for more than an hour. If the bells are small four or five can be put together in the fire but the bigger bells are baked one at a time.

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After it has been baked, the cotton wrapping is peeled off, and the excess mud sticking to the bell is rubbed off. The metal-coated outside is buffed to create a lustrous polished ton.

Finally, a shaped piece of Metal Bell Craft, usually shisham, both dense and hard, is hung in the cylindrical part of the bell structure converting the bell hollow into a musical piece. The solid Metal Bell Craft piece is attached to the bell’s dome roof with the help of a thin iron hoop that is pierced through the Metal Bell Craft at one end.

1.4.4 Sound and Tonal Settings

Each artisan gets a different and distinct tone from the bells that he makes. Just by listening to the sound an artisan can tell who has made the bell in his village. The sound that emanates from the bell is actually set by the bell maker with the help of an instrument called ekalavai. Each bell maker makes his own ekalavai.

The sound that each bell emanates depends on how well the metal is beaten, the shape and curvature of the bottom rim of the bell. On no account can different sized bells be combined in a single sequence or jhumar. This is owing to the fact that mixing different sized bells would lead to a conflict in tonal settings, thus creating a cacophony. The need for tonal harmony also means that the rims of all the bells in a jhumar be shaped identical to each other. A well-crafted jhumar is, thus, a collection of bells that are as similar, if not identical, in shape, size and tonal settings.

In the local market (in Bhuj, Gujarat and Nirona) bells are often referred to by their original names such as chota-paila, paila, dingla, do-dingla rather than their sizes. These names are the local currency equivalents for which the bells could be bought at that time. Within each size, the shape of the bells can vary and the rims are designed differently. Some are straight-edged, while others are worked in an undulating pattern and even in multiple rows of undulating lines. Sometimes the rims are reinforced or made heavier by adding thin strips of metal to create a new sound variation.

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1.5 Products and their Uses

Bell making in Bhuj, Gujarat is a sustainable craft as the raw material used are scrap, purchased from junkyard. Bell making craft is gaining popularity as decorative items are produced and for their beautiful sound. The bells come at a very high price and carry a life-time warranty. The orders for this craft comes more from abroad compared to India.. The price ranges from Rs. 50/- and goes up to thousands of rupees depending on the size and design of the product.

The different types of products made from these bells are outlined below:

• Sadiyavala Saregama,

• Ring Jumar,

• Dorivalo Saregama,

• Bharatwalo Patto,

• Neck bell for Cattles,

• Wind chimes,

• Festival Decoration and

• Key chain.

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Festival Decoration Product

Key chains

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1.6 Primary Market

These bells and jhumars are sold in the local markets-Nirona, Jhura and Bhuj, Gujarat. They are used as decorative musical items, somewhat like chimes, all the more since their tonal quality is meticulously crafted. Government emporia have also started buying these from the local producers. Some tourists who manage to reach the villages also contribute toward the sales.

However, maximum sales happen at the exhibitions and fairs in metros and when orders are made during these exhibitions. The demand has increased in the last decade and many new products have been introduced that were not there two decades ago.

1.7 Furnace

Furnace is a chamber made up of bricks and covered on the top with a cemented shed. Above the shed are few iron sheets to avoid the flame to escape. The clay wrapped iron bells are kept in the chamber and heated till red. It is a very traditional furnace except the fact that they use a blower that runs on electricity. Previously they used a blow pipe (sigdi) or a piece of hard cardboard sheet to spread the flame. The burnt coal i.e., grey ash is cleaned up every time they heat the bells. There are three furnace one in the workshop, one near the home which is the biggest and another one in the wedding area.

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2. Proposed Manufacturing Process Copper coated bells are manufacture based on the need of the time and reason this bell are made by collective work and skill of a family. They do not have any professional qualification but they have lots of skills learn from co artisan and in the family. The designs are traditional along with self-styled pattern and dyes and more for shaping and finishing of the products.

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2.1 SHERAING OF SHEET METAL The most common cutting processes are performed by applying a

shearing force, and are therefore sometimes referred to as shearing processes. When a great enough shearing force is applied the shear stress in the material will exceed the ultimate shear strength and the material will fail and separate at the cut location. This shearing force is applied buy two tools, one above and one below the sheet. Whether these tools are punch and die or upper and lower blades, A small clearance is present between the edges of the upper and lower tools, which facilitates the fracture of the material. The size of this clearance is typically 2 - 10% of the material thickness and depends upon the several factors such the specific shearing forces, material, and sheet thickness.

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2.2 HAND SHEARING PREPARE BLANK Hand shearing is also known as bench shear/ lever shear, is a bench mounted shear with a compound mechanism to increase the mechanical advantage. It is usually for cutting rough shapes out of medium size pieces of sheet metal, but cannot do delicate work.

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2.3 ROUND BLANKING Blanking and piercing are shearing process in which a punch and die are used to modify webs. The tooling and processes are the same between the two only the terminology is different in blanking the punched out of piece is scrap. The process for parts manufactured simultaneously with both techniques is often termed “pierce and blank”

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2.4 CUPPING OPERATION In drawing operation, where tools transforms the sheets of metal into cups, shells, or drawn shapes by subjecting the material to shell plastic deformation. Drawing operation may be called as cupping operation, it is a rather deep shell that has been drawn from a flat sheet.

2.5 BLANKS FOR HOOKS Blanks for hooks may done as curling. Curling is a sheet metal forming process used to form the edges into a hollow ring. Curling can also performed to eliminate sharp edges and increase the moment of inertia near the curled end. Other parts are curled to perform their primary function, such as door hinges. This is also use to curl a sheet strip into hook

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2.6 POLISHING BRASS WIRE Polishing is finishing processes for smoothing a workpiece surface using an abrasive and a work wheel or a leather strop. Technically polishing refers to processes that use an abrasive that is glued to the work wheel. Polishing is often used to enhance the appearance of an item, prevent contamination of instruments, remove oxidation, create a reflective surface, or prevent corrosion on wires.

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2.7 POWER PRESS It is a press which is comprised of a frame, a bed or bolsters date, and a reciprocating member called a ram or slide which exerts force upon work material on the ram and bed. Energy stored in the rotating flywheel of a mechanical press or supplied by a hydraulic system in a hydraulic press is transferred to the ram for its linear moments

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2.8 ELECTROPLATING It is a process the uses electric current to reduce dissolved metal cautions so that they form a thin coherent metal coating on an electrical oxidation, as in the formation silver chloride electrode. Electroplating is primarily used to change the surface properties of an object (e.g. abrasion and wear resistance, corrosion protection, lubricity, aesthetic qualities, etc.)

2.9 WELDING Welding is a fabrication or sculptural process that joins material, usually metals or thermoplastic, by causing fusion, which is distinct from lower temperature metal-joining techniques such as brazing and soldering, which do not melt the base metal.

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Types of welding

1. Butt Joints

2. Tee Joint

3. Lap Joints

4. Corner Joints

5. Edge Joint

6. Strap Joint

7. Plug Joint

2.10 WOOD CRAFT LATHE The Wood Craft working lathe is one of the most important machines used in a carpentry shop. Turning jobs in making cylindrical parts, the tools, tapers, radii, and other irregular shapes can also be easily turned. It resembles the engine lathe, and consists of cast iron bed, a headstock, tool rest live and dead centers, and speed control device. The workpiece either clamped between two centers or on a face plates. The lathe is supplied number of accessories for making it useful for a variety of jobs.

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2.11 HAND TOOL A hand tool is any tool that is not a power tool that is, one powered by hand (manual labour) rather than by an engine. Some examples of hand tools are garden forks, secateurs, rakes, hammer, spanner, pliers, screw-driver, nail peeler, anvil and chisels. Hand tools are less dangerous than power tools

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2.12 SPRAY COATING Spray coating is a technique where a device spray a coating (paint, ink, vanish) through the air onto a surface. Spray guns evolved from air brushes, and the two are usually distinguished by their size. Airbrushes are hand held and used instead of a brush for detailed work such a photo retouching, painting or porting in metals. Air guns spraying uses equipment that are generally larger. It is generally use to cover large surface.

2.13 MIG WELDING The MIG METAL INERT GAS, one process uses a continuously feeding wire (MIG) MIG a welding use an electric arc to make the weld. MIG welding is very simple and easy process, MIG welding on the other hand is more commonly used for your thinner gauge materials.

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2.14 ROLLING FIXTURE FOR OVAL ROUNDING Most of the work holders in this group hold a workpiece for an operation that requires rotation. Example may be found in turning, boring, grinding, or intermittent rotational for indexing the workpiece may be held and located on an external or internal Diameter for a milling operation requiring indexing, which means performing and repeating the operation in a certain angular relation.

2.15 FURNACE HEATING FOR HARDENING AND COPPER COATING

Hardening is metallurgical metal working process use to increase the hardness of a metal. The hardness of the metal is directly proportional to the uniaxial yield stress at the location of the imposed strain. The harden metal will have a higher resistance to plastic deformation then a less hard metal.

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Proposed Manufacturing Process

Hollow Cylinder

• Making Blank Rectangular

• Bending Hollow

• Thinking Edge For

Joint

Semi Circular Cup

• Blanking Round

• Cupping Hemisphere

• Thin Edge For Joint

Loop

• Cutting

• Bending

• Pushing in Hole And Fixing

Joining Both Piece By Hammering Fixing Loop On Top Of Semi Circular

COPPER COATING

Dipping In Mud Solution

Coating Brass & Copper Powder

Wrapped In The Cotton Pancake & Baked

Sound & Tone Setting

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3. Civil Constructions Required

Common Facility Centre (CFC) is proposed for in form of small workshop to manufacture the bell metal craft where in all the upgraded Technology will be available to all the bells manufacturer under one roof. All artisans can avail the facility i.e., machine tools equipment like furnaces, press, shearing machine, electroplating facility etc. the approximately area required is 2000 sq ft. The construction cost of the shed/ covered area will be @ rs.1500/sq feet. The total cost will be Rs.300sq Mt X @12,000 is approx 36, 00,000/-

3.1 Power and Electrification Sl. No.

Name of Machine Power Required Remarks

1 Power Press 3 H.P. 2.5 KW 2 Shearing Machine 2 H.P. 1.5KW

3 Metal Bell Craft Lathe 2 H.P. 1.5 KW

4 Electroplating 10 KW 5 Electric Furnace 23 KW

6 Welding Machines 5 KW 7 Lights And Fan etc 2 KW

8 Miscellaneous ( Pedestal, Hand Grinder, Polishing )

3 KW

Total 50 KW

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METHODOLOGY ADOPTED

A comprehensive methodology & approach was envisaged for

understanding the needs and requirement of the Bhuj, Gujarat Metal Bell Craft

Cluster in view of the extreme potential and skills exits in the region.

There are certain gaps & bottlenecks which have never been addressed in

totality due to which the Metal Bell Craft crafts from this region despite

potentials could not be projected

Keeping in view of the above points, specially the reasons for which the

Metal Bell Craft of Bhuj, Gujarat were not been able to projected in the world

map, a methodology has been envisaged encompassing vivid approach such as

feedback from HMCM New Delhi, direct interactions with the artisans,

entrepreneurs, exporters etc., vis.-a-vis. also organizations working in Bhuj,

Gujarat, visit of senior officials to the clusters and production centers.

HMCM New Delhi has organized Stakeholders Meet of Handicraft Artisans, NGOs and technical experts from MSME-TOOL ROOM (IGTR) Indore on 26th & 27th April, 2017 at Village Zura District, Padarathpur & Aashpur Metal Bell Craft Cluster to study the existing processes of making Metal Bell Craft carving products and Sadiyavala Saregama, Ring Jumar, Dorivalo Saregama, Bharatwalo Patto,

Neck bell for Cattles, Wind chimes, Festival Decoration and Key chains etc. and discussed with artisans and stakeholders to know their precise requirements about quality & process improvement, skill up gradation, improvement in manufacturing techniques, etc. We have also discussed about machinery & equipment to be installed in proposed Common Facility Centre. Based on the discussion with artisans and other stake holders, expert from MSME-TOOL ROOM (IGTR) Indore it finalized Machines & Equipment’s to be installed in proposed CFC.

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OBJECTIVES OF SET-UP THE CFC PROJECT IN BHUJ DISTRICT

HMCM proposes to establish common facility centre in this Metal Bell

Cluster with the following objectives:

To improve workplace.

To carry out faster & quality production by artisans for value addition and

increasing income level of artisan/craftsman.

To Produce New design of existing products and products selected under

product diversification.

Installation and commissioning of approved machines.

Training of artisans on machine and equipments set-up in common facility center.

This cluster offers good scope for improvement in production process with reduction in cycle time & improvement in inherent quality and aesthetic look of products (Sadiyavala Saregama, Ring Jumar, Dorivalo Saregama, Bharatwalo Patto, Neck bell for Cattles, Wind chimes, Festival Decoration and Key chains. etc.) The extra labour and wastages may be reduced with the use of simple and low cost tools & equipment. With the establishment of Common Facility Centre in the cluster the artisans would be able to produce products with good quality and surface finish. The CFC will work on job work conversion basis for the artesian on chargeable basis.

MACHINERY & EQUIPMENT TO BE INSTALLED

Accordingly, the proposed Common Facility Centre would be equipped with machinery/equipment such as Power Press, Shearing machine Semi automatic, Electric furnace, Hand shearing Machine, MIG Welding Machine, Round Blanking Tool, Cupping operation Tool (Hemisphere), Paint zoom PZ-1 HVLP Sprayer, Sets of hand tool, Table lathe for Metal Bell Craft works, Drilling Machine, Measuring Instruments, Fly Press, Furnace, Furnace with Blower. Details of Machinery to be installed in proposed CFC is given in Annexure - I.

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POWER & UTILITIES

The proposed CFC would have 1 No. DG Sets of 15 KVA, Air Compressor, Fire & Safety Equipment’s First Aid Facility, etc. The power connection shall be taken for 50 KW for CFC. The DG sets shall be used in case of power failure.

4 FINANCIAL IMPLICATIONS

Preoperative Expenses of Proposed CFC:

Particular Amount

Pre-Feasibility Report 93,500

Consultancy Charges (LS) 10,00,000

TOTAL 10,93,500

Land & Building: As per the guidelines, land & building for setting up of CFC to be provided by Clusters. It is estimated that requirement of land will be approx. 400 Sq. meter out of which 300 Sq. meter would be covered area to accommodate machinery & equipment, Office, Stores, DG Set, etc.

Land & Building Cost [Rs.]

Land: Area about 400 sq. meter. Leased by Cluster

Building : Work - Shed , Store ,Office etc about 300 sq. meter @ 12,000 sq. meter 36,00,000

Patricians and Furnishing (LS)

3,00,000

Total Land & Building 39,00,000

Machinery & Equipment and Misc. Fixed Assets:

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Proposed CFC would be equipped with Machinery & Equipment as given in Annexure-I. The total cost of machine & equipment & Misc. fixed assets estimated at Rs. 1.0 cr. This amount will be funded by HMCM Ministry of Textile, Govt. of India.

Manpower Requirement for CFC: The artisans have skills to operate most of the machines in CFC. However, for day to day operations a team comprising of one m a n a g e r , one or two skilled workers for operation of electroplating machine, power press, DG set, etc. need to be recruited on need basis.

WORKING CAPITAL [PER MONTH]

[1] Staff and Labour [per month]

Sr. No. Description No.

Salary@ Rs. Total Salary [Rs.]

[a] Administrative staff

i Manager 1 25,000 25,000

ii. Clerk /Accountant 1 15,000 15,000

[b] Technical Skilled & Unskil

led

i. Skilled worker 1 12,000 12,000

ii. Helper /Peon 1 8,000 8,000

Total 60,000

Perquisites @ 15 % 9,000

Grand Total 69,000 Say Rs. 70,000

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[2] Utility [per month]

Electricity 50 KWA 10/- 5,00

Water L S LS 1,000

Total 1,500

[3] Other Expenditure [per month]

01. Postage & Stationery 500

02. Phone & Fax 1,000

03. Repair & Maintenance 1,000

04. Traveling& convene 4,000

05. Consumable 700

06. Insurance 800

07. Taxes 10,000

08. Misc. Expenses 4,000

Total 22,000

[4] Total Recurring Expenditure [per month]

01. Staff and Labour 70,000

02. Utilities 1500

03. Other contingent expenses 22,000

Total

Say

92,500

95,000

[5] WORKING CAPITAL FOR THREE MONTHS = 95,000X 3

= 2,85,000

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FINANCIAL ANALYSIS

TOTAL CAPITAL INVESTMENT

01. Fixed Capital 1,00,00,000

02. Working capital for 3 months 2,85,00, 00

Total 1,02,85,000

[1] Cost of production [PM] :

Total recurring cost [PA] 11,40,000

Dep. on building @ 5 % 1,95,000 Dep. on machinery equips @15%

15,00,000

Interest of total capital investment @14%

14,39,900

Total Say

42,74,900 43,00,000

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5 Conclusions & Recommendation:

MSME-TOOL ROOM (IGTR) Indore recommends that establishment of Common Facility Centre for benefits of artisans is very much necessary with the objective to provide facility to artisans for manufacturing of value added existing products and products selected under product diversification for increasing brand image and income level of artisans. CFC would be utilized to its maximum by artisans of the cluster for job work basis for making existing & Sadiyavala Saregama, Ring Jumar, Dorivalo Saregama, Bharatwalo Patto, Neck bell for Cattles, Wind chimes, Festival Decoration and Key chains etc. Since these products of good design & quality will fetch better price from customers, artisans would be able to pay service charges of CFC without any problem. Hence it is estimated that investment made on CFC would be recovered within 10 years. However before setting up Common Facility Centre artisans of Village Zura District, Bhuj, Gujarat Cluster need to be convinced about benefits of CFC and they should come together to form Association or Sangathan which will act as SPV for running up of proposed Common Facility Centre.

MSME-TOOL ROOM (IGTR) Indore concludes that setting up of Common

Facility Centre at Village Zura District, Bhuj, Gujarat Cluster would be technically

feasible and economically viable.

On Acceptance of pre-feasibility report, MSME-TOOL ROOM (IGTR) Indore may

take up implementation of project for setting up of CFC at Village Zura District,

Bhuj, Gujarat Cluster on turnkey basis including hand holding support for period

of 3 months after project implementation.

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Broad Outline of Pre-Feasibility Report

Sr. No. Particular Details

1. Name of Craft Cluster Metal Coat, Bhuj, Gujarat

2. Handicrafts Manufactured Copper Coated Metal Bell Craft

3. Total No. of Artisans Approx. 500

4. Estimated Project Cost of proposed Common Facility Centre

A Land & Building 39 Lakhs

B Machinery & Equipment 1.0 cr.

D Preliminary & Pre operated expenses

11.4 Lakhs

E Institution Charges

(i) Pre feasibility Report

93,500

(ii) CFC installation Charge :

10 Lakhs

Total Project cost

1,60,97,500

5. Means of Finance

By HMCM New Delhi

Project Implementation Period

6 Months

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Annexure I

List of Machines & Equipment proposed to be installed in Common FacilityCentre

Sr. No.

Particulars Qty Unit Price Cost

1. Power Press 30 Tons Type fixed -"C" frame Capacity (Tons) 20 – 30 Area of Bolster (LR*FB) (500X375) TO (600X400) Air Pressure (Kg/Cm2) 5 Stroke Length 25 – 45 No. of Slide Strokes 45-50 Distance Between Bed and Ram 300 – 400 Stroke per min. 55 Height from Floor to top of Bolster 600 - 700 Bed Opening (Dia.) 100 – 130 Hole in Ram 38(Max) Shank Hole 30 - 35 Flywheel Dia. 800(Max) Main Motor (H.P.) 3HP/1440 RPM (Reputed Make)

Slide Stroke Length Adjustable 65-85

1 Nos. 5,000,00 5,00,000

2. Shearing machine Semi automatic mechanical, capacity 1270x2, blade width 50mm, blade thickness 12mm, hold down knife edge 20, stroke per min. 60, Motor 2 HP

1 Nos. 3,000,00 3,00,000

3. Electric furnace 3ft x 3ft x 4

ft Temperature range 900

to 1200 C

1 Nos. 5,000,00 5,00,000

39

4. Hand shearing Machine Shearing length 12inch, sheet thickness 2mm,

1 Nos. 25,000 25,000

5. MIG Welding Machine (Power source-CVR 250, Suitable wire-0.8, 1, 1.2mm, wire speed-1.5 to 1.8, wire roll drive-two, wire drive motor-DC, suitable wire spool capacity-15 kg.

1 Nos. 2,00,000 2,00,000

6. ARC Welding Machine (100Amps, 4KVA, electro size 14 SWG)

1 Nos. 25,000 25,000

7. Spot Welding Machine Input 440W 2 phase A/C, Frequency 50-60 Htz, Output 75-85 DC, Throat clearance 150mm, Throat depth 150-200mm

1 Nos. 70,000 70,000

8. Round Blanking Tool for size1 to 3 (interchangeable die)

1 Nos. 40,000 40,000

9. Round Blanking Tool for size 4 to 6 (interchangeable die)

1 Nos. 65,000 65,000

10. Round Blanking Tool for size 7 to 10 (interchangeable die)

1 Nos. 85,000 85,000

11. Round Blanking Tool for size 11 to 14 (interchangeable die)

1 Nos. 1,00,000 1,00,000

12. Cupping operation Tool (Hemisphere) for 1 to 3 size

1 Nos. 40,000 40,000

13. Cupping operation Tool (Hemisphere) for 4 to 6 size

1 Nos. 55,000 55,000

14. Cupping operation Tool (Hemisphere) for 7 to 10 size

1 Nos. 95,000 95,000

40

15. Cupping operation Tool (Hemisphere) for 11 to 14 size

1 Nos. 1,25,000 1,25,000

16. Paint zoom PZ-1 HVLP Sprayer (Multicolor)

1 Nos. 5000 5000

17. Electroplating machine (tank-10 liter, PP body, Digital display for volt, AMPS, Temp.)

1 Nos. 2,00,000 2,00,000

18. Sets of hand tool 2 Set 50,000 1,00,000

19. Table lathe for Wooden Craft works (length of bed-4/5ft., Center height-6.5", face plate Dia.-12", power required HP-1.5

1 Nos. 40,000 40,000

20. Drilling Machine 1 Nos. 25,000 25,000 21. Measuring Instruments 2 set 25,000 50,000

22. Fly Press Capacity 5 Ton, swing 1300 mm Dia., distance pillar center-630mm

1 Nos. 75,000 75,000

25. Furnace with Blower (Air flow rate-50 to 600mm) WC static pressure, Blower type-Centrifugal Blower, Power- 1H.P.

1 Nos. 2,00,000 2,00,000

26. Diesel Generator 50 KVA

1 Nos. 3,00,000 3,00,000

27. Estimated cost of Civil items 300 Sq./Mt. 12,000 36,00,000

28. Contingency 10,00,000 29. Implementation &

Monitoring Cost 10,00,000

Sub-Total 88,20,000

41

After adding 10% towards installation and Commissioning

8,80,000

Total Fixed Capital Say

97,00,000

1,00,00,000

42

Annexure II

List of Supplier of Machinery

HIMATLAL MACHINE TOOLS E-203, KALADEEP APPARTMENT B/H. SACHIN TOWER, SATELLITE, AHMEDABAD, GUJARAT

SHRI RELIEF ELECTRICAL & ENGINEERING WORKS OPP. SUKH SAGAR HOTE, RELIEF ROAD KADIYA KUI,AHMEDABAD,GUJARAT

ADD:- A/2, ALOK APPARTMENT, Nr. RAJSHREE TOWER, JODHPUR GAM, SATELITE, AHMEDABAD – 380015, MO : 9033643875, 094082 80303, E-mail : paurav6369@yahoo.co.in

Website : www.devamenterprise.in

43

Annexure III

List of Artisans or Manufacturing in the field of Metal Belt Craft

Sr. No.

NAME OF PARTICIPANT ADDRESS & CONTACT DETAILS (MOB/TELE/ EMAIL ID)

1. RAZAK SALEMAMAD LUHAR (MASTER ARTISIAN)

ZURA, BHUJ, KUTCH

2. MUSTAK ABDULLA LUHAR LUHAR VAS ZURA BHUJ,KUTCH 3. ABBAS KASAM 434,ZURA,BHUJ,KUTCH-370001

4. AYUB ABDULLA LOHAR ZURA BHUJ KUTCH 5. JAKAB KASHAM LOHAR 270,ZURA BHUJ KUTCH 370001

6. MAMAD SALEMAMAD LUHAR

438,ZURA,BHUJ,KUTCH-370001

7. LOHAR HUSN JAKAB JURIYA, ZURA, KUTCH 370510 8. LUHAR ROSHAN RAJAK IUHARVAS ZURA, BHUJ, KUTCH

9. LUHA HAJARA JANMAMAD

IUHAR VAS BHUJ KUTCH, 370001

10. LUHAR GULSERABAI AYUB LOHARVAS ZURA, BHUJ, KUTCH

11. KURSABAI 223 LOHARWAS ZURA BHUJ, KUTCH 12. SUMRA HAJRABAI OSMAN BHANUSHALI VAS ZURA,BHUJ, KUTCH

13. SIDHIK KASAM 434 ZURA BHUJ KUTCH) 14. SULEMAN JAKAB LUHAR MASJIDNI BAJUMA ZURA,BHUJ, KUTCH

15. REHANA ABBAS ZURA, BHUJ, KUTCH

16. SARABAI S LOHAR IUHARVAS ZURA, BHUJ, KUTCH

17. TAIYABA KASAM ZURA, BHUJ, KUTCH 18. MAST MOSIN HUSN

LUHAR MASJIDNI BAJUMA ZURA, BHUJ, KUTCH

19. FIROJ HUSEN LUHAR JURIYA ZURA KUTCH 370510)

20. SHAILESHGAR CHANCHALGAR GUSAI

SHANKAR MANDIR VISTAR BHUJ, KUTCH

21. SIRIN JAKAB 271 ZURA, BHUJ, KUTCH 22. RUKSANA SADIK 88 BHANUSHALIVAS THI VAKILVALI ZURA,

44

BHUJ, KUTCH

23. SAKINA HUSEN LOHAR IUHARVAS ZURA BHUJ, KUTCH 24. AKILA BANU S LUHAR IUHARVAS ZURA BHUJ, KUTCH

25. AMRUTBN KANJI 188,MORAWAS ZURA BHUJ,KUTCH 26. KANJI DEVJI JURIYA ZURA KUTCH 370510)

27. LUHAR HANIF KASAM 88 BHANUSHALIVAS ZURA, BHUJ, KUTCH

28. SALEMAMAD JAKAB LOHAR

IUHARVAS ZURA, BHUJ, KUTCH

29. PUSHPABN SHAILESHGAR GUSAI ZURA, BHUJ, KUTCH 30 HAWABAI SHULEMAN

LUHAR IUHARVAS ZURA BHUJ, KUTCH

31. FIROJ HAWABAI LUHAR IUHARVAS ZURA BHUJ, KUTCH