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Need Assessment Survey of Howrah Rolling Mill Cluster under the
Design Clinic Scheme for MSMEs supported by Ministry of MSME, Govt.
of India
Survey Team
Dr. Somnath Gangopadhyay, PhD, FABMS
Associate Professor,
Occupational Ergonomics Laboratory,
Department of Physiology
University of Calcutta
Krishnendu Sarkar, M.Sc.
Research Scholar,
Occupational Ergonomics Laboratory,
Department of Physiology University of Calcutta
Sujaffar Hosain Mollah, M.Sc.
Research Assistant,
Occupational Ergonomics Laboratory,
Department of Physiology
University of Calcutta
Acknowledgement
Mr. Shashank Mehta, Project Head, Design Clinic Scheme, National Institute of Design
Mr. Ashok Mandal, Coordinator, Eastern zone, National Institute of Design
Mr. Sudeb Mandal, Designer, National Institute of Design
Mr. Sankar Sanyal, President, Howrah Chamber of Commerce and Industries
Mr. Ramaswami, Howrah Chamber of Commerce and Industries
Mr. Pradip Chakraborty, Howrah Chamber of Commerce and Industries
Mr. Upaddhyay, Howrah Chamber of Commerce and Industries
Owners and workers of the different Rolling Mills studied
Table of contents
Introduction ....................................................................................... 1
Geographical Location: .................................................................. 2
Rolling Mill- History and present scenario ..................................... 3
Rolling Process ................................................................................... 5
Materials and method ....................................................................... 7
Questionnaire ................................................................................ 8
Ergonomics Checklist ..................................................................... 8
General Interview .......................................................................... 8
Study Units ..................................................................................... 8
Descriptive Study: Cluster Level ......................................................... 9
SWOT Analysis: ............................................................................ 10
Other Observations ...................................................................... 11
Development of Musculoskeletal Disorders ................................ 11
Poor Workplace ........................................................................... 11
Descriptive Study: Unit Level ........................................................... 12
1. AJAY INDUSTRIES ..................................................................... 13
2. HARYANA STEEL INDUSTRIES ................................................... 14
3. ALLOY STEEL ROLLING MILLS ................................................... 16
4. BHARAT STEEL INDUSTRIES ...................................................... 18
5. GOYAL ISPAT UDYOG ............................................................... 20
6. KK STEEL ................................................................................... 21
7. CROWN METAL INDUSTRIES .................................................... 22
8. DADA BHOMIA ISPAT Pvt. Ltd. ................................................. 24
9. POONAM ALUMINIUM METAL ................................................ 25
10. KULHARIA STTEELS Pvt. Ltd. ................................................... 27
11. KWALITY STEEL PROCESSORS ................................................. 28
12. SIDHI VINAYAK ALLOYS Ltd. ................................................... 29
13. SKG IRON & STEEL Co. ............................................................ 31
14. SUJATA STEEL INDUSTRIES ..................................................... 32
15. SHREE VIJAY LAXMII ROLLING MILLS Pvt. Ltd. ....................... 34
16. GADIA ALUMINIUM Pvt. Ltd................................................... 35
Design Possibilities (Cluster wise) .................................................... 37
Workplace Layout ........................................................................ 38
General Recommendations ......................................................... 39
Design Possibilities: Unit wise .......................................................... 40
Scope for research and development direction for future
initiatives ...................................................................................... 49
Design Clinic Workshop ................................................................... 50
List of figures
Figure 1: Map of Howrah ................................................................... 2
Figure 3: Flow diagram of rolling process .......................................... 6
Figure 2: Rolling process (Schematic) ................................................ 6
Figure 4: Existing workplace layout ................................................. 38
Figure 5: Proposed modified layout ................................................. 38
Figure 6: Bending posture and position of man cooler fan ............. 41
Figure 7: Low level of Illumination ................................................... 41
Figure 8: Poor working posture ....................................................... 42
Figure 9: Self made leg protecting guard ......................................... 42
Figure 10: Final products hinder normal movements ..................... 43
Figure 11: Poor work posture of the wrist ....................................... 43
Figure 12: Lack of proper safety shoe .............................................. 44
Figure 13: Worker at the face of the furnace works at very high
temperature ..................................................................................... 44
Figure 14: Workers using local goggles as protective equipment ... 45
Figure 15: Workers working with awkward posture ....................... 45
Figure 16: Unsafe work condition .................................................... 46
Figure 17: Handling of the big forcep .............................................. 46
Figure 18: Working at the furnace ................................................... 47
Figure 19: Bad layout ....................................................................... 47
Figure 20: Hazardous job at the face of the furnace ....................... 48
Figure 21: Existing working condition .............................................. 48
Figure 22: Proposed Design solution ............................................... 48
Figure 23: Dignitaries in the dais...................................................... 51
Figure 24: Dr. Gangopadhyay delivering his talk ............................. 51
Figure 25: Dr. Banerjee giving his talk.............................................. 51
Figure 26: Owners of different rolling mills ..................................... 51
Figure 27: Dr. Gangopadhyay discussing about Ergonomics ........... 51
Figure 28: Mr. Sankar Sanyal, President, HCCI ................................. 51
Figure 29: All the participants of the workshop .............................. 51
Figure 30: Need assessment survey presentation ........................... 51
Figure 31: Discussion with the owners ............................................ 51
Figure 32:Interactive session ........................................................... 51
Figure 33:Dr. Gangopadhyay discussing with the workers .............. 51
Figure 34:Improper safety shoes ..................................................... 51
Figure 35:All the participants of Day 2 ............................................. 51
Figure 36: Presentation on Need Assessment Survey ..................... 51
Figure 37: Discussion with the owners ............................................ 51
Figure 38: Dr. Gangopadhyay interacting with the workers ............ 51
Figure 39: Participants of day 3 ....................................................... 51
Figure 40: Presentation on Need Assessment Survey ..................... 51
Figure 41:Proper storage of raw materials ...................................... 51
Figure 42: Interaction with the owners ........................................... 51
Figure 43: All Participants of Day 4 .................................................. 51
Figure 44: Presentation on Need Assessment Survey ..................... 51
Figure 45: Interaction with workers ................................................. 51
Figure 46: Worker at the face of the furnace .................................. 51
Figure 47: Talking about the big forcep ........................................... 51
Figure 48: interactive session .......................................................... 51
Figure 49: Discussion with workers.................................................. 51
Figure 50: Safety shoe not proper ................................................... 51
Figure 51: All participants of day 5 .................................................. 51
1
Introduction
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
2 Geographical Location:
The Howrah district lies between 22°48′ N and 22°12′
N latitudes and between 88°23′ E and 87°50′ E longitudes. The
district is bounded by the Hooghly River and the North 24
Parganas and South 24 Parganas districts on the east, on the
north by the Hooghly district, and on the south by Midnapore
East district. On the west Howrah district is bordered by the
Ghatal sub-division of Midnapore West district, and partly by
the Arambagh sub-division of Hooghly district to the north-
west, and the Tamluk sub-division of Midnapore East district
to the south-west.
Boundaries of the district are naturally determined by
Rupnarayan River on west and south-west, and by Bhagirathi-
Hooghly River on east and south-east side. On north side, the
boundary is an artificial one except for Bally Canal on north-
east and Damodar River on north-west.
Annual normal rainfall is 1461 millimeter per year.
Annual maximum temperature varies between 32-39°C,
whereas minimum temperature varies between 8-10°C.
Figure 1: Map of Howrah
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
3 Rolling Mill- History and present scenario
The rolling mill was started in India in 18th
century.
Later on with the development of electricity re-rolling mill
started first at Howrah, West Bengal and gradually to other
parts of the country.
In 1966 there were about 400 re-rolling mills in India,
whose number increased to 1133 in 1980 and in 1986 increased
to over 1600 units. It is seen that Punjab is the highest number
of re-rolling mills. The second position goes to West Bengal.
Now re-rolling mills in India is about 2500 and in West Bengal
it is more than 300. The main concentration of re-rolling mill is
at Howrah Industrial Belt. The special advantages of Howrah
are the Ganges, National Highway, Largest Railway station,
Calcutta Port and other Engineering Industries.
After 1975, setting up of new re-rolling industry and
expansion of existing unit was declared ban by the Government
of India. Even then a few small scale units come up at Howrah
without government assistance and therefore they are not
allowed registration. These types of units, uses only scrap as a
raw materials and the investment is low. Later on Government
of India lifted ban due to imposition of liberalized industrial
policy.
The small scale industries play a pivotal role in our economic
development with particular advantages of low investment,
high potential for employment generation in rural and
backward area.
In the developed countries, the usage of steel is
phenomenal. In some of the developing countries too, there has
been substantial growth in steel consumption over the last few
years. This is largely attributable to the fact that in the recent
past there has been a tremendous change in construction
technology. Moreover the pre-engineering concept for
residential and office building based on steel framed
construction has become popular.
Today steel re-rolling is an important industry in the
country. The large scale units like Steel Authority of India
(SAIL), Tata Iron & Steel Company Ltd. etc which produce
steel, do not normally manufacture smaller sizes of sections
required for construction and structural work. Rolling smaller
section is done primarily in the small scale sector. Generally
there is no product specification in small scale re-rolling units
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
4 for producing particular sections and sizes. The product is
decided by the customer.
This survey aimed at detailed study of the existing re-
rolling mills that are located around Howrah, West Bengal. The
focus of the study was to generate detailed information about
the existing condition and to identify the need or area for
improvement of these rolling mills
5
Rolling Process
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
6 In metalworking, rolling is a metal forming process in which
metal stock is passed through a pair of rolls. Rolling is
classified according to the temperature of the metal rolled. If
the temperature of the metal is above its recrystallization
temperature, then the process is termed as hot rolling. If the
temperature of the metal is
below its recrystallization
temperature, the process is
termed as cold rolling.
Rolling is one of the
principal methods of plastic
working of metals employed to
manufacture a great amount of
square, round, angles, beams,
sheets etc. Rolling consists essentially in passing the metal
between revolving rolls.
Rolling is a continuous and regular process,
characteristic of which is an uninterrupted motion of the
worked metal through the zone of deformation. Continuous
process yield products of uniform structure and properties, as
the conditions of working of the metal are the same throughout
the length of the product.
In hot rolling process the raw materials (Iron scraps) are
heated in furnace to a temperature between 1120 0C to 1300
0 C.
The heating process ensures high plasticity and reduces the
resistance of flow. Flow diagram of rolling process
Figure 3: Flow diagram of rolling process
Raw Material Shearing
Heating in Furnace
Rought Rolling Finished RollingEnd Cutting (Twisting if necessary)
Finished Product
Figure 2: Rolling process (Schematic)
7
Materials and method
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
8
The Need Assessment Survey (NAS) of the rolling mills of
Howrah was carried out during the first week of August, 2012.
The survey team visited the different rolling mills for five days
and carried out the survey.
Following methods were followed to complete the study:
Questionnaire A short questionnaire on musculoskeletal disorder was
developed for the study purpose. The questionnaire consists of
two parts. 1st part contains the general information about the
workers and the 2nd
part contains questions regarding the
development of musculoskeletal disorders (MSD). This
questionnaire was performed among the randomly selected
workers of the rolling mills.
Ergonomics Checklist Ergonomics checklist is an observational method. Here,
researcher observes the workplace condition (both working and
physical) and accordingly makes entries in the checklist. The
checklist contains information like housekeeping, illumination
etc. of the work place. The checklist was used in all enlisted the
rolling mills of the cluster.
General Interview Finally the Owners of each rolling mill were
interviewed individually to get the information about the
rolling process in detail. The aim of this interview was to know
about the type and procurement of raw materials, technical
details about the process, the market need and customer base.
Study Units The study was carried out on the following units of the re-
rolling mills cluster.
Sl. No. Name rolling mill
1. Ajay Industries
2. Hariana Steels Re-Rolling Mills
3. Alloy Steel Rolling Mills
4. Bharat Steel Industries
5. Goyal Ispat Udyog
6. KK Steel
7. Crown Metal Industries
8. Dada Bhomia Ispat Pvt.Ltd
9. Poonam Metal
10. Kulharia Steels (Pvt.) Ltd.
11. Kwality Steel Processors
12. Sidhi Vinayak Alloys Ltd.
13. SKG Iron & Steel Co.
14. Sujata Steel Industries
15. Shree Vijay Laxmii Rolling Mills Pvt. Ltd
16. Gadia Aluminium Pvt. Ltd.
9
Descriptive Study: Cluster Level
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
10 SWOT Analysis:
Strength
Raw materials are procured from the local market
which is nearby.
The acceptability of the finished goods in the market is
good.
Weakness
Condition of the road is very poor leading to problems
in transportation.
There is no quality check of the raw materials, as a
result different types of raw material are used to make
same product.
There is no variety of the product.
There is no ergonomics and safety training for the
workers.
Opportunity
There is scope for the production of different varieties
of product.
Development of a Common Facility Centre (CFC) – the
units can buy the raw materials directly from CFC
Threats
Competition among the rolling mills – every mill tries
to sell their product leading to low profit margins. Units
with fewer sales become the sufferer.
Steep increase in the price of the fuel.
Road condition is one of the main threats. The trucks
loaded with finished goods are kept waiting for hours
for roads to clear. This adds to the cost of production.
The prices of the product have increased but the tax
exemption limit for this company has remained same as
before. Therefore, selling the same product (now at
higher price than before), the factory has to pay taxes
(as the limit remained same) for which they were
exempted before.
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
11 Other Observations
The re-rolling mills fall under the category of Micro Small and
Medium Enterprises (MSME). Like all other MSMEs, the
working of these units is mostly labor intensive. Although the
re-rolling of the iron scraps is done by the installed rollers, the
workers are the mainstay of the whole process. The jobs of the
workers include
Carrying the raw materials to the furnace
Pulling out the melted iron and placing them in the
roller
Pulling out the rolled iron from a roller and
subsequently putting it into the next roller
Pulling out the finished product from the final roller
Carrying the finished product.
Development of Musculoskeletal Disorders
During the whole process there are lots of repetitive
movements of the body along with twisting and bending of the
body. All these factors may lead to the development of
musculoskeletal disorder.
The short musculoskeletal disorder questionnaire
(mentioned in methods) was applied on the randomly selected
workers. On analysis of the questionnaire it was found that the
prevalence of the musculoskeletal disorder was high (80%)
among the workers. Most affected body parts was lower back
(75%) followed by the shoulders (50%) and wrists (50%).
Poor Workplace
Many of the units had pedestals (Man coolers)
installed in different places to dissipate the heat generated by
the rolling process. But most of the units didn’t place the man
coolers in proper position and some of the units have no such
facilities.
The noise level is high in these units. The mean
noise level around 99.5 dBA.
Housekeeping is very poor that adds ineffective
time in total manufacturing process.
12
Descriptive Study: Unit Level
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
13 1. AJAY INDUSTRIES
1.1 Raw Materials: Iron scraps are used as raw material. Iron
scraps from the Railway discarded coaches are also used
as the raw materials. This unit buys these raw materials
from the nearby local market.
1.1.1 Problem areas:
There is no quality management system for these
iron scraps. Therefore, different qualities of iron
scraps are used to make the product.
The sellers of the local market buy the raw material
from the railway in auction. After buying it from
railways, they process it before selling it to the
units. Thus the cost of the raw materials increases
for the unit and which ultimately increases the cost
of the final product.
1.1.2 Recommendations:
Setting up of a Common Facility Centre, from
where the unit will be able to buy the raw materials
directly.
A quality testing and certifying center can be setup
to screen the iron scraps separately.
1.2 Processing and product: The iron scraps are melted in
a furnace (~ 1100°C) and re-rolled until the desired
product is obtained. The main products of this unit are
Iron plates and squares.
1.2.1 Problem Areas:
Like raw materials, there is no quality check for the
final products.
1.2.2 Recommendations:
Screening the final products according to their
quality will help in better marketing of the goods.
1.3 Storage: The production of this unit is around 1 tonne
per hour. There is fixed storage space for the raw
materials and the final product.
1.4 Logistics:
1.4.1 Problem Areas:
The condition of the approach road to the unit is
very poor.
The roads are too narrow; this also hampers the
movement of the trucks to and from the unit.
1.4.2 Recommendations:
Improvement in the condition of the roads.
Improvement in the condition of the traffic.
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
14 1.5 Ergonomics and Safety:
1.5.1 Problem Areas:
The workers work without any proper personal
protective equipment.
There are repetitive movements of the body of the
workers along with twisting movements.
The workers at the furnace work at very high
temperature and sound.
1.5.2 Recommendations:
Proper personal protective equipment should be
provided to the workers.
Work rest schedule for the workers should be
introduced.
Proper ventilation should be implemented by
increasing the height of the units.
1.6 Marketing: The finished products are sold at the local
market.
1.6.1 Problem Areas:
There is no variety of products.
The customer base is limited and fixed.
Road condition is one of the main threats. The
trucks loaded with finished goods are kept waiting
for hours for roads to clear. This adds to the cost of
production.
The prices of the product have increased but the tax
exemption limit for this company has remained
same as before. Therefore, selling the same product
(now at higher price than before), the unit has to
pay taxes (as the limit remained same) for which
they were exempted before.
1.6.2 Recommendations:
Variety of product should be explored.
Other customer pool should be explored to increase
the customer base.
2. HARYANA STEEL INDUSTRIES
2.1 Raw Materials: Iron scraps are used as raw material.
Iron scraps from the Railway discarded coaches are
used as the raw materials. The unit buys these raw
materials from the nearby local market.
2.1.1 Problem areas:
Due to the absence of quality management system
for these iron scraps different qualities of iron
scraps are used together to make the product.
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
15 The sellers of the local market buy the raw
material from the railway in auction. After buying
it from railways, they process it among
themselves before selling it to the units. Thus the
cost of the raw materials increases for the units
and which ultimately increases the cost of the
final product.
2.1.2 Recommendations:
Setting up of a Common Facility Centre, from
where the unit will be able to buy the raw
materials directly.
A quality testing and certifying center can be
setup to screen the iron scraps separately.
2.2 Processing and product: The iron scraps are melted in
a furnace and rolled and re-rolled until the desired
product is obtained. The main products of this unit are
the TMT bars and other rounds of different diameters.
The daily production is around 6-7 tonnes
2.2.1 Problem Areas:
Like raw materials, there is no quality check for
the final products.
2.2.2 Recommendations:
Screening the final products according to their
quality will help in better marketing of the goods.
2.3 Storage:
2.3.1 Problem Areas:
There is no fixed storage space for the raw
materials and the final product.
The lack of fixed storage adds ineffective time to
the production time.
2.3.2 Recommendations:
Proper storage of raw materials and the final
product will reduce the ineffective time and
increase the productivity.
2.4 Logistics:
2.4.1 Problem Areas:
The condition of the approach road to the unit is
very poor.
The roads are too narrow; this also hampers the
movement of the trucks to and from the unit.
2.4.2 Recommendations:
Improvement in the condition of the roads.
Improvement in the condition of the traffic.
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
16 2.5 Ergonomics and safety:
2.5.1 Problem Areas
There are repetitive and twisting movements of
the body of the workers.
The workers work without any proper personal
protective equipment.
The workers at the furnace have to work at very
high temperature and sound
2.5.2 Recommendation
Work rest schedule for the workers should be
introduced such that no workers work for more
than one hour continuously.
Proper personal protective equipment should be
provided to the workers.
Proper ventilation should be implemented by
increasing the height of roofs of units
2.6 Marketing: The finished products, i.e. the TMT bars,
are then sold at the local market.
2.6.1 Problem Areas:
Problems in transport (delay in the movement of
the trucks) adds to the cost of production.
There is no variety of products.
The customer base is limited and fixed for the
unit.
2.6.2 Recommendations:
Variety of product should be explored.
Other customer pool should be explored to
increase the customer base.
3. ALLOY STEEL ROLLING MILLS
3.1 Raw Materials: Like all other units of the rolling mill
cluster, this unit also uses iron scraps as raw material.
These iron scraps are procured from the local market
and railways.
3.1.1 Problem areas:
There is no quality management system for the
procurement of iron scraps. Therefore, different
qualities of iron scraps are used for making the
final product. This may lower the quality of the
final product.
Railway auctions their waste wagons etc. The
sellers of the local market buy the raw material
from these auctions. After buying, they process it
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
17 among themselves before selling it to the units.
The cost of the raw materials thus increases.
Ultimately units have to purchase them at higher
prices.
3.1.2 Recommendations:
A quality testing and certifying center may be
established for the selection of iron scraps
Setting up of a Common Facility Centre, from
where the unit will be able to purchase the raw
materials in fixed price.
3.2 Processing and product: The iron scraps are melted in
a furnace (~11000 C) and rolled until the desired
product is obtained. The main products of this unit are
Iron plates and squares.
3.2.1 Problem Areas:
There is no quality checkup of the final product.
3.2.2 Recommendations:
Setting up of a quality check setup for the final
product will help in grouping them according to
their qualities.
3.3 Storage:
3.3.1 Problem Areas:
There is no fixed and separate storage space for
the raw materials and the final product. The lack
of fixed storage adds ineffective time to the
production time.
3.3.2 Recommendations:
Proper storage of raw materials and the final
product will reduce the ineffective time and
increase the productivity.
3.4 Logistics:
3.4.1 Problem Areas:
The physical condition of the approach road to the
unit is very poor.
The roads are too narrow and congested this also
reduces the movement of the trucks with raw
materials and finished products.
3.4.2 Recommendations:
Improvement in the condition of the roads.
Improvement in the condition of the traffic.
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
18 3.5 Ergonomics and safety
3.5.1 Problem Areas:
There are repetitive and twisting movements of
the body of the workers.
The workers work without any proper personal
protective equipment.
The workers at the furnace have to work at very
high temperature and sound.
3.5.2 Recommendations:
Work rest schedule for the workers should be
introduced such that no workers work for more
than one hour continuously.
Proper personal protective equipment should be
provided to the workers.
Proper ventilation should be implemented by
increasing the height of roofs of units.
3.6 Marketing: The finished products are sold at the local
market and to specific customers.
3.6.1 Problem Areas:
There are no design variations in products.
The customers are limited and fixed.
Road condition is one of the main threats. The
trucks loaded with finished goods are kept waiting
for hours for roads to clear. This adds to the cost
of production.
3.6.2 Recommendations:
Variety in product design should be explored.
Other customer pool should be explored to
increase the customer base.
4. BHARAT STEEL INDUSTRIES
4.1 Raw Materials: The unit buys raw materials from the
nearby local market.
4.1.1 Problem areas:
The sellers of the local market buy the raw
material from the railways in auction. Thus the
cost of the raw materials increases for the owners
of the units
4.1.2 Recommendations:
Setting up of a Common Facility Centre, from
where the unit will be able to buy the raw
materials directly.
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
19 4.2 Processing and product: The iron scraps are melted in
a furnace and rolled and re-rolled until the desired
product is obtained. The main products of this unit are
Iron plates.
4.2.1 Problem Areas:
Like raw materials, there is no quality check for
the final products.
4.2.2 Recommendations:
Screening the final products according to their
quality will help in better marketing of the goods.
4.3 Storage:
4.3.1 Problem Areas:
There is no fixed storage space for the raw
materials and the final product.
4.3.2 Recommendations:
Proper storage of raw materials and the final
product will reduce the production time.
4.4 Logistics:
4.4.1 Problem Areas:
The condition of the approach road to the unit is
very poor.
The roads are too congested for movements of the
trucks.
4.4.2 Recommendations:
Improvement in the condition of the roads.
4.5 Ergonomics and safety
4.5.1 Problem Areas:
There are repetitive movements of the body of the
workers.
There are also twisting movements.
4.5.2 Recommendations:
Work rest schedule for the workers should be
introduced such that no workers work for more
than one hour continuously.
4.6 Marketing: The finished products are sold at the local
market.
4.6.1 Problem Areas:
The customer base is limited and fixed.
Road condition is one of the main threats. The
trucks loaded with finished goods are kept waiting
for hours for roads to clear. This adds to the cost
of production.
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
20 4.6.2 Recommendations:
New customers’ needs should be explored
5. GOYAL ISPAT UDYOG
5.1 Raw Materials: Iron scraps are raw materials. The unit
buys these raw materials from the nearby local market.
5.1.1 Problem areas:
The sellers of the local market purchase the raw
materials from railways through auction. Thus the
cost of the raw materials becomes high for the
unit owners.
5.1.2 Recommendations:
Setting up of a Common Facility Centre, from
where the unit will be able to buy the raw
materials directly and in cheap rate.
5.2 Processing and product: After melting in furnace, the
melted scraps are re-rolled until the desired product is
obtained. The main products of this unit are iron wires,
plates and squares.
5.2.1 Problem Areas:
Unsafe working area
No quality check for the final products.
5.2.2 Recommendations:
Working conditions must be improved.
5.3 Storage:
5.3.1 Problem Areas:
No fixed and demarcated storage space for the
raw materials and the final products.
5.3.2 Recommendations:
Demarcated storage spaces are highly
recommended.
5.4 Logistics:
5.4.1 Problem Areas:
The roads are narrow, full of pot holes which
causes the slow movement of the transport
vehicles
5.4.2 Recommendations:
Immediate improvement of roads.
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
21 5.5 Ergonomics and Safety
5.5.1 Problem Areas:
Improper work methods due to unsafe working
conditions may decrease productivity.
5.5.2 Recommendations:
Application of proper interventions through
improvement of work method will decrease the
ineffective time.
5.6 Marketing: The finished products are sold to fixed
customers.
5.6.1 Problem Areas:
The customer base is limited and fixed.
No need to create variations in product design.
5.6.2 Recommendations:
To identify the need of customer a specific need
assessment protocol should be implemented by
which new customers may be identified.
6. KK STEEL
6.1 Raw Material: Iron scraps from the Railway discarded
coaches are used as the raw materials. The unit
purchases these raw materials from the nearby local
market.
6.1.1 Problem Areas:
Different qualities of iron scraps are used in
making a single product as there is no quality
checkup test for these raw materials.
6.1.2 Recommendations:
Setting up of a Common Facility Centre, from
where the unit will be able to buy the raw materials
directly.
A quality testing center can be setup to screen the
iron scraps separately.
6.2 Processing and product: The iron scraps are melted in
a furnace and re-rolled until the desired product is
obtained. The main products of this unit are the TMT
bars and other rounds having diameter 5 – 6 mm.
6.2.1 Problem Areas:
Like raw materials, there is no quality check for
the final products
6.2.2 Recommendations:
Screening the final products according to their
quality will help in better marketing of the goods
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
22 6.3 Storage: There is fixed and designated storage space
for the raw materials and the final product
6.4 Logistics:
6.4.1 Problem Areas:
The condition of the approach road to the unit is
very poor
The roads are too narrow; this hampers the
movement of the trucks
6.4.2 Recommendations:
Improvement in the condition of the roads.
6.5 Ergonomics and Safety:
6.5.1 Problem Areas:
Improper work methods due to unsafe working
conditions may decrease productivity
6.5.2 Recommendations:
Application of proper interventions through
improvement of work method will decrease the
ineffective time
6.6 Marketing: The finished products are sold at the local
market.
6.6.1 Problem Areas:
Road condition is one of the main threats. The
trucks loaded with finished goods are kept waiting
for hours for roads to clear. This adds to the cost of
production.
There is no variety of products.
The customer base is limited and fixed for the unit.
6.6.2 Recommendations:
Variety of product should be explored.
Other customer pool should be explored to
increase the customer base.
7. CROWN METAL INDUSTRIES
7.1 Raw Materials: Iron scraps are used as raw material.
Iron scraps from the Railway discarded coaches are also
used as the raw materials. The unit buys these raw
materials from the nearby local market.
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
23 7.1.1 Problem areas:
Lack of quality management system for the raw
materials. Therefore, different qualities of iron
scraps are used to make the product.
7.1.2 Recommendations:
A quality testing and certifying center can be setup
to screen the iron scraps separately.
7.2 Processing and product: The iron scraps are melted in a
furnace and re-rolled until the desired product is obtained.
The main products of this unit are Iron plates and rods.
7.2.1 Problem Areas:
Like raw materials, there is no quality check for
the final products
7.2.2 Recommendations:
Screening the final products according to their
quality will help in better marketing of the goods.
7.3 Storage:
7.3.1 Problem Areas:
There is no fixed storage space for the raw
materials and the final product.
7.3.2 Recommendations:
Proper storage of raw materials and the final
product will increase the productivity.
7.4 Logistics:
7.4.1 Problem Areas:
The roads are too narrow and very congested.
Condition of these roads damages the movement
of the trucks with raw materials and finished
products.
7.4.2 Recommendations:
Condition of the roads must be improved.
7.5 Ergonomics and Safety:
7.5.1 Problem Areas:
The workers work without any proper personal
protective equipment.
There are repetitive and twisting movements of
the body of the workers.
The workers at the furnace work at very high
temperature and sound.
The finished products are kept in such a way that
it creates problem in the general movement of the
workers.
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
24 7.5.2 Recommendations:
Proper personal protective equipment should be
provided to the workers.
Work schedule for the workers should be
introduced such that no workers work for more
than one hour continuously.
The place where the finished goods are coming
out should be arranged in such a way that it does
not hamper the general movements.
Proper ventilation should be implemented by
increasing the height of the roofs.
7.6 Marketing: The finished products are sold at the local
market.
7.6.1 Problem Areas:
There is no variety of products.
The customer base is limited and fixed for the
unit.
Road condition is one of the main threats. The
trucks loaded with finished goods are kept waiting
for hours for roads to clear. This adds to the cost
of production.
7.6.2 Recommendations:
Variety of product should be explored.
Other customer pool should be explored to
increase the customer base.
8. DADA BHOMIA ISPAT Pvt. Ltd.
8.1 Raw Materials: Iron scraps are used as raw material.
The unit buys these raw materials from the nearby local
market.
8.1.1 Problem areas:
There is no quality management system for these
iron scraps. Therefore, different qualities of iron
scraps are used to make the product.
8.1.2 Recommendations:
A quality testing center can be established to
screen the iron scraps.
8.2 Processing and product: The iron scraps are melted
and re-rolled until the desired product is obtained. The
main products of this unit are Iron squares.
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
25 8.2.1 Problem Areas:
Like raw materials, there is no quality check for
the final products.
8.2.2 Recommendations:
Screening the final products according to their
quality will help in better marketing of the goods.
8.3 Storage: There is fixed storage space for the raw
materials and the final product.
8.4 Logistics:
8.4.1 Problem Areas:
The roads are too narrow; this also slow down the
movement of the trucks to and from the unit.
8.4.2 Recommendations:
Immediate improvement of the approach roads.
8.5 Ergonomics and Safety:
8.5.1 Problem Areas:
The workers at the furnace work at very high
temperature and sound.
8.5.2 Recommendations:
Proper ventilation should be implemented
8.6 Marketing: The finished products are sold at the local
market.
8.6.1 Problem Areas:
There is no variety of products.
8.6.2 Recommendations:
Variety of product should be explored through
market research.
9. POONAM ALUMINIUM METAL
9.1 Raw Materials: Broken utensils are used as raw
materials for the rolling mills. The unit buys these raw
materials from the nearby local market.
9.1.1 Problem areas:
There is no quality management system.
Therefore, different qualities of raw materials are
used to make the product.
9.1.2 Recommendations:
A quality testing center can be established to
screen the raw materials.
9.2 Processing and product: The aluminium scraps are
melted in a furnace and then casted into different
shapes. These casted structures are then rolled until the
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
26 desired thickness of the product is obtained. The main
products of this unit are fan blades of different sizes.
9.2.1 Problem Areas:
There is no quality check for the final products.
9.2.2 Recommendations:
Screening the final products according to their
quality will help in better marketing of the goods.
9.3 Storage:
9.3.1 Problem Areas:
There is fixed storage space for the raw materials
and the final product.
9.3.2 Recommendations:
Proper storage of raw materials and the final
product will increase the productivity.
9.4 Logistics:
9.4.1 Problem Areas:
The approach road to the unit is full of pot holes.
9.4.2 Recommendations:
Condition of the roads should be improved.
9.5 Ergonomics and Safety:
9.5.1 Problem Areas:
The workers work without any proper personal
protective equipment.
There are repetitive movements of the body of the
workers.
The workers at the furnace work at very high
temperature.
9.5.2 Recommendations:
Proper personal protective equipment should be
provided to the workers.
Proper rest should be given to workers to decrease
the heat stress.
Proper ventilation should be implemented by
increasing the roof height of the unit.
9.6 Marketing: The finished products are then sold at the
local market.
9.6.1 Problem Areas:
There is no variety of products.
The customer base is limited and fixed for the
unit.
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
27 9.6.2 Recommendations:
Variety of product should be explored.
Other customer pool should be explored to
increase the customer base.
10. KULHARIA STTEELS Pvt. Ltd.
10.1 Raw Materials: Iron scraps are used as raw material.
10.1.1 Problem areas:
There is no quality management process for these
iron scraps.
10.1.2 Recommendations:
A quality testing center may be setup in locality
10.2 Processing and product: The iron scraps are melted in
a furnace and rolled and re-rolled until the desired
product is obtained. The main products of this unit are
Iron plates and squares.
10.2.1 Problem Areas:
Use of old machine with minimum maintenance
cause occasional problems in manufacturing
process.
10.2.2 Recommendations:
Periodical maintenance is required
10.3 Storage:
10.3.1 Problem Areas:
The lack of ill-defined storage adds ineffective
time in total production process.
10.3.2 Recommendations:
Proper storage of raw materials and final products
10.4 Logistics:
10.4.1 Problem Areas:
The approach road to the unit is full of pot holes.
10.4.2 Recommendations:
Roads should be properly repaired
10.5 Ergonomics and Safety:
10.5.1 Problem Areas:
The workers work without any proper personal
protective equipment.
There are repetitive and twisting movements of
the body of the workers during work
10.5.2 Recommendations:
Proper personal protective equipment should be
provided to the workers.
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
28 Proper rest pauses required
10.6 Marketing: The finished products are sold at the local
market and fixed customers
10.6.1 Problem Areas:
There is no variety of products.
The customer base is limited and fixed.
10.6.2 Recommendations:
Variety of product should be explored.
Other customer pool should be explored to
increase the customer base.
11. KWALITY STEEL PROCESSORS
11.1 Raw Materials: The unit buys iron scraps as raw
materials from the nearby local market.
11.1.1 Problem areas:
There is no quality management system for these
iron scraps.
11.1.2 Recommendations:
A quality testing and certifying center can be
setup to screen the iron scraps separately.
11.2 Processing and product: The iron scraps are melted in
a furnace and rolled and re-rolled until the desired
product is obtained. The main products of this unit are
Iron plates.
11.2.1 Problem Areas:
Like raw materials, there is no quality check for
the final products.
11.2.2 Recommendations:
Screening the final products according to their
quality will help in better marketing of the goods.
11.3 Storage:
11.3.1 Problem Areas:
There is no fixed storage space for the raw
materials and the final product.
11.3.2 Recommendations:
Proper storage spaces are required to avoid
production loss.
11.4 Logistics:
11.4.1 Problem Areas:
The roads are congested; this hampers the easy
movement of the trucks with raw materials and
finished products.
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
29 11.4.2 Recommendations:
Improvement in the condition of the roads.
11.5 Ergonomics and Safety:
11.5.1 Problem Areas:
There are repetitive and twisting movements of
the body of the workers.
The workers at the furnace work at very high
temperature and noise.
11.5.2 Recommendations:
No workers should work for more than one hour
continuously.
11.6 Marketing: The finished products are sold at the local
market.
11.6.1 Problem Areas:
The customer base is limited and fixed.
Road condition is one of the main threats. The
trucks loaded with finished goods are kept waiting
for hours for roads to clear. This adds to the cost
of production.
11.6.2 Recommendations:
Other customer pool should be explored to
increase the customer base.
12. SIDHI VINAYAK ALLOYS Ltd.
12.1 Raw Materials: Iron scraps from the Railway
discarded coaches are used as raw materials. The unit
purchases these raw materials from the nearby local
market.
12.1.1 Problem areas:
There is no quality management system for these
iron scraps. Therefore, different qualities of iron
scraps are used to make the product.
12.1.2 Recommendations:
A quality testing and certifying center can be
setup to screen the iron scraps separately.
12.2 Processing and product: The iron scraps are melted in
a furnace and re-rolled until the desired product is
obtained. The main products of this unit are plates and
squares.
12.2.1 Problem Areas:
There is no quality check for the final products.
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
30 12.2.2 Recommendations:
A quality checking center can be established. This
will help in screening the final products according
to different qualities.
12.3 Storage:
12.3.1 Problem Areas:
Lack of well-defined space for storage of raw
materials and final product.
12.3.2 Recommendations:
Proper areas should be allocated for storing the
raw materials and the final products. This will
improve the productivity by reducing the
ineffective time.
12.4 Logistics:
12.4.1 Problem Areas:
The condition of road is very poor.
The roads are too narrow and highly congested.
12.4.2 Recommendations:
Improvement in the condition of the roads.
Improvement in the condition of the traffic.
12.5 Ergonomics and Safety:
12.5.1 Problem Areas:
The workers work without any proper personal
protective equipment.
The workers at the furnace work at very high
temperature.
12.5.2 Recommendations:
Proper personal protective equipment should be
provided to the workers.
Ventilation should be improved by increasing the
roof height of the unit
12.6 Marketing: The finished products are sold at the local
market.
12.6.1 Problem Areas:
Lack of variety of products
12.6.2 Recommendations:
Variety of product can be explored.
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
31 13. SKG IRON & STEEL Co.
13.1 Raw Materials: Iron scraps are used as raw material.
13.1.1 Problem areas:
There is no quality management system for these
iron scraps. Therefore, different qualities of iron
scraps are used to make the product.
13.1.2 Recommendations:
A quality testing center can be established to
screen the iron scraps.
13.2 Processing and product: The iron scraps are melted in
a furnace and rolled until the desired product is
obtained. The main products of this unit are Iron plates
and squares.
13.2.1 Problem Areas:
There is no quality check for the final products.
13.2.2 Recommendations:
Screening the final products according to their
quality will help in better marketing of the goods.
13.3 Storage:
13.3.1 Problem Areas:
Lack of well-defined space for storage of raw
materials and final product.
13.3.2 Recommendations:
Proper areas should be allocated for storing the
raw materials and the final product. This will
improve the productivity by reducing the
ineffective time.
13.4 Logistics:
13.4.1 Problem Areas:
The condition of road is very poor.
The movements of the trucks are hampered as the
roads too narrow.
13.4.2 Recommendations:
Improvement in the condition of the roads.
Improvement in the condition of the traffic.
13.5 Ergonomics and Safety:
13.5.1 Problem Areas:
The workers work without any proper personal
protective equipment.
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
32 There are repetitive movements of the body of the
workers.
There are also twisting movements.
The workers at the furnace work at very high
temperature and sound.
13.5.2 Recommendations:
Proper personal protective equipment should be
provided to the workers.
Work rest schedule for the workers should be
introduced such that no workers work for more
than one hour continuously.
Proper ventilation should be implemented by
increasing the height of the units.
13.6 Marketing: The finished products are sold at the local
market.
13.6.1 Problem Areas:
There is no variety of products.
Road condition is one of the main threats. The
trucks loaded with finished goods are kept waiting
for hours for roads to clear. This adds to the cost
of production.
13.6.2 Recommendations:
Variety of product should be explored.
14. SUJATA STEEL INDUSTRIES
14.1 Raw Materials: Iron scraps from the Railway
discarded coaches are used as the raw materials.
14.1.1 Problem areas:
There is no quality management system for these
iron scraps. Therefore, different qualities of iron
scraps are used to make the product.
14.1.2 Recommendations:
A quality testing center can be setup to screen the
iron scraps separately.
Setting up of a Common Facility Centre, from
where the unit will be able to buy the raw
materials directly.
14.2 Processing and product: The iron scraps are melted in
a furnace and re rolled until the desired product is
obtained. The main products of this unit are Iron rods.
14.2.1 Problem Areas:
There is no quality check for the final products.
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
33 14.2.2 Recommendations:
Screening the final products according to their
quality.
14.3 Storage:
14.3.1 Problem Areas:
Lack of well-defined space for storage of raw
materials and final product.
14.3.2 Recommendations:
Proper areas should be allocated for storing the
raw materials and the final product. This will
improve the productivity by reducing the
ineffective time.
14.4 Logistics:
14.4.1 Problem Areas:
The condition of the approach road to the unit is
very poor.
The roads are too narrow; this also hampers the
movement of the trucks to and from the unit.
14.4.2 Recommendations:
Improvement in the condition of the roads.
Improvement in the condition of the traffic.
14.5 Ergonomics and Safety:
14.5.1 Problem Areas:
The workers work without any proper personal
protective equipment.
There are repetitive movements of the body of the
workers.
There are also twisting movements.
The workers at the furnace work at very high
temperature and sound.
14.5.2 Recommendations:
Proper personal protective equipment should be
provided to the workers.
Work rest schedule for the workers should be
introduced such that no workers work for more
than one hour continuously.
Proper ventilation should be implemented by
increasing the height of the units.
14.6 Marketing: The finished products are sold at the local
market.
14.6.1 Problem Areas:
There is no variety of products.
The customer base is limited and fixed.
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
34 Road condition is one of the main threats. The
trucks loaded with finished goods are kept waiting
for hours for roads to clear. This adds to the cost
of production.
14.6.2 Recommendations:
Variety of product should be explored.
Other customer pool should be explored to
increase the customer base.
15. SHREE VIJAY LAXMII ROLLING MILLS Pvt. Ltd.
15.1 Raw Materials: Iron scraps are used as raw material.
15.1.1 Problem areas:
There is no quality management system for these
iron scraps.
15.1.2 Recommendations:
A quality testing center can be setup to screen the
iron scraps separately.
15.2 Processing and product: The iron scraps are melted in
a furnace and rolled until the desired product is
obtained. The main products of this unit are Iron rod.
15.2.1 Problem Areas:
Like raw materials, there is no quality check for
the final products.
15.2.2 Recommendations:
Screening the final products according to their
quality will help in better marketing of the goods.
15.3 Storage: There is fixed storage space for the raw
materials and the final product.
15.4 Logistics:
15.4.1 Problem Areas:
The condition of road is very poor.
The roads are too narrow; this also hampers the
movement of the trucks to and from the unit.
15.4.2 Recommendations:
Improvement in the condition of the roads.
Improvement in the condition of the traffic.
15.5 Ergonomics and Safety:
15.5.1 Problem Areas:
The workers work without any proper personal
protective equipment.
There are repetitive movements of the body of the
workers.
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
35 There are also twisting movements.
The workers at the furnace work at very high
temperature and sound.
15.5.2 Recommendations:
Proper personal protective equipment should be
provided to the workers.
Work rest schedule for the workers should be
introduced such that no workers work for more
than one hour continuously.
Proper ventilation should be implemented by
increasing the height of the units.
15.6 Marketing: The finished products are sold at the local
market.
15.6.1 Problem Areas:
There is no variety of products.
The customer base is limited and fixed.
Road condition is one of the main threats. The
trucks loaded with finished goods are kept waiting
for hours for roads to clear. This adds to the cost
of production.
15.6.2 Recommendations:
Variety of product should be explored.
Other customer pool should be explored to
increase the customer base.
16. GADIA ALUMINIUM Pvt. Ltd.
16.1 Raw Materials: Broken aluminium utensils are used as
raw materials for the rolling mills.
16.1.1 Problem areas:
There is no quality management system for these
raw materials.
16.1.2 Recommendations:
A quality testing center can be setup to screen the
iron scraps separately.
16.2 Processing and product: The utensils (raw materials)
are melted and the molten aluminium is then poured
into different casts to produce the desired product.
16.2.1 Problem Areas:
Like raw materials, there is no quality check for
the final products.
16.2.2 Recommendations:
Screening the final products according to their
quality will help in better marketing of the goods.
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
36 16.3 Storage: There is fixed storage space for the raw
materials and the final product.
16.4 Logistics:
16.4.1 Problem Areas:
The condition of road is very poor.
The roads are too narrow; this also hampers the
movement of the trucks to and from the unit.
16.4.2 Recommendations:
Improvement in the condition of the roads.
Improvement in the condition of the traffic.
16.5 Ergonomics and Safety:
16.5.1 Problem Areas:
The workers work without any proper personal
protective equipment.
There are repetitive movements of the body of the
workers.
There are also twisting movements.
16.5.2 Recommendations:
Proper personal protective equipment should be
provided to the workers.
Work rest schedule for the workers should be
introduced such that no workers work for more
than one hour continuously.
Proper ventilation should be implemented by
increasing the height of the units.
16.6 Marketing: The finished products are sold at the local
market.
16.6.1 Problem Areas:
There is no variety of products.
The customer base is limited and fixed.
Road condition is one of the main threats. The
trucks loaded with finished goods are kept waiting
for hours for roads to clear. This adds to the cost
of production.
16.6.2 Recommendations:
Variety of product should be explored.
Other customer pool should be explored to
increase the customer base.
37
Design Possibilities (Cluster wise)
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
38
FURNACE
FURNACE
Workplace Layout
The current layout of the rolling mill is shown in figure
20. In this layout, the individual rollers are arranged side by
side. The movement of the melted iron is shown by the arrow
heads. In this present layout there is lot of ineffective time in
pulling out the rolled iron and putting it into the next roller.
This layout also requires lots of bending and twisting
movement of the workers.
A proposed modified layout of the workplace is shown in
figure 21. In this proposed modified layout, the roller will be
arranged one after the other. The melted and rolled iron will
move from one roller to the next roller in a continuous process.
This layout will reduce the frequent bending and twisting
movements.
Figure 4: Existing workplace layout
Figure 5: Proposed modified layout
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
39 General Recommendations
There is continuous use of water to cool the rolled iron.
This water is drained out of the factory. A suitable
drainage system may be installed to recycle this water.
This will reduce the wastage of water in the process.
The workers, who work at the face of the furnace, work
at a very high temperature. Suitable personal protective
equipment like thermal suite, hand gloves, safety
goggles and safety shoes should be provided to shield
them from high temperature.
Pedestals may be installed at the back the workers to
dissipate the heat generated by the whole rolling
process.
40
Design Possibilities: Unit wise
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
41
The worker bends repeatedly while working. Also the
position of the man cooler fan is not correct
Recommendations
The height of the platform of the rolling machines may be made adjustable.
The direction of the man-cooler fan should be such that the workers feel
the affect of it.
1. Ajay Industries
2. Poonam Aluminium Metals
Level of illumination in the workplace is low. Working in this
low illumination workplace is very risky.
Recommendations
The level of the illumination of the workplace can be improved by the
installation of the natural skylights. This will help in illuminating the
workplace with natural lights.
.
Figure 6: Bending posture and position of man cooler fan
Figure 7: Low level of Illumination
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
42 3. Haryana Steel Industries
4. Alloy Steel Rolling Mill
There are continuous repetitive movements and twisting
movements of the body during the work process. This will
lead to the development of the musculoskeletal disorder.
Recommendations
Ergonomics modification of the workplace can aid in reducing the chances of
developing Musculoskeletal disorder.
The worker use jute made leg guard. This guard is not
proper and can be less effective in protecting the
workers from the injury.
Recommendations
Safety shoes can be designed to suite the context of the workers. The
shoe should provide necessary protection to the workers.
.
Figure 8: Poor working posture
Figure 9: Self made leg protecting guard
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
43 5. Goyal Ispat Udyog
6. Crown Industries
The finished products are kept in such a way that
they hinder the normal movements.
Recommendations
Designing of proper storage area will help in sorting out this problem
Workers work with poor working postures
that include frequent bending and twisting of
the body.
Recommendations
The handle of the forcep can be made adjustable so
that the bending can be eliminated
Figure 10: Final products hinder normal movements
Figure 11: Poor work posture of the wrist
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
44 7. Bharat Steel Industries
8. Dada Bhomia Ispat Pvt. Ltd.
Working without proper safety shoes can lead to
serious injuries
Recommendations
Proper safety shoes should be provided to the workers so that he
can be protected from the injuries.
Worker at the face of the furnace works at
very high temperature
Recommendations
Heat resistant shield can be installed between the worker and the
furnace to screen the workers from the high heat
Figure 12: Lack of proper safety shoe
Figure 13: Worker at the face of the furnace works at very high temperature
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
45 9. Shree Vijay Laxmii Rolling Mill Pvt. Ltd.
10. Kulharia Steels Pvt. Ltd.
Workers using local goggles as protective
equipment
Recommendations
Proper ergonomically designed safety goggles should be provided
in place of the local goggles
Workers working with awkward posture
Recommendations
The height of platform of the rolling machines can be made
adjustable. This will help in reducing the awkward posture
Figure 14: Workers using local goggles as protective equipment
Figure 15: Workers working with awkward posture
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
46
The transference of the hot molten iron
from a roller to the next roller is very
unsafe
Recommendations
Protective barriers can be provided to shield the feet of the
workers
There is awkward posture of the wrist
during the handling of the big forcep
Recommendations
The modification of the design and increase in awareness
about good handling technique will help in reducing the
awkward postures of the wrist. Further the upper part of the
forcep should be made of non-heat conducting material
11. SKG Iron and Steel Co.
12. Sujata Steel Industry
Figure 16: Unsafe work condition
Figure 17: Handling of the big forcep
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
47 13. Kwality Steel processor
14. Gadia Aluminium Pvt. Ltd.
Workers working at very high
temperature at the face of the
furnace
Recommendations
Proper heat shields can be placed between the worker and the
furnace. This will help in screening the worker from the heat.
There is repetitive movement of the
body along with twisting
movements.
Recommendations
The layout is such that the worker needs to move
continuously from right side to left side in order to transfer
the rolled aluminium to the next level. The successive
levels of operation can be arranged in a straight line. This
will reduce the repetitive movements.
Figure 18: Working at the furnace
Figure 19: Bad layout
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
48
Recommendations
Figure 21 shows the existing condition,
which is very unsafe as there is risk of
getting injured. The proposed design
solution for this problem is shown in
figure 22. The exit point of the molten
iron and its entry into the next roller will
be covered by the structure as shown in
the figure. This will help will reducing
the risk of injury.
15. Sidhi Vinayak Alloys Ltd.
16. KK Steel
Workers working at very high
temperature at the face of the
furnace
Recommendations
Proper heat shields can be placed between the worker and
the furnace. This will help in screening the worker from
the heat.
Figure 20: Hazardous job at the face of the furnace
Figure 21: Existing working condition Figure 22: Proposed Design solution
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
49 Scope for research and development direction for future initiatives
Process Immediate Intervention Mid-term Intervention Long-term Intervention
Raw Materials
Heating in Furnace
Rolling
Finished Product
Designing proper storage area Setting up of quality testing
center
Setting up of Common Facility
center
Providing workers with proper
heat resisting clothing
Installation of heat shield between
worker and the furnace
Exploration of new latest
technology in heating the iron in
furnace
Rotation of the working shifts of
the worker such that no worker
works at a stretch
Ergonomic modification of the
layout of the workplace
Designing of the sliding structure
to aid the workers
Exploration of new technologies
and machineries
Proper storage area can be
designed
Setting up of quality testing
center
The opportunity to develop new
and different varieties of product
should be explored
Design Clinic Workshop
September - October 2013
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
51
Howrah Rolling Mill Design Clinic Workshop (Day One)
Venue: Fortune Park Panchiwati, Howrah
Date: 28th
September 2013
Schedule
1. Inauguration
2. Inaugural speech
3. Need assessment of rolling mills – Dr. Somnath Gangopadhyay
4. Tea Break
5. Rolling - a technical perspective- Dr. Debamalya Banerjee
6. Ergonomics in rolling Mill– Dr. Somnath Gangopadhyay
7. Interactive session and conclusion
8. Lunch
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
52
he five day Design Clinic Workshop of the Howrah re-rolling mills was inaugurated on 28th
September 2013. Many distinguished dignitaries attended the program. Mr. Sankar Sanyal,
President, Howrah Chamber of Commerce and Industries (HCCI) presided over the ceremony.
Many other members of the HCCI were also present. Dr. Somnath Gangopadhyay, Associate
Professor, Occupational Ergonomics Unit, Department of Physiology, Calcutta University and Dr.
Debamalya Banejee, Associate Professor, Production Engg. Department, Jadavpur University
were the invited speakers in the program. The inaugural session was attended by the owners of
different rolling mills of Howrah.
The inaugural speech was delivered by Mr. Sankar Sanyal wherein he introduced and welcomed
the dignitaries to the dais. Then he briefed about the importance of Need Assessment Survey for
the rolling mills which was done previously by Dr. Somnath Gangopadhyay. He also discussed
about the fruitful association between National Institute of Design (NID) and HCCI for the
improvement of productivity in different rolling mills.
Mr. Sanyal’s speech was followed by an informative talk from Dr. Gangopadhyay. His
deliberation emphasized on the Need Assessment Survey that was carried out by him in the rolling
mills. Starting with the meaning of Need Assessment Survey, his lecture encompassed regarding
the procedures he followed, the results derived from the survey and the suggestions put forward to
improve the conditions of the rolling mills.
After the tea break, Dr. Banerjee delivered his lecture. His talk entailed the current global
procedures practiced in rolling mills and the ways to improve it.
T
Figure 23: Dignitaries in the dais.
Figure 24: Dr. Gangopadhyay delivering his talk
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
53 Dr. Gangopadhyay gave his second deliberation on Introduction to Ergonomics and its application in rolling mills. This was followed
by an interactive session.
Finally Mr. Sanyal concluded the program by summarizing the day’s events.
Figure 26: Owners of different rolling mills Figure 25: Dr. Banerjee giving his talk
Figure 27: Dr. Gangopadhyay discussing about Ergonomics
Figure 28: Mr. Sankar Sanyal, President, HCCI
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
54
Figure 29: All the participants of the workshop
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
55
Howrah Rolling Mill Design Clinic Workshop (Day Two)
Venue: Rolling Mill, Belgachia, Howrah
Date:29.09.2013
Schedule
1. Presentation on Need Assessment Survey Dr. Somnath Gangopadhyay
2. Discussion with the owners Dr. Somnath Gangopadhyay
3. Interaction with the workers Dr. Somnath Gangopadhyay
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
56
he second day of the Design Clinic Workshop was continued on 29th
September,
2013 at a rolling mill in Belgachia, Howrah. The focus of this day was to have a
one to one discussion with the owners as well as with the workers. Dr. Gangopadhyay
began the workshop by giving a detailed presentation on the Need Assessment Survey
of the rolling mills. This was followed by a discussion with the owners of the mills
regarding the survey, the outcome of the survey and the proposed suggestions. This
discussion was followed by another discussion with the workforce of the factory. This
was an interactive session where the factory owners as well as the workers participated
graciously.
Highlights of the workshop
Proper work rest cycle is being implemented in the factory.
Workers use safety shoes but that are not proper.
Suggestion of common facility centre was welcomed.
Workers were advised and made aware about working with good posture
T
Figure 30: Need assessment survey presentation
Figure 31: Discussion with the owners
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
57
Figure 34:Improper safety shoes Figure 33:Dr. Gangopadhyay discussing with the workers
Figure 32:Interactive session Figure 35:All the participants of Day 2
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
58 Howrah Rolling Mill Design Clinic Workshop (Day Three)
Venue: Rolling Mill, Dharmatala Road, Howrah
Date:30.09.2013
Schedule
1. Presentation on Need Assessment Survey Dr. Somnath Gangopadhyay
2. Discussion with the owners Dr. Somnath Gangopadhyay
3. Interactive session with workers and owners Dr. Somnath Gangopadhyay
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
59
he third day of the Design Clinic Workshop was continued on 30th
September, 2013 at a rolling mill in Dharmatala road, Howrah.
This day also focused on one to one discussion with the owners and
workers.
Presentation on the Need Assessment survey was followed by
interactive session with the workers.
Highlights of the workshop
Workers were advised and made aware about working with
good posture
Job rotation for the workers was proposed
Proper personal protective equipment is required for the workers
working immediately in front of the furnace.
Proper work rest cycle is being implemented in the factory.
Suggestion of common facility centre was welcomed.
T
Figure 36: Presentation on Need Assessment Survey
Figure 37: Discussion with the owners
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
60
Figure 38: Dr. Gangopadhyay interacting with the workers
Figure 39: Participants of day 3
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
61 Howrah Rolling Mill Design Clinic Workshop (Day Four)
Venue: Rolling Mill, Ghusuri, Howrah
Date:03.10.2013
Schedule
1. Presentation on Need Assessment Survey Dr. Somnath Gangopadhyay
2. Discussion with the owners Dr. Somnath Gangopadhyay
3. Interactive session with workers and owners Dr. Somnath Gangopadhyay
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
62
he fourth day of the Design Clinic Workshop was continued on 3rd October,
2013 at a rolling mill in Ghusuri, Howrah. This day also focused on one to
one discussion with the owners and workers.
Dr. Gangopadhyay started the day with the presentation on Need Assessment
Survey of the rolling mills. This was followed by discussion with the owners and
interactive session with the workers.
Highlights of the workshop
Proper storage space for raw materials were identified
Workers were advised and made aware about working with good posture
Proper personal protective equipment was advised for the workers working immediately in front of the furnace
Production of different variety of products was discussed
Use of overhead cranes for moving materials was encouraged
Proper work rest cycle is being implemented in the factory.
Suggestion of common facility centre was welcomed.
T
Figure 40: Presentation on Need Assessment Survey
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
63
Figure 42: Interaction with the owners Figure 41:Proper storage of raw materials
Figure 43: All Participants of Day 4
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
64 Howrah Rolling Mill Design Clinic Workshop (Day Five)
Venue: Rolling Mill, Dharmatala road, Howrah
Date:04.10.2013
Schedule
1. Presentation on Need Assessment Survey Dr. Somnath Gangopadhyay
2. Discussion with the owners Dr. Somnath Gangopadhyay
3. Interactive session with workers and owners Dr. Somnath Gangopadhyay
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
65
he fifth and the last day of the Design Clinic Workshop was continued on
4th October, 2013 at a rolling mill in Dharmatola road, Howrah. This day
also focused on one to one discussion with the owners and workers.
Dr. Gangopadhyay started the day with the presentation on Need Assessment
Survey of the rolling mills. This was followed by discussion with the owners and
interactive session with the workers.
Highlights of the workshop
Workers were advised and made aware about working with good
posture
Safety shoes are being used but that are not proper
Proper work rest cycle is being implemented in the factory.
Suggestion of common facility centre was welcomed.
Proper storage space for raw materials was identified
T
Figure 44: Presentation on Need Assessment Survey
Figure 45: Interaction with workers
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
66
Figure 47: Talking about the big forcep Figure 46: Worker at the face of the furnace
Figure 48: interactive session
Need Assessment Survey of Re-rolling Mills | Occupational Ergonomics Laboratory | University of Calcutta
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Figure 50: Safety shoe not proper Figure 49: Discussion with workers
Figure 51: All participants of day 5
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