Diagnostic study report on Metal embossing craft cluster of Patan

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Research and Documentation

Diagnostic Study Report of

Metal Embossing Craft Cluster in Patan, Gujarat Craft Analysis


Funded by:

Š 2013 Design Innovation and Craft Resource Centre (DICRC) CEPT University , Ahmedabad, India.

iNDEXT-c Government of Gujarat


Diagnostic Study Report of Metal Embossing Craft Cluster in Patan, Gujarat Field Researchers: Anusha Babel, Mitraja Vyas, Vrushali Burle Project Co Ordinator: Bishakha Shome


Preface Traditional knowledge is the technical, social, organizational and cultural collective memory of human responses to the complexities of life, and is a part of the great human experiment of survival and development. These traditional folk and elite sciences are intertwined with their distinct ancient cultures and worldviews. Unfortunately, modernization has homogenized the categories, reducing diversity of worldviews in ways similar to the destruction of biodiversity. Many anthropologists who have recently worked with so-called ‘primitive’ peoples have been surprised to learn of some of their highly evolved and sophisticated technologies. The term ‘Traditional Knowledge System’ was thus coined as a scientific system which has its own validity, as a supplement to modern science. The Phenomenon of large no. of Small Scale Industry (SSI) units manufacturing the same (or similar products) existing or historically developing in close proximity to each other (in clusters) has been observed in different periods and diverse industrial environments. “Clustering” as an engine of growth was noticed internationally in the well networked clusters (usually referred to as Industrial districts”). In the global scenario it has been observed that small units of crafts or individual artisans are unable to face competitive pressures because of their isolation and ineffective linkages with relevant support, organization and commercial service providers. This realization has led to increased interest and research in clustering as well as attempts to replicate the process through planned intervention in the developing countries including India. Gujarat has a rich legacy of crafts which have contributed enormously to the history and heritage of architecture. These crafts are being practiced all across the state. The present cluster of Metal Crafts situated in Patan, a small town belonging to Patan District of North Gujarat, is unique due to its contribution to the religious crafts and space making crafts sector of the state over a period of 200 years. This cluster located around the Jain temple complex of Patan offers immense opportunities to grow into a potential crafts cluster subject to implementation of cluster development program in line with holistic approach of the United Nations Industrial Development Organization (UNIDO). This Diagnostic Report on Metal Crafts of Patan is one of the series of cluster mapping reports conducted by the Design Innovation and Craft Resource Center (DICRC). A substantial amount of research – both primary and secondary – has been involved in order to conduct the diagnostic study of this cluster. Following is an account of the methodology employed in order to carry out the study.

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Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat


Table of Contents 1. Metal craft cluster of Patan Methodology Background of metal craft in Gujarat

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2. Metal Craft of North Gujarat Overview About the metal craft cluster Significance of the craft cluster Introduction to cluster products/services Artisans of the cluster: The Panchal community Details of cluster Artisans Infrastructure and Workshop of different artisans

20 21 23 23 23 26 31

3. Structure of cluster Structure Core cluster Artisans for metal craft of Patan Basic statistics of the cluster Concentration of Units/Business Cevelopment providers Current Institutional Matrix Who Does Who Pays(WDWP) Matrix Socio Economic Conditions of Artisans Socio Condition Variability Factor

38 39 40 40 41 42 46 48

4. Description of cluster Infrastructure Material Tools and Equipments

52 56 61

5. Process Process of Creation Aangi Making Backdrops Doors/Boxes

68 68 70 72

Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat

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5. Products made by Artisans Introduction to cluster products/services Related craft forms Suggestive product ranges

76 77 80

6. Analysis Business operation & value chain analysis Quality of products/services Related sub clusters Business development service analysis Performance/Ability cluster Development challenges Analysis of key issues & suggested solution

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84 85 86 86 87 90 91


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Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat 8. Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat


01 INTRODUCTION TO CLUSTER MAPPING

Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat 9.


Images: The DICRC team mapping craftspeople on field.

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Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat


01. Introduction to Cluster Mapping About craft cluster mapping

Cluster Mapping Is an approach towards identifying, understanding and developing a detailed inventory of craftspeople practicing a given craft in a concentrated area. These concentrations are commonly refered to as a cluster, which is defined as “a group of producers making the same or similar things in close vicinity to each other�. The process involves maooing of clusters of different types of Space making Crafts (SMC) and Surface Narrative Crafts (SNC) and their applications such as Elements (Interior Architecture elements, Furniture, Objects and Accessories) integrated within it. The process also involves mapping of craftspeople who are skilled in SMC and SNC’s along with mapping their work places The prime objective of the study is to create a consistent database on clusters and sub-clusters and establish a common methodology throughout upon which further design innovation, technological intervention, statistical and economic analysis can be based. The study also aims at identifying, through the collection of statistical data, the most promising clusters upon which successful innovation strategies can be built. The final objective of the study is the formulation and further validation of policy recommendations on the successful promotion of innovation cluster development related to buildings crafts in Gujarat in particular with a cross-border dimension.

Methodology

The approach towards this study was structured along the lines of the Cluster Development Program (CPD) introduced by UNIDO in order to contribute to the overall performance and collective efficiency of the Small and Medium Enterprise (SME) clusters for sustainable development by assisting selected local communities of firms and associated institutions in the clusters. The Study was designed in two parts - quantitative survey of Artisans in the cluster (through structured questionnaire), and qualitative discussion with focused groups, opinion leaders, and a variety of stakeholders of the cluster. A detailed methodology was followed to gather information on the cluster, identify the main actors, and collect trade and business data from them. Various tools including desk research, field visits, one-on-one interviews, and surveys were used to collect the required information.

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Images: The DICRC team mapping craftspeople on field.

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Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat


Following is a step-by-step description of the methodology used: 1.Desk Research and Setting Up of First Field Visit • Identifying and establishing contact with NGOs, individual artisans, master craftspeople and entrepreneurs working in the area to explore potential local project partners and resources. • Identifying design and other professionals who have previously worked with artisans belonging to the cluster and discussing with them the future scopes of the cluster. • Referring to books, documents and other reading material for sourcing initial archival material on the crafts process, design repertoire, local dynamics and existing linkages to markets. 2.Field visits • The researchers carried out initial field visit of 7-10 days to meet the artisans, groups and organizations working in the area. • Once the clusters were identified, field visits were carried out as and when required. 3.Documentation of the Craft Production Process • A detailed documentation of the craft production process was carried out. 4.Survey of Artisans • Demographic profiles of the artisans and ancillary workers, including their geographical locations were mapped. A selection and survey of over 30 artisans was also conducted. The data was then compiled in a computerized format to obtain aggregate statistics from the survey forms. 5.Value Chain Mapping • A detailed mapping of the metal crafts value chain was carried out. The mapping identified actors in the cluster who were involved in the business of crafts production and sales including master craftspeople, traders and other marketing intermediaries. • A detailed analysis of the existing commerce in the cluster, including current sources of credit accessed by artisans and traders, was then undertaken. Metal crafts of Gujarat owe a very ancient lineage in the Gujarat and it underwent rise and fall in demand with time. Communities of Kanasaras, Panchals, Luhars, Sonars and the like have traditionally been involved in the process of metallurgy and metal crafting. With their indigenous skills and knowledge they have been creating vast gamut of metal crafts serving miscellaneous purposes.

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Images: Range of products and applications of metal embossing

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Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat


Background of metal craft in Gujarat

Dhatu, Hiranya, Mahaadhatu are the various names by which metal has been recognized in Gujarat and has been a significant element in crafting and sculpting the history of the state. Metal craft developed to a fine art suffusing every stratum of society in spite of metal ore not being naturally prevalent in the state. Over centuries, metal smiths in the province have shaped this multifaceted element into varied forms using wide ranged skills and techniques. Different qualities inherent in each metal are coherently utilized by the craftspeople working with metal yielding an extensive range of quality products. In history of Gujarat, metal finds its earliest reference going back to 4000 years ago during the Indus Valley Civilization. The varying topography, diverse cultural values, aesthetic appreciation, creative ingenuity and foreign influences have been some of the diverse factors inspiring the metallurgists or craftspeople of Gujarat. Metal, has been a popular constituent in crafting wide range of products like vessels and wares for utilitarian purposes, coinages, jewellery for ornamentation, objects of religious significance, arms and armaments, tools and equipment and varied multifaceted creations. In the wide vista of space making crafts, metal resplendently finds its significance in being used along with other popular materials in architecture, as a considerable material for creating furniture and a prevalent element for crafting decorative and utilitarian space enhancing objects. Iron, copper, bronze, silver, gold, tin, lead, aluminium and the like have been the prevalent materials used by craftspeople contributing to the built heritage traditions of Gujarat. Miscellaneous techniques like casting, molding, stamping, embossing, inlay cladding and many more have over centuries been explored and evolved by architects and craftspeople of the state to create a wide range of space making and enhancing crafts. The earliest evidence of metal in the history of Gujarat traces back to most popular port city Lothal of ancient Indus Valley Civilization. Pitaras or chests, furniture, lamps, bells, utensils, idols of gods and goddesses, ceremonial vessels and objects, hardware and architectural elements created of metal display the regional styles and development of metal crafts of the province. The art of metal crafting and metallurgy further advanced in Gujarat under the royal and religious patronage. With the varied cultural and foreign influence coming through the trade routes, the tools, equipments, techniques progressed and a vast gamut of crafts employed the use of metal. The tippanikaam or beaten metal work exemplifies the dexterity of the

Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat

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craftspeople of this region. This complex process of beating and turning a metal sheet to three-dimensional objects has been a recognized technique of Gujarat and has been used for varied architectural and utilitarian purposes. Copper and brass for their anti-bacterial and other medicinal properties formed an integral part of religious spaces and household in the region. Tippanikaam on copper and brass created wide range of vessels and utensils, which were each designed and fabricated to serve a particular purpose or aid in a specific chore. The art of casting metal has been popular in rural areas of the state for creating bells in a variety of shapes and sizes for cattle, tools and equipments, and as part of carts or architectural elements. Traditionally the temple structures all over Gujarat affirm the dexterity of stone artisans, while objects used for rituals, confirm the imagination and creativity of the metal artisans. Figurines of deities, reflecting local beliefs, myths and legends are created with deftness of casting metal in the ingenious forms and shapes. Jainism and Hinduism promoted this craft form by patronizing the skills for creating idols, objects for religious and ritualistic purposes and smaller objects like sacred narrative panels or decorative objects.Swaying swings form an avoidable part of interior as well as exterior spaces of a household in Gujarat. These fixtures are often decorated with solid brass chains adorned with figurines of women, animals birds etc. The craft of sword and artillery making under the reign of different rulers advanced with time and displayed aesthetical use of metal casting. This craft goes back to almost 1000 years and the earliest documented mention is found in the Jain miniatures going back to fifteenth century. Persian and Mughal miniatures also illustrate varieties of armaments stating the dexterity of metal smiths. Chandi or silver is one of the most significant elements for creating crafts in the region. This opulent due its malleable properties has been one of the most preferred metal for varied metal crafting techniques like cladding, filigree, inlay, embossing and the like. From religious objects to jewelry, furniture to ceremonial carriages has over centuries been created showcasing the opulence of its patrons and the creative skills of the artisans in the region. Silvers crafts are handed down as part of family heirloom and play a significant role in every festivity or religious eremony. The dexterity of crafting this metal has found mention in texts dating back to the earliest historical periods but with coming of the Europeans it sophisticated to its zenith. Design rudiments narrating the sway of Dutch, Portuguese and British influences not only brought in a range of decorative elements but also increased the diverse assortment of

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Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat


products collection. Along with the traditional articles silversmiths adapted to create silverware meant and fashioned to compliment European taste. Elaborately decorated cutlery sets, chandeliers, decorative objects were created for enhancing the space while large pieces of furniture were clad with decorated silver sheets displaying the richness and creative expertise of that era. Amongst other metals, iron casting developed during the European period and found its utmost usage in creating elements for architecture or as supportive material for built forms. Cast iron grills, jalis, form an integral part of architecture of that period and can be popularly seen in various built forms structured during the European era. This technique of casting was further explored in creating furniture, lamp posts, gates and many other space enhancing elements.

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Diagnostic Study Report Metal Craft Cluster Patan, Gujarat Diagnostic Study Report onon Metal Craft Cluster ofof Patan, Gujarat


02 THE METAL CRAFT OF NORTH GUJARAT

Diagnostic DiagnosticStudy StudyReport Reporton onMetal MetalCraft CraftCluster ClusterofofPatan, Patan,Gujarat Gujarat

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Overview Patan, located near Anhilwad Patan, the erstwhile capital of Gujarat is a significant town in the history of the state. Patan is also known as Sri-sthal or a “pious place”. It is situated on the left bank of the River Saraswati, around 24 kms upstream of Anhilwad Patan, the old capital of Gujarat before Ahmedabad was founded in the first quarter of the fifteenth century. The town is a revered destination, flanked by temples, kunds, ashrams and other sacred structures. It is mentioned in the Rigveda as existing at that time as the Dashu village. The legend is that the great sage Vyashya had donated his bones to God Indra here at Patan. Patan is also believed to be located at the junction of two rivers Ganga and Saraswati. Even in the Mahabharata, the great Indian epic, it is mentioned that the Pandavas had visited the place while they were in exile. During the 4-5th A.D a large number of Gurjara people from Iran settled in this part. Around the 10th century, under the Solanki rulers, this town was at the pinnacle of prominence and glory. It derived its name from the great ruler of Gujarat, Siddhraj Jaisinh from the Solanki dynasty. Raja Siddhraj built a magnificent temple dedicated to Lord Shiva called as the ‘Rudra Mahalaya’ in 12th century AD. The temple was an architectural wonder with a three-storeyed ‘shikhara’, 1600 pillars, 12 entrance doors, central ‘mandapa’ and porches on east, north and south and sanctum in west. Around the temple, there were 11 shrines of Rudra. The eastern gate was adorned with beautifully carved ‘Toran’, with a flight of steps leading to the Saraswati River. The ornamentation of the temple was

PATAN

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Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat


exuberant as shown by the elaborate and detailed carvings of the pillars and the beautiful Toran, which are the only remains of the temple today. During the Sultanate time the place was under the rule of local dynasty ruling from Palanpur. Later on in 15th century the place was brought under the Mughal rule by Akbar. Under the Mughal rule the town developed and flourished. The town also holds importance for the Bohra Muslims, an affluent Muslim community spread all over the world. They have contributed significantly to the development of Patan. Their old Havelis and mansions, some over 100 years old have a markedly European flavor and a walk through the ‘Bohra Vad’ is like a stroll through an England replete with the lamp lighters at dusk. So enamored were they by the style & existence of living in the 19th century Europe that as a sign of opulence and to gain respectability amongst the community they tried to create a slice of Europe in their hometown. This, they did by imitating the Victorian architecture. The facades are rich in variety and aesthetic expression with intricate details in wood. Thus the living spaces of the Bohra community or the so-called ‘Bohra Havelis’ represent a nostalgic visual straight out of a Dickenson novel.

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The Metal Craft Cluster of Patan Metal Crafts of Patan encompass variety of metals like silver, copper, aluminium, crafted with diverse techniques like embossing, cladding and inlay. Historically, it is believed that the creators of the craft forms belonging to the Panchal community descended from Georgia and settled in Patan during the reign of Solanki rulers. A tradition which dates back to more than 1000 years is utilised for creating various space making crafts. Catering chiefly to religious purposes, this craft has been promoted by the Jain and Vaishnav communities. Non-ferrous metals are significantly used by the artisans of this region due their various properties constructive in adorning the craft forms. Some of the techniques which are used by the metal craftspeople are:

i. Metal Cladding: Local Name: Madhai Kaam Related Crafts:

English Name: Wood and Metal Cladding Local Name: Naqshi Kaam English Name: Wood Carving

Cladding is the process of covering a surface or structure with another or similar material. In Patan, the artisans working with wood and metal, work together to create varied designs for large scale products and architectural elements.

Metal Cladding on wood ii. Metal Embossing: Local Name: Madhai Kaam English Name: Wood and Metal Embossing Related Crafts: Local Name: Naqshi Kaam English Name: Wood Carving

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Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat


Embossing is a technique that creates a pattern on material. Metal embossing is the art of creating raised and sunken designs or relief on thin metallic sheets. There are a number of ways to emboss something. Some artists emboss by hand, using hand held tools to stamp out a pattern in the material being embossed. This technique will create unique raised designs which cannot be replicated. Embossing of this style is often used for customized art projects, or when ordering an embossing die would seem impractical. Both dry and heat embossing techniques are used for hand embossing projects, depending on how the artist wants the finished piece to look.

Metal Embossing

Inlay of stone in Metal

iii. Metal Inlay: Local Name: Jadtar Kaam English Name: Wood and Metal Inlay Related Crafts: Local Name: Naqshi Kaam English Name: Wood Carving Metal inlay is a process in which the metal is set into wood or another metal so that it forms part of the design, or is carved or molded so that precious or semi-precious stones may be set into it.

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Significance of the Craft Cluster

Metal craft cluster of Patan holds an immense historical, religious and economical significance. At present the cluster can be defined as an ‘established cluster’ and can be further worked upon to develop it into a ‘mature cluster’. (Established Cluster: Clusters are dynamic and have a recognizable life cycle. The lifecycle is often described in different ways but can be represented simply as a cyclical process containing four stages. Out of which Established Clusters are the ones which are considered reasonably well set up in comparison to other clusters and are perceived to have room for further growth.) i. Revitalizing this cluster would be part of preserving the living craft heritage of Patan, Patan district. ii. The cluster has historical importance which has been passed down through generation of traditional artisan communities. iii. Artisans of this cluster are skilled with diverse technique of metal crafting. iv. The cluster has tremendous potentiality of being developed as an integral component of contemporary space making crafts and hence can have a wider strata of clientele.

Introduction of the Cluster Products/services:

Metal Embossing is a traditional craft-form in which idols, narrative plates, artifacts etc. that are particularly related to the Hindu and Jain religion are embossed in copper and plated with pure or German silver. Also, doors, chariots and donation boxes for the temple are carved in wood and plated with German silver. Patan is the hub for Metal Embossing, Cladding and Inlay work, majority of which is done for the Jain Temples across the nation. The materials i.e metals are used in different forms and purpose, like silver is generally used in powdered form, copper is used to make Aangi and for cladding, zinc which is known as German silver used for cladding on doors, dropboxes and windows, brass is used to make locks, dhawaja and cladding.

Cluster Artisans: The Panchal Community

Descendants of Shree Vishwakarma are spread throughout the India and the World. Originally from Georgia, the Panchals travelled down through Central Asia towards the Punjab in an area then known as Gujjar Pranth. News reached them of Maharaja Solanki, who as part of his desire for the expansion of his kingdom, wanted to build a vast palace ‘rudramahal’ in Patan.Experts in the art of building flocked towards Patan, the majority of these were Panchals. Solanki selected 1000 Brahmins to aid with the new palace. Each Brahmin had assigned to him various experts in the crafts, again the majority being Panchals. After the palace was built the Brahmins together with their craftsmen were to return to the Punjab. Instead, Solanki offered them an alternative. To each of the 1000 Brahmins, he assigned a town to live. In whichever town the Panchals settled they took on its name. Their family line, ‘Kutumb’, or surname,

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Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat


became that of the town in which they had settled. For example, the surname Vadgama originated from ‘Vadgam’, Valambhia from ‘Valam’, and Talsania from ‘Talsan’ and so on. Panchal community of Patan is one of the most prominent artisanal group contributing to the creation of metal crafts serving the religious segment by creating varied space making, utilitarian crafts. Descendants of Shree Vishwakarma are spread throughout the India and the World. Originally from Georgia, the Panchals travelled down through Central Asia towards the Punjab in an area then known as Gujjar Pranth. News reached them of Maharaja Solanki, who as part of his desire for the expansion of his kingdom, wanted to build a vast palace ‘rudramahal’ in Patan. Experts in the art of building flocked towards Patan, the majority of these were Panchalss. Solanki selected 1000 Brahmins to aid with the new palace. Each Brahmin had assigned to him various experts in the crafts, again the majority being Panchals. After the palace was built the Brahmins together with their craftsmen were to return to the Punjab. Instead, Solanki offered them an alternative. To each of the 1000 Brahmins, he assigned a town to live. In which ever town the Panchals settled they took on its name. Their family line, ‘Kutumb’, or surname, became that of the town in which they had settled. For example, the surname Vadgama originated from ‘Vadgam’, Valambhia from ‘Valam’, and Talsania from ‘Talsan’ and so on. Panchal community of Patan is one of the most prominent artisanal group contributing to the creation of metal crafts serving the religious segment by creating varied space making, utilitarian crafts.

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Cluster Artisan Details Workshop -1 Details Owner: Harishkumar and Dilipkumar Panchal Location: Near Jain Dining Hall, Pipla sher, Patan - 384265 Products: Wooden articles for Jain and Vaishnav Temples Number of craft people: 7

01

Name: Harishkumar Bhogilal Panchal Experience: 30 years Workarea: Production, maintenence, and dealing with artisans Skill: Drawing, carving and embossing in metal

02

Name: Dilipkumar Bhogilal Panchal Experience: 25 years Workarea: Technological upgradation, dealing with raw material suppliers and clients, and delivering finished products Skill: Human resource management

03

Name: Nanji Rana Experience: NA Workarea: Electroplating and finishing Skill: Electroplating and finishing

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04

Name: Jignesh Suthar Subhash Suthar Experience: 6 years each Workarea: Embossing in metal and finishing Skill: Embossing in metal and finishing

05

Name: Subhash Rana Experience: 10 years Workarea: Inlay of gems in embossed products Skill: Inlay of gems

06

Name: Naresh Thakur Experience: 17 years Workarea:Embossing Skill: Drawing, carving and embossing in metal

07

Name: Pravin Rana Experience: 7 years Workarea: Inlay of gems in embossed products Skill: Inlay of gems

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Workshop-2 Details Owner: Panchal brothers Location: Moti sara, near Panchasara Jain Derasar, Patan - 384265 Products: Articles for Jain and Vaishnav Temples. Number of craft people: 3

01

Name: Maheshbhai Experience: 15 years Skills: Wood carving and metal embossing

02

Name: Suman Panchal Experience: 15 years Skills: Wood carving

03

Name: B.R. Rana Experience: 6-7 years Skills: Metal embossing and diamond inlay

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Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat


Workshop-3 Details Owner: Manishbhai Soni Location: Moti sara, near Panchasara Jain Derasar, Patan - 384265 Products: Articles for Jain and Vaishnav Temples Number of craft people: 4

01

Name: Manish Soni Experience: 10 years Skill: Wood carving and metal embossing

02

Name: Bhavin Prajapati Experience: 4 years Workarea: Embossing and finishing Skills: Drawing, carving, embossing in metal and finishing

03

Name: Raju Thakur Exrerience: 6 years Workarea: Metal embossing and finishing are major area of work Skills: Embossing in metal and finishing

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04

Name: Ravi Prajapati Experience: 8years Workarea: Drawing, carving and metal embossing Skills: Electroplating and finishing

Workshop-4 Details: Owner: Arvindbhai and Navinbhai Panchal Location: Chashiya dhara, Patan - 384265 Products: Articles for Jain and Vaishnav Temples (Wood carving and Metal Cladding)

01

Name: Arvindbhai Panchal Experience: 35 years Workarea: Wood carving and metal (sheet) cladding Skill: Wood carving and metal (sheet) cladding

02

Name: Navinbhai Panchal Experience: 40 years Workarea: Wood carving Skill: Wood carving

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Workshop/Infrastructure-1 The workplace of different Artisans had different settings according to place available and types of work done by them, financially well Artisans had three rooms for working on different process, marginal Artisans had one to two rooms mostly in their residential place. The following are workplaces and infrastructure of different artisans.

Name: Storage Details: Materials like nails, adhesive and bigger toolsare kept in open shelves. Due to different shapes and sizes of materials storage was unorganised- Harishbhai

Name: Overhead shelves Details: No proper storage place and the shelves made were open, tools may fall down and injure the artisans.Harishbhai

Name: Prayer place Details: Dispite of having insufficiet space craftsperson manage to make small place for prayer. Most of them worshiped god VishwakarmaHarishbhai

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Name: Working area for embossing Details: Very small area and only one door which hardly helped any sunlight or air to come in. polishing, embossing , welding all were done in same room

Name: Working area for diamond setting Details: residential room is converted into workspace for diamond inlay, small tables provided and lighting arrangements are made to help artisans for small detailing.

Name: Working area for silver platting Details: Heating, embossing and metal platting were done in same room, sufficient lighting and storage was not available here.

Name: Working area for washing and welding Details: Washing, welding and sand rubbing processes are done on roadside causing traffic disturbance and no drainage facility for waste water.

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Name: Corner of room Details: Tool bags and farma are generally hanged on wall for easy excess.

Name: Packing of finished products Details: One of the corner of room is used for packing and storage of finished products. packing is done with old newspapers.

Name: Storage and drinking water place Details: Due to insufficient storage, place under staircase is converted into shelves with kaddapa stone

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Workplace/infrastructure-4

Name: Storage Details: Wooden shelves are made in inbuilt storage space which are used to store catalogs, papers, albums etc

Name: Storage for tools Details: Space below staircase is converted into storage by making shelves of kaddapa stones and plywood, but not enough for electrical equipments

Name: Place for prayer Details: Dispite of having insufficiet space craftsperson manage to make small place for prayer. Most of them worshiped god Vishwakarma.

Name: Workshop of Navinbhai Details: Front room of house is used as workplace, flooring is of kaddapa stone, one window and one door, tubelights etc making workplace a bit comfortable.to work. Less storage place and tools were kept in wooden boxes.

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Name: Working area Details: One room of house is used as workplace with two doors and one window with orioer lighting. All processes like metal cladding, embossing, finishing etc are practiced in same room.

Name: Workong area Details: View of corner with tools and products in process. All tools and equipments are put in bags and wooden boxes

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03 STRUCTURE OF CLUSTER

Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat


Structure Core Cluster Actors

Core cluster actors of the craft form can be sub-divided into three groups. Though all are equally essential to the entire process, sub dividing them into groups assists in better understanding of their role and bring about an upliftment based on their individual interaction with each other. The groups are: i. Primary Group: this group primarily consists of the practitioners or the executor of the craft form. ii. Secondary Group: this group is made of all the suppliers of all the various materials necessary for execution of the craft form. iii. Tertiary Group: this third division is the market link which helps in promotion and disseminating information about the craft form which in turns aids in generating sales and getting orders.

Figure: Cluster Pyramid of Metal Crafts in Patan

Core Cluster for metal craft of Patan

The core cluster consists of the traders, suppliers, head artisans and ancillary workers. i. Primary Group The head artisans Decades back, the head artisans themselves were engaged with different processes of embossing but today they have undertaken all the responsibility of taking order and executing them on site. The head 38.

Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat


artisans (usually father and son) own the workshop and their portion of work is to design the ornamentation on the story plates, chariots and other artifacts and head artisans basically look after the artisans working under them. Sometimes head artisans do drawings to make new designs. They hire skilled artisans who work on making the products. Artisans Artisans are the group workers under the guidance of head artisans. Artisans are assigned to work which is usually directed to them by head artisans according to their skills. They get paid by head artisans. ii. Secondary The suppliers The suppliers are the most important people who supply the materials to the artisans and the artisans in Patan generally get their raw material from kalol and Ahmedabad (manak chowk and lokhand market) or they ask client to get their material. Raw materials like metal and tools they get from Ahmedabad and kalol. Material like acid and POP are locally available. Ancillary workers As wood carving is also the part of the process of metal embossing, there are ‘mistry’ who basically work in wood carving. Sometimes the head artisans hire wood carver to carve it for them to get the carved wood as per the required size. Carved wood is then covered with the selected metal sheet and metal sheet is then beaten on top of carving so that it takes the shape of the carving done on wood. So to make structure of wood some of head artisans hire wood carver who gives the carved wood to cover it with metal sheet. iii. Tertiary The traders The traders are the people who help artisans to get the international and national market deal, they are the middle person in between the client and the artisans

Basic statistics of the cluster i. Large scale and Export Houses: • The units belonging to Harish Bhai Panchal and Manesh bhai Panchal unit can be a good example of large scale, they also have international clientele. • Harish bhai and Dilip bhai have two floor houses as their work shop. Ground floor is basically used for embossing process and first floor is dedicated to diamond and minakari work on metal products like aangi • mukhut etc.

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• Even Jayantilal bhai has a work shop with three rooma dedicated to Diamond and Minakari work. ii.Small Scale • Suman bhai and his three brothers have a small workshop and they even go to the site for work. • There workshop is about 12’ X 13’ small work shop near their house where they work whole year. iii. Micro Scale • Naveen bhai and his brother Arvind bhai have their own work shop in their house, one room in house is dedicated to their work. • They get job work from Harish Bhai and some more large scale parties. iv. Artisan: •There are number of artisans who work on per day basis. • Master artisans have their own workshop, and they employ the other artisans.

Concentration of Units/ Business Development Providers (BDPs) i.Area wise details of units Seven families are there in Patan who have been traditionally working on this craft form and are located on the same street called moti sara. Men folk of the community are usually involved in this craft form. Historically there were more workshops spread over the town, but at present these 7 families constitute the small scale cluster. ii.Public/ Private organized/ Private unorganized Private unorganized units, although they are settled in same area they have no organized business development structure or strategies.

Current Institutional Matrix

The current institutional matrix depicts various stakeholders in Patan Metal cluster. The nature of relationship among these cluster actors is not always very clear and direct. Some of them have very remote relationship and it is limited to the extent of organizing some registration programs and providing some marginal services. Based on the role of these various support institutions, associations and strength of their inter-linkages and cooperation, they are given a full point scale. The score ‘1’ indicates there is very weak linkage between these cluster actors while score ‘5’ indicates there is strong inter-linkage between the stakeholders. This cooperation may be expressed in terms of joint planning, solving others problems, organizing seminars etc.

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Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat


The current institutional matrix shows the relationship between the stakeholders. A strong relationship and inter-linkage among the stake holders can not only solve problems of the cluster but also could help in sourcing technology, finance, streamlining marketing etc for overall growth of the sector. It is therefore necessary that interlinking among the stake holders be strengthened by organizing meetings and motivating each other. It is also necessary that relationship between enterprises be strengthened for success of the cluster.

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Direct/Indirect role of Government departments in Cluster The Government departments which have direct/indirect stake in the cluster and can certainly play a very significant role for the overall growth of the cluster. The current Institutional matrix for this cluster is shown below:

Department

Role in cluster

Cluster Relation Scale

Schemes

Indext C: Industrial Extension Cottage

Development

2

1. Prime Ministers Employment Generation Program 2. Shri Vajpayee Bankable Scheme 3. Web marketing of crafts 4. Proforma of ID Car 5. Exhibitions

Gramodyog Vikas Kendra DIC: Industries Commissionerate Government of Gujarat

Development Cluster Development

0 3

1. Gram udyog Sankul Yojana 1. Quality upgradation 2. Cluster development 3. Infrastructure development 4. Market development 5. Seminar and workshops

GSHHDC: Gujarat State Handloom & Handicrafts Development Commissioner of Cottage Industry

Develpoment, Training, Marketing

2

1. Raw material for employment 2. Artisans Security scheme

Financial

1

1. Manav Kalyan Yojana 2. Shri Vajpayee Bankable Yojana 3. Promotion of Co-operative sector 4. Cluster Development scheme

KVIC: Khadi and Village Industries

Development, Training, Employment, Facilities, Insurance

0

1.Prime Minister Employment Generation Program 2. Tools kits for Self-Employment 3.Rural Employment Generation Program 4. SFRUTI 5. Rural Industry Service Centre 1. Technology upgradation 2. Research & Development 3. Cluster development 4. Market promotion

GIDC: Gujarat Industrial Development Corporation

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2


Department

Role in cluster

Cluster Relation Scale

Schemes

CED: Centre for Entrepreneurship Development ITI: Industrial Training Institute

Development, Training

0

1. Cluster Development Schemes 2. Skill Development

Training and skill development

1

1. Craftsman Training Scheme 2. Artisans Training Scheme

RTI: Rural Technology Institute of Gujarat National Small Industries Corporation

Training and skill development, R & D, Development

1

1. Training

0

1. Bank Credit Facilitation 2. Export Credit Insurance 3. Performance & Credit Rating 4. Raw material assistance 5. Bill discounting scheme 6. Government purchase 7. Exhibitions 8. Marketing Intelligence Service

GITPC: Gujarat International Trade Promotion Council State bank of India NABARD

Promotion and marketing

0

1. Marketing

Financial Development & Financial

2 0

SISI: Small Industry Service Development Institute Gujarat Institute of Research & Development Development Research

1. Credit programs 2.Development & promotional functions

1. Training workshops

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From the institutional matrix it is pretty clear that District Industries Centre has moderate linkages with local association. But it has very weak/no relationship with other R&D and Financial Institutions. The metal cluster requires a lot of technological intervention in the field of metallurgy. In spite of this, there are hardly any linkages between any R&D organization and local Institutions are at present seen within the cluster. The current institutional matrix clearly shows that the relationship between these stakeholders is either minimal or moderate. This is one of the drawbacks of the metal cluster of Patan. All leading clusters worldwide, which are widely quoted in various articles, journals and books and which also provides a model for the developing and emerging clusters, exhibit a very strong relationship among the stakeholders and the cluster actors. A strong relationship and inter linkages among stakeholders can not only solve the problem of the cluster but also could source technology, finance, marketing etc. for the overall growth and development of the cluster. It is therefore important that the inter-linkage among these stakeholders needs to be strengthened by organizing meetings and motivating each others. This can be taken up as a capacity building exercise for the cluster. It is very clear from the diagnostic study that not only inter linkages among stake holding institutions needs to be strengthened but also the relationship between individual enterprises and associations needs to be improved. A win-win situation has to be created where all the cluster actors and stakeholder work in units. The above cluster Map of Metal Cluster indicates the various linkages and actors that exist in this cluster (the bold lines indicates the prevalence of organization where dotted lines indicates the organization to be developed). So far Public Policy is concerned there are institutions like DC(SSI), Central Excise and Customs, Sales Tax Department, Department of Factories and State Pollution Control Board. These organizations decide the policies which have direct repercussion on the activities of the industry. There are Commercial Service Providers like chartered accountants, export consultants, and merchant bankers. The actors in this category provide valuable services on commercial basis. In Patan, the availability of services are not omnipresent and efforts should be made in strengthening these Business Development services. In the nucleus of the cluster Map there is artisans involved in manufacturing Metal craft products and the Middlemen who play a very important role while enjoining heavy profit. The linkage among these SMEs is job-specific and commercial oriented. Another important thing, which needs to be highlighted here, is the practices of sub contracting.

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Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat


Middlemen take up jobs and get it done in some other firm. Subcontracting is widely prevalent in this cluster and this gives flexibility in the operating system. Among the constituents of backward linkages there are raw material suppliers and suppliers of machinery, tools and other inputs. Among the forward linkage members there are marketing agents, exporters and large industries. Though most of the marketing activity around 80% is done through marketing agents, traders and exporters but there are enterprises who are supplying products directly to the religious clientele. Based on the detailed discussions and research with the unit holders an attempt was made to identify service providers in all segments and understand who pays for these services. It was not possible in some cases to calculate the exact percentage. Based on the information collected during the course of discussion a very close account has been drawn in preparing ‘Who Does Who Pays Matrix’ The matrix indicates that the BDS market in Patan related to metal cluster is very week. Some of the services provided to the cluster were identified as training (including design training), loan syndication and market development. In majority of these services the units or the entrepreneurs themselves provided for the services. Apart from the willingness issue the affordability factor also needs to be considered here. For the units the religious clients are the only source of orders. And hence, new concepts in design, marketing, standardization, skill development etc are not paid much heed.

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Who Does Who Pays (WDWP) Matrix BDS

Who Does

Who Pays

Remarks

Access to finance

Entrepreneur/ Banks

Private loans

Capacity Building

Entrepreneur

Self

Product Development

Entrepreneur

Client/self

Infrastructure

Entrepreneur

Self

Market Development Entrepreneur

Self

Artisans who work under head artisans they generally get financial loans from the head artisans. Larger scale artisans take personal loans from banks or clients. Over years the craft has been handed over to next generation through apprentice methodology. Most of the capacity building is built on work. Any new product experimentation or development is done based on the requirement of the clientele. Almost all the units have been structured on self finance and without any institutional support. Market development is done by the artisans through mouth to mouth publicity or through the religious popularity of the products.

Socio Economic Condition of Artisans

The Metal craft cluster of Patan can be grouped into three categories based on their socio-economic status - Well off, Marginal and Poor workers.

Figure: Pie chart showing the socio-economic condition of the artisans in percentage

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Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat


i. Well off Income

• Monthly income 18,000 – 20,000. • No other extra source of income. • Annual income tentatively 2,00,000 Rs

Working capacity-

• Working for whole year. • Number of hours working per day- 8-10. • MNumber of days working in a week-6-7.

Awards

• None • No information about any Award facilities.

Marketing channels • National and international market. • Indian market- Mumbai delhi, Nagpur, kutch , rajesthan, vadodara. • Nation market – Chicago, paris. Demographic study • Name registered with the DIC as a craft person • Recognized and working with Jain association. • Own infrastructure, Working facilities and residence. • Some of these artisans have registered their names in government through the parth NGO running in Patan.

ii. Marginal Workers Income

• Monthly income 3600 - 5000 • No other extra source of income. • Annual income 40,000 – 50,000 Rs

Working capacity-

• Working for whole year. • Number of hours working per day- 8-10. • Number of days working in a week-6-7.

Awards

• None • No information about any Award facilities. • No participation in any fairs.

Marketing channels • Indian market- Mumbai, Delhi, Rajasthan, Ahmedabad. Demographic study • Name not registered with any government body but some of them are progressing, they are in process to get their name registered with government. • Recognized and working with Jain association. • Own residence and some craftsmen have workshop at home itself. • They heir craftsmen as per the requirement.

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iii. Poor Income

• Monthly income 2000 – 2500 Rs. • Other source of income -------• Annual income 20,000 – 40,000.

Working capacity-

• Working for whole year. • Number of hours working per day- 8-10. • Number of days working in a week-5-6. • Work only when they need money.

Awards

• None • No information about any Award facilities.

Marketing channels

• Word of mouth. • Work for a person who has their own workshop.

Demographic study

• Name not registered with any government body. • Work as laborers under well off units in the same field. • Work only when they feel need, work to get sufficient money to survive for the rest of the time

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Socio conditions Variability factors Factors Total Number of artisans

Earlier status Atisans and male members in family

Present status (2000) 2 person for drawing, 1 for wood carving, 2-3 for metal embossing.

Helping hands

Family members

2- 3 person

Production cost

Depend on the market rate of the metals

Depend on the market rate of the metals

Sources of raw material

Old utensils and metal from local market. Old utensils were used as raw material 1 or 2 Aangi in a year Local market

Kalol and manak chowk at Ahmedabad.

Availability of raw materials Monthly Earning Market

Other sources of livelihood Volume of products Motifs/design Competitors

Metal sheets of different thickness readily available in market International market

None

Referred from holy books Traditional Very less no. of units were In the town itself, different unit are there in patan. So less competitors of each other. competition and they use to work to fulfill their daily needs.

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Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat


04 DESCRIPTION OF THE CLUSTER (INFRASTRUCTURE, MATERIAL, TOOLS AND EQUIPMENTS)

Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat


Infrastructure The workplace of different artisans were different according to their income and on the basis of that it can be classified into two major categories: Financially well Artisans and Marginal income Artisans.

1.Financially well off Artisans Financially well to do artisans in Patan have two to three rooms as their workshop which is around 400600sft area and the flooring material used is Kota stone. It is Tough, Non- water absorbent, Non-slip and Non-porous properties make it the obvious choice of the crafts people. Also it is affordable and is available in all sizes. The work space is usually 10 to 11 ft high. One of the workshops has a small workspace on the upper level which is not well lit in terms of natural light. Although there is sufficient artificial light required for the gem setters to work, the area is improperly ventilated. SPACE WORK AREA STORAGE

ADMINISTRATION OTHERS

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DISCRIPTION • Work area of the artisans is generally a rectangle room and they keep the cylinder outside to heat tar so that fumes can go out and the room is free from suffocation. • Even artisans with bigger workshop face problem of insufficient storage place/ units. • No proper organized storage space; all open shelves with dust accumulation problem. • All the tools and equipments are put in the bags, so artisans need to search for particular tools every time they are working. • Some of the workshops like Harish bhai’s and Mukesh bhai have small storage spaces where they put all their accounts records or journals. • No Proper lighting in evening. • Less window space leads to insufficient day light and ventilation. • The spaces are not segregated according to the tasks. This affects the efficiency of the artisans. • Harish Bhai’s workshop does not have a wash area required for washing the metal. The artisans perform this task on the lane outside the shop, causing disturbance to the passer-by’s.

Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat


Common working area where embossing and finishing takes place

Artisans shining the copper angi on the street

Equippments for electroplating

Artisans working on stone/diamond inlay in metal

Cluttered Storage space

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2. Artisans livng with marginal income The general description of workshops owned by marginal income artisans is as follows: Small room with one entrance door and windows, which usually consist of one table which serves as a account desk with the storage below has all the documentation of work that has been done till now. Over head storage on all the four walls, small cabinets made within the walls to store tools and raw material as per work requirement.

SPACE WORK AREA STORAGE

ADMINISTRATION OTHERS

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DISCRIPTION • Artisans like Suman bhai and his brothers have a room around 100-200sft area, they take order from client and they try to work on site. • Overhead cabinets have good storage capacity even the unit in wall ‘aala’ has storage place but still there is need of storage as all the four brothers are working in the same workshop. • No proper organized storage space; all open shelves getting dust. • All the tools and equipments are put in the bags, so always one has to search for particular tool. • Less Raw material storage space. • A study table in the room serves the administration purpose, table have all the documents in storage below cabinates. • No Proper lighting in evening. • No proper distribution (segregation) of space according to the task. • Suman bhai doesn’t even have a proper wash area for the process of washing the metal with acid and washing the artifact after the process.

Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat


One room workshop of Panchal Brothers

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Materials Raw material usedfor metal embossing can be divided into two categories: Primary and Secondary depending on their utilization.

1.Primary Materials

• Wood is used to give volume to the object. • Metals used are copper, silver, brass, zinc and aluminium primarily as metal sheets. • The sheets are of varying thickness, which is measured in gauges—the higher the number of the gauge, the thicker is the sheet, and correspondingly, the lower the number of the gauge, the thinner is the sheet. • The sheets used in this region are in between 34-42 gauge thickness; in general for Cladding-34 gauge is used and for embossing 42 gauges serves the purpose. • Materials are generally used by artisans are as per the need and requirement of the clientele. • The metal is locally sourced from kalol or Ahmedabad.

Names

Appearance

Characteristics

Applications

Copper

• Copper is a reddish orange, soft metal that takes on a bright metallic lustre.

• Excellent ductility and toughness over a wide range of temperatures.

• Of all the metals, copper is majorly used for making the angi (ornamentation of the idol). • It is used in the sheet form according to the required gauge. • For metal embossing, the sheet is beaten on a tar mould of the idol, inorder to give it the required shape. • Once the angi is given the required shape, it is heated, scrubbed with mud and washed with water before electroplating it with German silver. • The artefact is then ready for decorative embossing and later finishing (polishing).

• It is malleable, ductile and an excellent conductor of heat and electricity. • Copper surfaces exposed to air gradually tarnish to a dull, brownish colour. • If water and air are present, copper will slowly corrode to form the carbonate verdigris often seen on roofs and statues.

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Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat


Names

Appearance

Silver

Characteristics

Applications

• Silver is a very ductile, malleable (slightly harder than gold), monovalent Coinage metal with a brilliant white metallic luster that can take a high degree of polish. • It has the highest electrical conductivity of all metals, even higher than copper, but its greater cost has prevented it from being widely used in place of copper for electrical purposes.

Silver itself is very expensive for making angi for large idols; hence it is usually used to make smaller articles like diays (lamps). However, In our study, we would not be dealing with the articles made completely in silver.

• Along with copper, the other metals like brass, zinc and aluminium are used for cladding carved doors, windows, chariots and other articles made in wood. • Once clad, the carving on the articles is retouched with the help of a chisel and hammer.

Brass

Brass is a yellowcolored alloy of copper and zinc. The more zinc in the metal the more yellow it appears.

•Is easily shaped, stamped and deep drawn. • It has fair electrical conductivity, excellent forming and drawing properties and good strength. • Different grades of brass, with different amounts of zinc, have different characteristics in surface smoothness, corrosion-resistance, ease and quality of machining, response to plating, ductility levels, chemical and temperature limits. • Brass is impervious to most common conditions, except for prolonged exterior exposure and substantial abrasion. • It tends to yellow from high temperatures.

Zinc

Zinc is a bluish-silver, lustrous metal that tarnishes in moist air, producing a layer of carbonate.

• Zinc reacts both with acids and alkalis. • Fair conductor of electricity and burns in air with a bright bluish green flame producing white clouds of the oxide.

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Names

Appearance

Characteristics

Aluminium

• Aluminium is a silvery white metal. • Its appearance is dulled and its reactivity is passivated by a film of aluminium oxide that naturally forms on the surface of the metal under normal conditions.

• Soft, durable, lightweight, ductile and malleable. • Non magnetic metal which does not easily ignite. • It serves as a good reflector of light and an excellent reflector of medium and far infrared radiation.

Names Sag

Technical Details Fine and moderately compact grains. It contains large quantity of fluid resinous matter or oil which prevents water logging and thereby safeguards it against timber-boring insects and also prevents rusting of iron.

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Characteristics It is hard, durable, glossy and smooth and shows compact textures. It is good for bold high relief carving and low relief carving. It is also good for undercutting and carving in round because of the arrangement of grains.

Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat

Applications

Applications Wood is used as the prime base material for cladding. The articles like doors, windows, chariots, donation boxes are first made in wood. Various motifs are carved on these items and then they are clad with sheets of metals like copper, zinc, brass etc.


Wood: Saag wood Wood is used to give a basic volume to the object. Traditionally wood is the material used for constructional purpose. Wood is used here for metal cladding, to make the initial structure of the product and then is carved which is finally finished with metal sheet stick on the carved wooden product for eg. Door, dan- peti, rath etc.

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2. Secondary Materials

Secondary materials include those materials which support the craft process or the ones which are added as embellishment. • Production material- Tar is used to form molds. • Finishing materials- Sand, Tamarind water, Silver water and Plaster of Paris • Embellishing materials-Stones or diamonds

Raw Materials Accessibility

•There is no system for Raw Material banking •Most of the materials are Available in local market and the rest they get it from Kalol and Ahmedabad. •Sometimes raw material is provided by clients.

Transportation of Local Materials

•For local transportation or purchase of raw materials, the artisans depend on self transportation. Most of the artisans own two wheelers like cycle or scooters. •For large scale purchase the artisans depend on hired rickshaw services.

Raw material costing (present day)

Material costing is totally dependent upon the recent rate of metal running in market.

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3. Tools and Equipments

• A large number of tools are used by the artisans of this cluster. • On the basis of their procurement the tools can be categorised into two types i.e. indigenous and imported. The former includes those which are made either by themselves or by the local ironsmith according to the specification, whereas the latter includes those designed and manufactured using machines, standardized and available in hardware shops. • The tools and equipments are by and large hand operated. • The number of tools spears large because of the variations of products and diversity of techniques being used by the artisans. • The requirement of tools also varies and depends upon the type of metal ware produced and the raw materials used.

Name: Farma Details: Farma is made using pencil, ink pens and sketch pens. Small sketches are converted into frama of real product size to be made. Each farma is customised according to design.

Name: Paper Mold Details:Paper mold is a type of farma has been developed for exact measurement of idol. Module is always made with high precision as ther is no scope of changes on later stage Layers of thin paper are glued on original idol using adhesives like fevicol

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Name: Katkona/Marking tool Details: These tools are made out of wood and are available in market, it is used for accurate measurement while making drawings on paper

Name: Mearurement tools Details: This tool is mainly used in measurement of circles, curves and arches. Sharped iron tip creates impression on metal sheet and scale guide for proper measurement

Name: Hathodi/Hammers Details: Used in various applications like beating metal sheets and nailing . They are available in various sizes and are used according to requirements

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Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat


Name: Chisels Details: These tools are used for embossing. It is available in various sizes, and can be used as required for embossing designs.

Name: Tools for Embossing Details: These are various tools used for rounding, flattening and nailing. It is used as per the details of the design

Name: Tongs Details: Tongs are made of iron and are available in different shapes. It is used in various processes, like holding heated metal sheets etc. It can be purchased from Ahmedabad.

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Name: Metal carving tool Details: These tools are used for carving on metal sheets. The tips ofthese tools are curved which helps giving curved shape to designs, deapth of curving depends on the amount of pressure given. It has to be sharpened frequently.

Name: Gunj Details: Border and edges are sharpen with help of aari and rubber is used as pad to prevent the sheet from extra pressure during hammering Name: Fillers Details: It is used to give finishing to the edges of product. It made of iron and contains different texture which helps to smoothen the edges. It can be used on wood also.

Name: Brush Details:After silver platting is done, surface is cleaned with metal wire brush, making it easy to clean corners and intricate designs

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Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat


Name: Poslishing tool Details: It is used for washing and cleaning the products before final finishing, it works on electricity and is easily available in local markets

Name: Finishing tools Details: This tools are used for final detailing of the products and giving it aesthetically appealing look.

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05 PROCESS OF CREATING PRODUCT

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Process Of Creation The three major categories of products that are made using metal embossing are Aangi, Back Drops, Doors/boxes. It involves various steps to reach to final product. Conceptualization and drawing is common step to start with in all three categories, it involves master craftsperson and client. Discussions on designs, patterns and cost at done to finalize the product. Designing is of products is based on available references like religious or holy books, photo catalogs and tracing papers.

Aangi making

Step-1 Paper mold: Paper mold is type of farma which is made for exact measurement of idol. Measurements is taken by pasting layers of paper with glue. At this stage high precision is taken as it is the base of design and there is no scope of changes at later stage

Step-2 Tar pouring: After the mold is ready the melted tar is poured inside the paper mold and it takes exact shape of mold creating hard surface.

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Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat


Step-3 Beating metal: In order to get proper shape, heated metal sheets are beaten with the help of tool called mallet, these metal sheets stick to mold due to melted tar and starts gaining the shape of mold.

Step-4 Heating: The tar is removed by heating metal mold giving proper shape to metal mold of Aangi.

Step-5 Finishing: After it comes into proper shape embossing, finishing and other detailing are done as per the finalized design.

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Back Drops

Step-1 Pasting drawing: The approved drawing is converted into 1:1 scale and later it is pasted on surface of board.

Step-2 Embossing:Embossing of basic and large designs are done with the help of hammer.

Step-3 Detailing: Melted tar is poured in back side of hammered metal sheet strengthening the surface for further detail embossing work.

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Step-4 Removing tar: Embossed metal sheet is again heated to remove the tar

Step-5 Finishing: After embossing edges and corners are finished with filer and other detailing is done

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Doors/boxes

Step-1 Pasting drawing: The approved drawing is converted into 1:1 scale and past on wooden surface.

Step-2 Machine carving: According to drawing pasted wood is carved with the help of router machine

Step-3 Hand craving: After cutting with router machine wood detailed carving is done with hand

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Step-4 Nailing and hammering: As per design, metal sheets of different thickness are then nailed and hammered which creates rough, raised and sunken surface of design

Step-5 Detailing: Different sizes of chisels and tools are used for detailed embossing and finishing

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05 PRODUCTS MADE BY ARTISANS

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PRODUCTS Introduction to cluster Products/services The products and services of craft cluster includes Metal embosing, Wood carving and metal cladding. Metal embossing products include doors, raths, backdrops, patala, aangi, dan peti, accessories etc Wood carving products like doors, backdrops, patala, dan peti. Metal embossing with meenakari and diamond work are done for doors, rath, backdrops, patala, aangi, dan peti, accessories.

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Related Craft forms Name of craftperson: Avindbhai

Name: Wooden sculpture Details: Sculpture made out of teakwood, intricately carved, finished with polish, varnish and / oil paints

Name: Statue of wood clad german silver Details: Statue made of wood and cladded with german silver. Glass colors and stone inlay is used for bearutification

Name: Household temple door Details: Carved wooden door clad with germna silver, brass and copper sheets. Figures, floral motifs and peacocks are prominently used

Name: Ornaments (Mukut) Details: Copper embossing finished with silver platting, decorated with the help of stone inlay and glass colors. The designs are customised accoring to Idol

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Name: Lamp Details: Lamp made of wood and cladded with german silver, available in designs generally animals and floral patterns. These are portable and height varies from 6’to 2’

Name: Frame Details: Carved wooden frame clad with germna silver, brass and copper sheets. It is customised and height varies from 1’ to 3’

Name: Charriot (rath) Details: Carved wooden and cladded with germna silver, brass and copper sheets. Adhesive and nails are used for assembling. Height varies form 1’ to 5’

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Name: Platform for God (sihasan) Details: Copper embossing finished with silver platting, decorated with the help of stone inlay and glass colors. Designs are customised

Name: Statue Details: Statue made of wood and cladded with german silver. Glass colors and stone inlay is used for enhancement

Name: For household temple Details: Made of wood and cladded with german silver, and brass sheets. Small floral patterns in borders and religious motifs are used

Name: Household temple Details: Wood carved and cladded with german silver, brass and copper sheets. Designs are customised. Height varies from 1’ to 3’

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Suggestive product ranges Structural / elements −Cladding on Columns −Doors, window panels with various combinations like partially embossed, full embossed, combined with other material. −Frames for doors, windows. −Grills, railings, stairs steps( patterns) −Ceiling panels −Wall claddings with/ without framing −Flooring patterns as inlays Product based −Furniture elements like chair back, hands, legs, table tops etc −bedding −curtain rods −knobs, latch, handles etc −lampshades −stands, costrel, accessories −memento, medals

Costing of Products/services

• Material-material costing is totally dependent upon the recent rate of metal running in market • Tools and equipments some of tools and equipments for the embossing and carving is made by the artisans themselves and some they brought from the lokhand market of Ahmedabad and from Kalol market • Infrastructure-infrastructure is different for different level of practicing artisans. Like harish bhai at one hand has three rooms and he employed 15- 20 artisans for their workshop. • Wages -60Rs a day for learners/helpers and 120 Rs a day for labour work. • Job Work- some of the artisans come for temporary work, head artisans hire them according to work they have ‘perution’ is the main season for these people to work so this time they hire maximum worker. • Conveyance-paid by client sometimes and sometimes by the master artisan.

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Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat


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Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat


07 ANALYSIS

Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat


1. Business Operations and Value Chain Analysis Infrastructure • The workspaces could be segregated according to various stages in the process of metal embossing. • A space where the craftspeople can gather for discussions with their clients. • Proper storage facilities for tools, raw materials as well as finished products. • A workspace for embossing and finishing the products. • A semi open space for activities like - heating the copper, scrubbing the angi with mud, washing the angi and electroplating. Raw material • Detailed research needs to be conducted for assuring the accountability and functionality of the raw materials if the cluster delves into other sectors like space making crafts. • Bulk purchase of raw materials will ensure cost efficiency and sustainable production process. • Raw material storage facilities need to be given more emphasis. Technology Units are working with traditional manufacturing techniques that are obsolete. Practically the tiny units of this cluster are not using any machinery and all operations are carried out by hand. Machines used without electricity can be introduced to make operations faster and can be popular through the cluster development program to make this cluster convert into mechanization. Though the hand skills passed down through generations must also be recognized and encouraged for preservation of traditional skills. Production Process • There are only 7-8 workshops catering to the needs of the religious sector. • Whatever be the volume of orders, the entrepreneurs in this cluster are able to meet that. • Sub contracting arrangement is widely prevalent in the cluster. Marketing • Products are marketed within and outside India. • The marketing happens through traders or dealers or direct client linkages within the religious sector. • In the area of globalization, the marketing activities of the entrepreneurs need to be integrated in order to capture more market

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Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat


share. • As the units are small it is almost imperative that networking is done in order to capture larger orders which will ensure economies of the scale and develop accountability of the entrepreneurs. • In the resent scenario, entrepreneurs can join hands, form a group and grab larger orders. • There can be brand building initiative where all the products can be projected under one brand name showcasing the USP of metal cluster in Patan. Human Resource • A majority of the enterprises are family owned. • The owner and other family members are the manager, operator marketer, technician and negotiator. • There is hardly any qualified people recruited from outside or services of any consultant used in the cluster. As a result no new ideas are added on and the entire process has remained traditional. • Level of awareness of the entrepreneurs, especially in technical and marketing areas is not as high as it should be.

2.Quality of Products/services Materials • Wood: Wood is generally used as a base material for making donation boxes (Daan Peti), doors, windows, chariots (Rath) etc. for the Jain Temples. These objects are carved out in wood and later, sheets of various metals like zinc, copper and brass are clad on the objects by beating and nailing them on the wood with the help of a mallet. Teak wood is widely used for the base materials as it is easy to work with. • Copper: Copper is one of the prime materials for both - ornamentation (Angi) of the Idols as well as for cladding the wood based items. It is a ductile metal with very high thermal and electrical conductivity. Pure copper is soft and malleable; an exposed surface has a reddish-orange tarnish. • German silver: German silver is an alloy of copper with nickel and often zinc. The metal is named for its silvery appearance, but contains no elemental silver unless plated. The reason German silver is preferred is that it has a good machinability (the ease with which a metal can be machined to an acceptable surface finish) and is corrosion resistance. • Brass: Brass is an alloy of copper and zinc. The proportions of zinc and copper can be varied to create a range of brasses with varying properties. Brass has a muted yellow color which is somewhat similar to gold and is often used as decoration. It is softer than most other metals in general use and is relatively resistant to tarnishing.

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Design • For both embossing on copper and for the cladding on wood, the designs for ornamentation are hand drawn by the artisans. • Illustrated Jain epics are usually the reference for designing the story plates. • The most common motifs found in wood carving are flowers, leaves, peacock, apsaras, kalasha etc. • As the cluster has been catering to a particular group of clientele over a long period, there are no new design variations.

Functionality

Angi: Angi is made for the purpose of ornamentation for the idols in Jain temples. Hence the purpose of the products is more of ornamental than functional. Woodcarving: Whenever the items like doors, windows, chariots or the donation boxes undergo wear and tear, they are brought back to the workshop where first, the plated metal is separated from the carved wood and is sent to scrap. The already existing wood carving is then retouched, and new metal plates are clad on it.

Conclusion

Metal Embossing in Patan is a traditional craft form that dates back to almost 200yrs. This craft form is practiced exclusively for making products for the Jain temples. As most of the products (Angi, story plates, donation boxes, chariots etc) are related to God, the artisans make sure that they only use good quality materials be it wood or metal.

3. Related Sub Clusters

Wood carving: Wood carving is one cluster that is closely related to metal embossing. The products like donation boxes (Daan Peti), doors and windows, char iots (Rath) etc. which are made for the Jain temples across the nation, are first carved out in wood and later, clad with sheets of various metals like zinc, copper and brass. Some wood carving artists are hired by master artisans as per requirement while others like Navinbhai Prajapati and Arvindbhai Prajapati have their own workshops where they work independently as per the placement of orders.

4. Business Development Service (BDS) Analysis

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Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat


• Associations • The artisans work independently on all their assignments. Sub contracting is done within the clusters through the job workers. • Private Organized BDS Providers: • The artisans receive orders from Jain temple trusts all over the nation and at times from the trusts overseas as well. • The artisans have their workshops near the Panchasara Jain temple. Hence the artisans regularly provide services to the Panchasara Jain Derasar trust situated in Patan. • Private unorganized BDS Providers • All the metal embossing artisans of Patan, collect their raw materials and tools from various suppliers in Kalol and Ahmedabad (manek chowk) respectively. These suppliers form the major unorganized BDS Providers.

5.Performance/ability of the cluster • Historical Performance Metal Embossing is a traditional craft-form practiced in Patan for over 200 years now. The artifacts produced using this technique are primarily related to the Jain religion and are made exclusively for the jain temples. The products include – ornamentation (known as Angi) for the idol, chariots, doors and windows, donation boxes, narratives on metal sheets and many such objects. • Geographical Location Of all the places in India, Jainism has had the most significant influence in Gujarat. This craft form is practiced exclusively in Patan, a small town in the Patan District situated in the Northern part of Gujarat. All the workshops of all the artisans’ practicing this craft form are located near the Panchasara Jain Temple in Patan. • Setbacks faced by the cluster Drawbacks in Infrastructure Although the cluster is well established, and most of the artisans work independently, the workspaces are not very well organized. The workshops also lack proper storage and drainage facilities. • Lack of Technological Know-How The artisans work manually during most stages in the process of metal embossing. While technological advancements in terms of machines and equipments could help cut down labor intensive work, there is

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limited intervention in that area. •Before making every new product, the artisans first sketch the article on paper, at times in the same scale and proportions, which makes the task time consuming. There are a few artisans who own laptops and computers, but are unaware of soft-wares that could help them simplify the design process. • Aspects favoring the cluster • Monopoly in the market • The metal embossing cluster of Patan is one of its kinds. The articles produced by the artisans cater to Jain temples across the nation and the craft form is practiced exclusively in Patan. • Inherited Skills • The craft form is over 200 yrs old. The artisans practicing metal embossing are familiar with the materials and techniques and are skilled in their area of work.

6. Development Challenges • Equity & Growth Lack of Education as well as Institutional Linkages Metal embossing is a traditional craft form therefore the skills and techniques associated with the craft are all manually performed. Due to Lack of education as well as awareness, the artisans are unaware of the technological advancements in terms of machineries and equipments that could help in cutting down the labor intensive tasks involved while working. Limited Market As the products are primarily made for the Jain temples, the range of the products is limited. This in turn leads to a limited market, thereby hindering the growth of the craft. • Design Metal embossing is a traditional craft related to Jainism, a very prominent religion practiced all over the nation and specially in Gujarat. Due to the religious aspect of the craft, artisans refrain from taking initiatives to make any kind of design interventions to the craft. • Market The limited range of products puts this craft form in a limited market. Besides, the only means through which the artisans acquire clients is the word-of-mouth. According to most artisans, they get ample amount of work form Jain temple trusts all over the nation and they do not feel the need to promote their craft form through any other means. Hence

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the craft form has not attained the kind recognition it should have. Capacity Building Although craft form falls under well established clusters, the infrastructure needs to be improved to a great extent. Due to the shortage of space, some of the activities involved in making the products are carried out on the streets, often causing trouble to the passerby’s. A well organized workspace can lead to increased work efficiency. • Institutional Linkages Even though it is a flourishing craft, it has a limited market. Also due to the lack of interest shown by the artisans towards marketing the craft form, the craft is not very well recognized among general public, and also fails to attract the attention of various Institutions, working with which could probably help the craftspeople in taking their skills to the next level.

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7. Analysis of key issues & suggested solutions in business operations BDS Area Infrastructure

Major issues The area of the workshops is insufficient for the scale of the work that is done. In most of the workshops, there is no segregation of spaces and the whole procedure right from preparing the mould to finishing is carried out within two small rooms. Also, at certain workshops, the activities such as heating the tar and copper; and washing the products, is carried out on the streets.

Raw material

The raw materials are usually bought by the clients themselves, hence there are no major issues related to materials. Due to lack of education and awareness, the craftspeople are unaware of the technological advancements in terms of techniques and machinery. Although a few of them possess laptops and computers, the artisans are not aware of soft-wares that could help them simplify the design process.

Technology

HRD

Quality control

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The demand of these products increases during the Jain festive season (Payushn). The workshops need to hire extra help almost six months before Payushn. This is the period when young artisans are hired. Once the work load decreases, they work at other places for the next six months before returning during the peak season. As the artisans are not in constant touch with their work, it takes a lot of time for the young artisans to master the skills and techniques. Hence, the consistency in the quality of the products is affected to a great extent.

Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat

Suggested solutions A larger, adequately lit and well ventilated area should be provided. Spaces in the workshop should be segregated as per different functions for example: Office; Wood carving area; Metal Embossing area; an area for heating the tar and copper; an area for storage etc. Proper drainage facilities should be arranged for.

Institutional linkages can provide the artisans with an opportunity to interact with designers and exchange their views on the craft form. It would also for the artisans, open a window to the happenings in the field of design. Short period workshops can be conducted for the artisans in order to teach them various soft-wares.

Introduction of new range of products can help generate a constant work flow throughout the year, thus providing the young artisans with an opportunity to polish their skills and learn the techniques.

Working on the same craft for a longer period of time would help the artisans to get a grip on the skills and this would in turn lead to consistency in the Quality of the goods produced.


BDS Area Market

Major issues Although the market is very strong, the products cater to only a set group of clients that is, the Jain temple authorities.

Suggested solutions Introducing a new range of products can help expand the clientele.

A. DERIVATIONS 1. SWOT ANALYSIS STRENGHT Parameters Products

Strengths Majority of the products made by these artisans are for the Jain temples.

Implications Metal embossing is a traditional craft form, being practiced for over two hundred years now. Its religious association makes it an established craft form. This factor acts as a huge time saver and also plays a major role in maintaining consistent quality of the products. The location of clusters near one another simplifies the process of cluster formation.

Infrastructure

Once the raw materials are brought to the workshops, the whole process takes place in the same workspace. All the artisans practicing this craft are located close to one another.

Raw Material

According to the artisans, the materials These factors play a prominent role in used in the process are all of the maintaining consistent quality of the best quality as the product range is products as well. produced for the use of temple. Besides, the client themselves buy the raw materials and send it to the artisans.

Technology

As the artisans follow traditional techniques, the process of metal embossing uses technology in a minimal manner. At present the only way in which the artisans use technology is in the form wood cutting saws.

This factor points out the fact that the cluster is rich in Traditional skills and that technology is used to cut down the labor intensive work.

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Parameters Human Resource

Strengths Human resource is easily available. There are a few artisans who have opted for this craft over their family business. For example, Nitishbhai Panchal chose metal embossing over his generations old family profession of Jewelers.

Implications

Quality

Metal embossing is a traditional craft form. The raw materials required for this craft are expensive and the clients themselves buy and send the raw materials to the artisans. The articles produced by theses artisans serve a religious purpose.

Being a traditional craft form the artisans practicing this craft are highly skilled. As the clients themselves buy the required raw materials, there is no issue of artisans using inferior quality materials. The artisans are God fearing and as the products serve a religious purpose, they work with utmost sincerity.

Markets

The present product range caters to the religious sector. The ornamentation of idols in the temples is changed every year during Payushn. Energy & Envi- Over the period of time, when the ronment wood based designs undergo wear and tear, the products are brought back to the workshop. The metal is scraped off and sent to scrap but the wood is re-worked on, the patterns finished; and clad with new metal sheets.

This craft form is being practiced for over 200yrs. The religious association plays an important role in its steady demand in the market. Thus reusing wood instead of altogether discarding the old products and making new ones.

WEAKNESS Parameters Products Infrastructure Raw Material

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Weakness The products are made for a fixed group of clientele. The most prominent factor is shortage of space. This often leads to The raw materials (German silver, copper and brass) are too expensive for the artisans to buy themselves. They are brought to the artisans by the clients.

Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat

Implications Hence the range of products is limited. This often leads the artisans to extend their workspace to the streets. Due to this reason, the artisans have to be very calculative in terms of measurements and need to work with a lot of precision.


Parameters Technology

Human Resource Quality

Markets

Information & Communication Technology

Weakness At certain workshops, technology is not at all used in the making of products. Most of the artisans are part time workers.

Implications This makes certain parts of the process very labor intensive.

Therefore, over the period of time, the products from the same workshop lack consistency. Human resource affects the quality of Although the materials used are of superior products. quality, the inconsistency in maintaining the human resource does affect the quality of the products. For the local people, there are limited Although the craft cluster is an established products to choose from, as most of one, because of its limited market, the craft the products cater to the religious form is not recognized to local people. sector. Even though some of the crafts Therefore they are unaware of the means of people have an access to computers advertising which could give recognition to and technology, they lack the their craft. knowledge and understanding. The lack of interaction with designers prevents Also they are not linked to design them from knowing the possibilities of future institutions in any manner. development of their craft form.

OPPORTUNITIES Parameters Products

Infrastructure

Raw Material

Strengths There already is a fair amount of knowledge in terms of skills and techniques. The artisans are located close to one another. They are all located around the Panchasara Jain temple in Patan. The crafts person are used to working with limited materials but have mastered the skills and techniques.

Implications Therefore there is a possibility of expanding the range of products. This can help simplify the process of cluster formation. Therefore there is a scope of introducing new materials along with new designs.

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Parameters Technology

Strengths Some of the artisans use a few electronic equipments and have an access to technology in terms of computers and laptops. They have also shown very keen interest in learning these devices.

Human Resource

Lot of young people in town show interest in working with the craft from.

Quality

Markets

Implications Use of electronic equipments would help decrease the labor intensive work and help the artisans to focus on the skill part. With the help of computers, soft-wares, internet etc. they would be exposed to contemporary happenings.

Therefore if the artisans are trained well and work at the same place for a longer period of time, there are possibilities of improved skill levels. Human resource affects the quality of Human resource and quality are interrelated. products. Hence, Improved skill levels would in turn lead to better quality products. The craft form has an already a steady Hence there is a possibility of introducing new market, a fair amount of business designs and space making elements using understanding is present among the different (cheaper/affordable) metals while artisans. retaining the current techniques that the artisans work with.

THREATS Parameters Products

Strengths The current product range and the market are limited.

Infrastructure

The limited amount of space affects the efficiency of the artisans. It also limits the size of the products to be worked on by the artisans. The raw materials used in the craft form expensive and hence the products made out of them are limited to the interiors and are small in size.

Raw Material

Technology

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There is a lack of education and information.

Diagnostic Study Report on Metal Craft Cluster of Patan, Gujarat

Implications Therefore, if at all the market sees fall in demand of the product in the future, the artisans would not have any other products to bring to the market. The space restrictions could hinder the orders of large scale products.

This provides the products; a limited product range and in turn a limited market.

Due to this the artisans are unaware of the current happenings in the markets. It also hinders technological advancements.


Parameters Human Resource

Quality

Markets

Strengths Most of the young artisans who currently practice the craft form work on the craft only during the peak six months. Human resource affects the quality of products. The product has limited market and the craft people are not exposed to the contemporary design requirements.

Implications Due to the lack of continuously working with the craft for a longer period, there is no uniformity in working with the products. As the human resource and quality are interrelated, the inconsistency in the former would affect the latter. Hence, if at all the demand for the current products falls, the artisans would not have any other products to replace the former in the market.

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Design Innovation and Craft Resource Centre (DICRC), CEPT University, Ahmedabad Contact :+079-26302470 Ext- 380, 381 , email: dicrc@cept.ac.in


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