DESIGN INITIATIVES FOR FIROZABAD GLASS CLUSTER Written and compiled by Ms. Neelima Hasija
DESIGN INITIATIVES FOR FIROZABAD GLASS CLUSTER
Written & compiled by Ms. Neelima Hasija
First published in India in 2012 by National Institute of Design Š 2012 National Institute of Design, Ahmedabad Department of Science and Technology All rights reserved. no part of this publication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission of the copyright owner. ISBN: xx-xxxxx-xx-x Written by Ms. Neelima Hasija Designed by Ms. Dhwani Shah Set in Mrs Eaves and Panefresco Printed on Art paper, Matt, 160 gsm
ACKNOWLEDGEMENTS
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Design Initiatives for Firozabad Glass Cluster
NID-DST COLLABORATION
NID is recognised by the Department of Scientific & Industrial Research (DSIR) under Ministry of Science and Technology, Government of India, as a scientific and industrial design research organization. NID's graduates have made a mark in key sectors of commerce, industry and social development by taking role of catalysts and This proposal was initiated in response to the discussion held at the Department through thought leadership. of Science and Technology (DST) Department of Science and Technology meeting at INSA, Delhi. Based on the Department of Science and Technology discussion the proposal for cluster development through Design interven- (DST) was established in May 1971, with the objective of promoting new areas tion was formulated by the Ceramic of Science and Technology and to play and Glass design discipline of National the role of a nodal department for Institute of Design (NID). organizing, coordinating and promoting S & T activities in the country. The National institute of Design department has major responsibilities (NID Ahmedabad) for specific projects and programmes National Institute of Design (NID) and supports institutions and organizis internationally acclaimed as one of ations to partake in its responsibilities the foremost multi-disciplinary instifor the country's development, considtutions in the field of design education ering its core objectives. Ceramic and and research. The Business Week, USA Glass Discipline at NID has been has listed NID as one of the top 25 supported for its “matters relating to European & Asian programmes in the institutional Science and Technology world. The institute functions as an autonomous body under the department capacity building including setting up of new institutions and institutional of Industrial Policy & Promotion, infrastructure” and “design and deveMinistry of Commerce & Industry, lopment” endeavors. Government of India.
CONTENTS
1/ The Project / pages 6-13
Background (p.8-9) Approach & Methodology (p.10-13) 2/ Field research and Inferences / pages 14-17
Identified needs & opportunities (p.16,17) 3/ Flame work Artisan Cluster / pages 18-29
Existing Infrastructure (p.20-21) Design Intervention Activities (p.22-23) Design Intervention Outcome (p.24-29) 4/ Mass produced Consumer Glassware Industries / pages 30-41
Existing Infrastructure (p.32-33) Design Intervention Activities (p.34-35) Design Intervention Outcome (p.36-41) 5/ Industry based on “handicraft blowing, cutting, engraving etc.� / pages 42-49
Existing Infrastructure (p.44-45) Design Intervention Outcome (p.46-49) 6/ Conclusion / pages 50-51
Design Initiatives for Firozabad Glass Cluster
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THE PROJECT Product Developement Initiative for the cluster of glass industries of Firozabad. Objective of the project was to research and identify challenges and nature of design intervention required for the development of micro, small and medium scale glass industries and its challenges. This project specifically focused on Firozabad, a district located in Uttar Pradesh, one of the northern states of India.
Task also focused on creating awareness amongst the aforesaid unorganized cluster about utilization of design and the competitive advantage of original designs. Moreover, this project also encouraged close co-operation between the academics and the industry; anticipating long term benefit for the cluster's development.
Design Initiatives for Firozabad Glass Cluster
Background Firozabad, “The Glass City”Firozabad is located in the northern state of India, Uttar Pradesh, one of the largest and most densely populated states. A fairly large part of the country's unorganized small scale glass production (almost 70%) is concentrated in Firozabad district. The town has a natural cluster of labor-intensive small -scale glass producers of tableware, container glass, mouth blown handicraft ware, bangles, beads, toys etc.
Meerut Delhi
Moradabad Ghaziabad Aligarh Firozabad Lucknow
Jaipur Kanpur Jhansi
Also called “the glass city” is considered to be the largest cluster of small-scale glass industries in the world with around 421 registered small and medium enterprise. Amongst these 190 units are in running condition. Besides tableware and bangle making industries, there are clusters of flame work artisans located in and around the city making toys, figurines, accessories etc. Historical BackdropThere are indications which reveal the existence of glass in India around 2000 years back. Several objects and artifacts have been found providing such strong evidences. Glass making as an activity was never confined to a particular community or caste as any other traditional craft practices in India. It was being practiced by several communities located across the country.
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However, Firozabad as a cluster got formed much later and actualized in the regime of Mughals to support their need of utility products and artifacts made in glass. The ancient name of this city was Chandwar Nagar, while Firozabad as a name was given in the regime of Akbar by Firoz Shah Mansab Dar. Bangle making was probably one of the first techniques which got introduced to this cluster, followed by blowing, engraving, cutting etc.
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The state map of Uttar Pradesh showing Firozabad
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Shops in the Bangle market
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A variety of colorful glass bangles on display at a shop
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Glass market area near Firozabad Railway Station
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Firozabad is also popularly known as “Suhaag Nagri� owing to the fact that the cluster in-houses the production of chudi (glass bangles) which is one of the significant part of a married women's (suhaagin's) assemble. 4
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Presence of high level of skills for blowing, cutting, engraving, polishing, toy and jewellery making with the help of torch work, etc. are still visible in the cluster, however limited to a very few production setups. The entire region is engaged and in one or the other way earns through this material's production. Besides, it is estimated; around 2 lac skilled and semi-skilled workers practicing glass come to Firozabad city from nearby villages with the purpose of work and return back late in the evening; bangle industries, being the largest employee for these workers.
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Design Initiatives for Firozabad Glass Cluster
Approach & Methodology The entire project was spread over two years. Numbers of factors were considered to generate productive results from this process; Several field visits were made to Firozabad with the purpose of forming a better understanding of the sector in terms of its skills, techniques, market linkages, available technology, work culture etc.
APPROACH IN A NUTSHELL
Based on this brief survey, Firozabad sector was categorized into sub-clusters, on the basis of manufactured goods. In addition, many other macro as well as micro aspects of these categories such as existing infrastructure, level of skills available, quality of raw material, recycling of raw material, connectivity with other organizations such as the Government as well as NGO's etc. were also identified and defined.
- Interaction with the government and NGO’s
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- Field visits for research - Identifying the clusters
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Active participation by post graduate students of Ceramic & Glass Program, NID and Design Associates, in this process supported the mammoth task of collecting and collating data as well as bring back understanding and insights from the cluster for further developments in the area. Since the beginning, the process encouraged participation of the Firozabad industry through close interaction. The industries and other sub-clusters were identified within the first 6 months of the commencement of the project and were closely associated and
- Collaboration with glass industries for new production possibilities - Workshops and seminar with the craftsmen for adding value to their existing product range
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Visiting the home of a flame work artist in Dhoukeli
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Field Visit to the village of Dhoukeli
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involved for feedback sessions at regular intervals. Insights generated through this process helped in holding workshops and also develop a new product range, addressing the requirements of the identified consumer.
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A flamework artist sharing his views at the seminar
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Discussing scope of collaboration with glass industries
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Workshop with flame work artists at NID
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Seminar for glass industry owners
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Flame work artists visiting NID
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Field visit to an export glass industry
Design Initiatives for Firozabad Glass Cluster
Approach & Methodology Product development was based on intense research and the information generated from the essential sources brought in insights to support the envisaged outcome and hence to marginalize the risk involved towards the success in its execution.
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The Design seminar offered in the cluster helped in sensitizing the industry with design process established for and from within their environment and with great deal of understanding towards their work culture. Being an academic institute and grooming the potential design professionals for the sector, continuous involvement of the interested students and fresh graduates was encouraged. This helped the students and the involved graduates to ascertain in-depth understanding of the possibilities and limitations of the MSME cluster and also sensitized them towards its work culture. The resultant is; number of graduates working closely with the producers in the cluster and adding value to its design vocabulary. Timely interventions by PRC committee at regular intervals also helped in bringing clarity towards the approach and process being followed.
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Participants of the design enhancement capability workshop
2 Mr. Rajesh giving
a demonstration of his skills 3
Student-craftsmen interaction, learning from each other
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A stall was arranged and facilitated for the flame work artists at the Dilli Haat to enable them to sell their products and also help them connect directly to the end user as well as understand market requirements 5
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Flame work artists along their stall at the Delhi Haat
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Flame work artists with their wares at the Dilli haat
Design Initiatives for Firozabad Glass Cluster
BANGLE MAKING
FLAME AND LATHE WORK
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FIELD RESEARCH
CONSUMER BASED GLASSWARE INDUSTRY
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IDENTIFIED CATEGORIES
HANDICRAFT BLOWING
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INFERENCES Through field research, Firozabad was classified under four distinct categories taking view of skills and techniques available in the cluster.
Field research helped in analyzing and identifying with the strengths, weaknesses and opportunities of the cluster as well. Project closely engaged itself with three of them for design and skill development, considering the potential & effectiveness. These categories are as follows:
1. Flame work artisans located across Firozabad. 2. Mass produced, consumer ware glass industries. 3. Industry based on “handicraft blowing and cold processes for surface finishes and decoration such as cutting, engraving etc.�
Design Initiatives for Firozabad Glass Cluster
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There is a visible dearth of indigenously designed and developed good quality glass products from India. With the lack in good designs and product innovation the glass industries merely remain an outsourcing manufacturing units for the national as well as international market. Also, glass industries in India has been facing a major setback because
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of infiltration of Chinese manufactured goods at much lower cost or consumers reach to better quality goods from other countries. However, the strengths which this cluster of MSME in the country withholds; such as skilled artisans, possibility of batch production or mass production, blowing / flame work techniques possible under the
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Map indicating identified clusters in Firozabad
same backdrop, linkages with the Moradabad brass industries, market linkages with international markets cannot be overlooked. Considering the above strengths it is critically required to further brand it as “Designed in India” as a by word for quality and utility in parallel to “Made in India” and earn value through “Design”
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INFRASTRUCTURE
SKILLS AVAILABLE
STRENGTHS
CHALLENGES
Pot furnace
Mould blowing and free blowing
Manpower and variety of skills
Not directly in touch with the user
Cutting and polishing
Craftsmanship
Lathe Equipment
Sand blasting
Torch Work
Acid etching
Mass and batch production possible in the same backdrop
Glass cutting
Glass casting
Glass Polishing
Lamp work
Tank furnace Automated Plants
Linkages with Moradabad brass industries
Quality of raw material Standardization of tolls, material and work flow Critical ergonomic inputs for tools and work space
Lathe Work Cold Bending Bangle Making Slumping and fusing
Lack of innovation and originality Firozabad as a brand yet needs to mark its identity
Design Initiatives for Firozabad Glass Cluster
1. FLAME WORK
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ARTISAN CLUSTER Flame work artisans are located in small pockets across Firozabad and each of these smaller clusters displays its own specialized technique, product range and market. The flame work artisans are located in small pockets across Firozabad and each of these smaller clusters displays its own specialized technique, product range and market. Very few artisans from each cluster are directly connected with the market; most of them have reach to the market through the visiting buyers for the domestic market. It is practiced as a cottage industry where the artisans work with very low infrastructural setup
established within their residences. The setup includes an indigenously manufactured torch as equipment; which is fueled by LPG cylinders and Oxygen cylinders and some minimal locally made tools. The number of artisans employed through this craft based produce is quite large. Around 250-300 families in Firozabad are self employed and earn their living through this process.
Design Initiatives for Firozabad Glass Cluster
Existing Infrastructure
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These clusters can be further classified under two main categories, considering the raw material they use for making of the artifacts. Artisans residing within the city of Firozabad in the localities named Khushwaha Nagar and Railway Colony work mainly with Borosilicate glass (procured from China), while the one's located in Jain nagar produce jewellery for tourist market in soda lime glass (procured from the local manufacturers). The artisans located on the periphery of the city can be found in smaller villages such as Dhonkeli and Langhi. These clusters specifically practice with Soda lime glass and both clusters product range is distinctly different from each other.
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A flame work artisan from Dhoukeli.
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Tools used by flame work artisans.
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Small sized moulds for shaping glass.
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The products being produced by these clusters range from figurines, glass jewellery to souvenirs such as glass stirrers etc.
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A sample of existing product range of flame work artisans
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Ganesh Idol created by one of the flame work artist
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Design Intervention Basis the identification of the flame work clusters across Firozabad, couple of artisans from each cluster were selected for an initial workshop held at NID, Ahmedabad. The objective of this workshop with identified skilled and semi skilled flame work artisans were to explore and gauge the potential of product development for the contemporary market and its requirements. The workshop focused was more towards understanding their skill levels and training requirements.
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These workshops spread over number of months, engaged with variety of groups also helped in consolidating a product range considering the realistic scenario in terms of skills, techniques, sensibilities, available infrastructure and market connect.
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Flame work artisan working along with a Nid student
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Flame work artisans in discussion with some students.
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Flame work artisans demonstrating their own skills.
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Following this, a workshop was offered by the designers and design students of ceramic and glass discipline, NID at Firozabad itself. This workshop had around 10-12 artisans practicing with both the types of glass. Here, it helped to disseminate the developed range to a larger group of artisans and also bring in visibility towards the ongoing project for the cluster itself.
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Some more workshops held at NID included larger number of artisans. They were invited to Ahmedabad. The objective and focus of these was to provide exposure to the newer market's, contemporary requirements and to the process of design, including new products and forms been developed.
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Skilled craftsmanMr Rajesh at work.
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Students & artisans working together
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The participants of the workshop.
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Discussing the output of the workshop
Design Initiatives for Firozabad Glass Cluster
Design intervention outcome
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A colorful range of Glass jewellery items-earrings and pendants
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A set of few small animal glass toys and figurines
Design Initiatives for Firozabad Glass Cluster
Design intervention outcome
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Glass Napkin Holders
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Glass Stirrers
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Glass button accessories
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Glass Tea Light (Candle holder)
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Fish visiting card holder
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Fish visiting card holder in use
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A show piece of Lord Ganesha with agarbatti holder
Design Initiatives for Firozabad Glass Cluster
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Glass Accessories for an aquarium
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A variety of glass flowers
Design Initiatives for Firozabad Glass Cluster
2. MASS PRODUCED
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CONSUMER WARE GLASS INDUSTRIES Also called “the glass city,� Firozabad is considered to be the largest cluster of small-scale glass industries in the world with around 421 registered small and medium enterprise. Amongst these 190 units are in running condition. Production of domestic glass ware such as tableware, tumblers, jars etc. came in much later to the glass manufacturing units of Firozabad. However, at this moment it does seek lot of attention from the domestic market. With gas
pipeline coming in, it has remarkably improved the quality of glass being produced in this cluster and has also helped the industry to sustain the tough competition posed by the organized sector from within the country.
Design Initiatives for Firozabad Glass Cluster
Existing Infrastructure 3
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Brands like lazer and eagle have captured a considerable percentage of the domestic market, specifically the lower and middle segment of the consumer market as well as the hospitality segment. The manufacturing process followed by these industries ranges from mouth blowing in moulds, machine blown and press molding methods.
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Traditional Bhatti or furnace
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Old Glass moulds stored
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Glass blowing in moulds
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Machine blown glass
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Packing the mass produced glass jars
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Worker using press mould
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Press mould in use
Design Initiatives for Firozabad Glass Cluster
Design Intervention Approached several industries, identified the appropriate one considering their interest towards collaborating and participating in this DST project for the first phase of product development. “Firozabad Ceramics Private Limited� officially endorsed themselves as a collaborating industry in this project. A brief study of their existing brand identity was made through market visits and user interaction. As a preliminary project, a range of surface ornamentation was generated for the industry. This gained appreciation from market reflecting on the sales of the season. Industry also showed keen interest in further involvement and investments in the project towards product development in the area of tableware. A new range of drink ware, tableware, snack platters etc. have been developed for domestic market.
A few samples from the range of surface ornamentation generated for the industry by the students at NID.
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Table ware was designed for Indian users considering and optimizing the need of Indian regional cuisinessnack plates, vegetable and soup bowls, dessert bowls etc that were stackable and also ergonomically fit.
Design Initiatives for Firozabad Glass Cluster
Design Intervention Outcome
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Plan view of the bowl
Section view of the bowl
Elevation of the bowl
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A set of dessert bowls designed for Eagle Glass Deco Pvt. Ltd.
Design Initiatives for Firozabad Glass Cluster
Design Intervention Outcome
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Plan view of the bowl
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Elevation of the bowl
15 modules@ 24째
pressed pattern
Volume: ~ ~ 20 OZ pressed pattern
biggest grain mercury texture
Module for graphic in press molding (scale 1:1)
smallest grain mercury texture Biggest grain mercury texture
Section view of the bowl
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A set of bowls designed as a part of a dinner set for Eagle Glass Deco Pvt. Ltd.
Design Initiatives for Firozabad Glass Cluster
Design Intervention Outcome Plan view of the plate
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R 50
R 30
Patterns on the plate
Arrangement of the plates
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A set of four snack plates designed for Eagle Glass Deco Pvt. Ltd.
Section view of the plate
Elevation of the plate
Design Initiatives for Firozabad Glass Cluster
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3. INDUSTRY BASED
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Firozabad displays high craftsmanship in the technique of cutting, polishing and glass blowing. Handicraft blowers, who can blow independent of moulds, have reduced considerably, while the one's who blow in moulds are still present in large numbers. Availability of the variety of skills and craftsmanship within the cluster provides a good platform to the export houses an edge to sustain in this competitive environment. Large section at EPCH (Export Promotion Council of Handicrafts, NOIDA centre) has representation of handicraft based glass producers from Firozabad. Apart from merely producing the designs
shared by the international buyers, Firozabad units/export houses do offer their new/original designs each season through IHGF (Indian Handicraft & Gift Fair) for the visiting international vendor. This, if approved does get a place in the international market, though it rarely carries its Indian brand to the global retail space; hence, posing limited visibility to its Indian origin.
Design Initiatives for Firozabad Glass Cluster
Existing Infrastructure Pot furnaces as well as tank furnaces are being equally utilized by these production units. However, the number of pot furnaces (essential to achieve variety of coloured glass at the same time) have declined substantially in Firozabad, considering the high operation cost; giving way to tank furnace and hence posing limitations in terms of achieving coloured glass. Though, this has been considerably overcome by techniques of spraying colour, luster application etc. however; at the cost of essential methods and techniques of producing coloured glass.
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A worker at the Glass factory
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Workers at cutting & polishing area
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Griding and Finishing
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Workers involved the silvering process
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A worker shaping a glass vase
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Coloured glass bowls
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An intircately cut glass bowl
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Various glass cutting, polishing, silvering etc processes being employed in creating coloured glass products.
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Design Initiatives for Firozabad Glass Cluster
Design intervention outcome
A few meetings and discussions with the independent groups of handicraft blowers, ranging from master craftsmen (glass blowers, engraver etc.) to skilled and semi skilled artisans was made. The purpose was to bring in understanding towards their way of working with Firozabad industries, clients, distributors etc. A visit to IHGF (Indian Handicraft and Gift Fair) event was also made to gauge contemporary trends, export
requirements and the potential of Indian industries and available skills for the export market. These visits also helped to identify the appropriate industries, dependent on handicraft blowing; to connect them to the project and invite them in to participate in the entire process of development through design.
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Activities here, focused more on design intervention in the export market. A range of tea lights and Christmas tree accessories was developed.
Design Initiatives for Firozabad Glass Cluster
Design intervention outcome
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Design Initiatives for Firozabad Glass Cluster
IN CONCLUSION
Overall the project was aimed at developing new designs for the MSME cluster of Firozabad. However, looking back, in the hind sight outcome and the impact has been in manifolds. This project in true sense gave NID n opportunity to understand the unorganized glass based sector of the country and chalk out a design approach for the cluster. It helped in forming a better understanding of the work culture and complex interdependent structure of the cluster as well. This, in a long run will be of good academic value to the discipline and the students pursuing ceramic and glass.
Š 2012 National Institute of Design, Ahmedabad Department of Science and Technology
ISBN xx-xxxxx-xx-x
Department of Science and Technology Ministry of Science and Technology Government of India