bamboo incense stick cluster, nalbari

Bamboo Incense Stick Cluster, NalbariNeed Assessment Survey Report

for DCS-MSME2013

submitted by

Mridul Mitra

N.A.S for Bamboo Incense Stick Cluster, Nalbari | 2013 | Mridul Mitra, Design Consultant, [email protected]


My experience of conducting the Need Assessment Survey for the Bamboo Incense Stick Cluster at Nalbari, has been one of learning and fulfilment and was made possible by the support and goodwill of a wonderful team of people.

I would like to express my heartfelt gratitude to Ms. Nilufar Sheikh, Project Officer of the North-East, DCS-MSME, NID, whose energy, enthusiasm and support have helped me every step of the way.

I would like to thank Mr. Dibakar Thakuria, Extension Officer, DIC, Nalbari, who very kindly devoted time from his busy schedule to guide me through the units in the district. My gratitude to all the artisans of the cluster, who allowed me into their lives and helped me understand the workings of the cluster.

I would like to thank the DCS-MSME team at NID, especially Mr. Shashank Mehta, Mr. Ashok Mondal and Mr. Kirti Parmar for giving me this wonderful opportunity learn and expand my horizons.

Acknowledgements


Abstract Commencement of the NASIncense or agarbatti in IndiaOn Assam and NalbariAbout Tihu town and the ClusterIntroduction to IncenseIncense making in Tihu, NalbariUnit 1 - The Bahumukhi Incense Stick Product company (BISP)Unit 2 - The Northeast Incense Powder CompanyUnit 3 - Gargi Dhupkathi UdyogUnit 4 - Food Processing Centre & Dhupkathi Making Udyog, MakhibahaUnit 5 - Saujhi Self Help GroupUnit 6 - Rong J.L.S.GStudy of raw sticks from the Nalbari ClusterStudy of scented sticks from the wholesale market at GuwahatiInterview with Mr. Bani KalitaProposals for product development for incense sticksUnit 7 - Maniram Bah-bet UdyogUnit 7 - Champak Bah-bet UdyogUnit 8 - Sangita Bamboo Root ZooUnit 9 - Sunita Cycle StandSurvey of Wholesale Markets at GuwahatiSummation of observations and suggested measuresSWOT AnalysisSuggestions on the improvement of the rolling techniqueSuggestions for ergonomic worksationsSuggested future InitiativesList of people to visit - supplied by the DIC, NalbariAnnexures (Prelimary reports)

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Contents

N.A.S for Bamboo Incense Stick Cluster, Nalbari | 2013 | Mridul Mitra, Design Consultant | Email: [email protected] 5

Abstract

The project Bamboo Incense Stick Cluster, Nalbari is organised by the Office of the Director of Industries and Commerce (DIC), Government of Assam, under the Design Clinic Scheme, launched by the Ministry of Small and Medium Enterprises, Government of India, of which NID is the designated Nodal Agency. The scope of the project is to organise a Design Awareness Programme for the Bamboo Incense Stick Cluster at Nalbari (Assam) and consists of two modules:

Part I - The Need Assessment Survey (NAS): This entails a macro and micro study of the cluster. The macro study involves understanding the cluster structure, the dynamics within its comprising units, the capabilities of the cluster as a whole and its relationship with the marketplace. The micro study requires extensive research of the product(s) of the cluster as well as the manufacturing processes, ergonomics, tooling details, logistics, branding and packaging. The NAS facilitates in the identification of gaps or requirements in manufacturing, product design, ergonomics, branding, packaging, logistics and market development which, with appropriate design intervention, will aid in the betterment of the areas mentioned above, leading to an improvement in the overall development of the cluster, and the livelihood of the people involved in the activity.

Part II - The Design Clinic Workshop: This requires a discussion with MSME members on the insights garnered from the NAS. The resultant information is utilised to formulate solutions, through design, to common problems faced by the cluster. Case study presentations and subject experts aid in improving the importance of design thinking among the participants. In addition, individual members can interact with the designer(s) and gain insights into their product and processes and obtain appropriate suggestions on their improvement.

N.A.S for Bamboo Incense Stick Cluster, Nalbari | 2013 | Mridul Mitra, Design Consultant | Email: [email protected]

On arrival at Nalbari, I was introduced to the units involved in the manufacture of agarbattis in Tihu town and the surrounding villages. In addition, the DIC office at Nalbari had provided a sheet of artisans involved in agarbatti manufacture, as well as a list of people involved in bah-bet or bamboo and cane crafts. As the project brief was centred on bamboo incense stick making at Nalbari, I first covered the artisans and units involved in this activity. In addition, I conducted a survey of the wholesale markets for agarbattis in Guwahati, trying to gather information from the various traders, who were very reticent on any trade details. To conclude with the bamboo incense stick making cluster activities, I interviewed Mr.Kalita, the owner of the NGO that is the hub of the incense stick making activities in the area. In the course of the interview, I discovered that he had recently established a round stick making facility near Guwahati and obtained his assent to visit and document the process there. Once these activities were accomplished, I also visited a few of the cane and bamboo craft artisans, in order to gain a holistic account of the craft activities in the area.

In addition to the checklist provided by the DCS-MSME office, I composed my own questionnaire and fact gathering sheet, elaborating on the points for easy referencing. All the data collected by me has been collated in the checklist and fact sheets. The activities in the main units are documented with the help of both, whereas, new units such as the round stick making unit, and the secondary units (for this survey) of cane and bamboo are documented using the DCS-MSME list only.

Commencment of the NAS


Incense stick or agarbatti making, in India, is a 3000 crore and growing market. The agarbatti area is fragmented with many companies and their brands available throughout the domestic market. The bulk of the agarbattis manufactured in India are hand rolled by women in rural households - it is a well established cottage industry and provides these women with a supplementary source of income. Agarbattis in India are popularly available in 8” and 9” sticks. Though the actual production (of rolling the agarbattis) is concentrated almost exclusively in rural and semi-rural areas, processes such as scenting and packaging are handled by SSIs. Top brands such as ‘Cycle’ agarbattis and ITC’s ‘Mangaldeep’, function by outsourcing majority of the production to SSI units, NGOs, SHGs and cottage industries, with the largest concentration in the southern states such as Karnataka and Andhra Pradesh, with initiatives being organised in Orissa, Bihar. Tripura, Madhya Pradesh and Uttar Pradesh. Agarbatti rolling happens mostly in homes by women, occassionally assisted by the children of the household. NGOs or contractors provide the raw material to the workers who roll the agarbattis on a low wooden table, in a squatting or cross-legged sitting position. The unscented sticks are collected and supplied by a network of NGOs or contractors, to factories where the next processes of scenting and packaging are carried out. The finished products are marketed through India, using the extant marketing and distribution chains, by established brands under their own brand names.

Agarbattis, a staple feature of Indian devotional activities, is now branching out as products associated with aromatherapy, meditation and yoga. As a result, newer markets are opening up in the Middle East, Europe, Africa, and in countries in North and South America. In addition, the Indian diaspora across the globe provides a good market for exports of agarbatties and allied products.

Incense or agarbatti in India

Packaging, distribution, marketing

Scenting and/or packaging

Raw materials (powders, charcoal, bamboo)

Assembly of material into raw sticks

Branded Retailers

Small Scale Units

NGOs & Contractors

Rural Households

Method of operations and hierarchy in the incense stick industry


The state of Assam is located in the north-eastern region of India and forms the gateway to the other states of the north-east. Assam is a land of plains and river valleys and its fertile soil supports tropical evergreen and deciduous forests, broadleaf hill forests, pine and swamp forests, grasslands and a variety of bamboo, orchids and ferns. Bamboo and cane are integral to the cultural, social and economic traditions of the state, and is one of its most valuable natural resources. Natural bamboo forests are found in abundance in the state and is also cultivated in groves and private plantations. There is considerable traditional skill in the working of bamboo and cane, its products are ubiquitous in local households. Its main areas of utilisation include home construction and fencing, household articles, agricultural and fishing implements as well as basketry, food and fuel. Traditional expertise in the working of cane and bamboo into products of high utility as well as aesthetic value is part of the skill-set of most of the rural populace, and is now the core of a thriving cane and bamboo handicraft industry.The Nalbari district in Assam is bound by Darang and Kamrup districts on the east, and by Barpeta district on the west. The northern side is defined by the Indo-Bhutan international border, and by the river Brahmaputra on the south. Situated in the plains of the Brahmaputra valley, the district covers an area of 999.90 sq.km. and is criss-crossed by the rivers Nona, Buradia, Pagaldia and the Tihu. The area is rich in bamboo and cane and these two materials form the backbone of large chunks of activities in village life. They are used extensively in construction of homes, animal pens, furniture and a plethora of other household items, implements for fishing and farming and hand-crafted products for sale. The making of incense sticks is a relatively new activity to the district, with the crux of the bamboo incense stick making cluster being situated in Tihu town, which comprises 39 villages, covering an area of about 130 sq.km and is approximately 80km from Guwahati.

On Assam and Nalbari

District map of Assam


A cluster is a geographic concentration of units, comprising a city or town or adjacent villages and their adjoining areas, producing similar products and facing common opportunities and threats. An artisan cluster is a congregation of household units producing handloom and or handicraft products and often belongs to a community traditionally producing the product(s).

In 2009, the bamboo incense stick making activity was initiated in Nalbari cluster by the Bahumukhi Pratibha Vikas Samiti, an NGO owned by a Guwahati based businessman, Mr. Bani Kalita, a previous resident of Tihu.The Bahumukhi Incense Stick Product (BISP) company, a subsidiary of the Bahumukhi Pratibha Vikas Samiti, is the main manufacturer of incense sticks, and outsources or job-works a large part of its production to smaller household units in the nearby villages.

Tihu town and its surrounding villages are a vision in green, blue and warm brown through its lush verdure, water bodies and fertile earth. Agriculture, goat farming, weaving and manufacturing of handicrafts are revenue generating activities for the people; a large section of the populace is also employed in government service. It is well connected to Nalbari by road and rail, and has ample civic amenities such as four hospitals, eight higher secondary schools, four banks and a number of government offices.

The women of the town are of an enterprising nature and make up a large percentage of the workforce employed in agarbatti manufacturing. They are keen to learn new ways and means of improving the product and the production capabilities of their units.

About Tihu town and the clusterView of the main street, Tihu


Indian incense brands

Incense cones Solid incence sticks Incence in coil form


Incense is defined as aromatic gums and resins, woods and barks, leaves, flowers and buds, seeds and fruits, roots and rhizomes and certain animal derived materials, which, on burning, produce a fragrant odour.

An intrinsic part of numerous religious ceremonies, examples of its usage can be traced back to ancient cultures in Egypt, India and China. The 3rd century BCE witnessed the emergence of incense as a major item of trade between the Middle East, India, Africa and the Mediterranean. These trade routes were collectively called the Incense Route, and flourished till the 2nd century CE. Today, incense is used extensively across South-East Asia, China, Japan and India, and of late, is finding a growing market in the West and South Americas.

Incense is prepared by the mixture of dried and powdered aromatic substances, and a binding powder,such as the powdered bark and leaves of certain plants. It may or may not contain an oxidising agent such as charcoal powder, and is available as loose powders, pellets, cones, cored sticks and solid sticks. It can be broadly categorised into two varieties:

Indirect burning incense: this type requires a continuous supply of heat from an external source such as a brazier or a lamp as there is no oxidising agent. The mixture is formed into pellets or powders, and placed above a heat source, allowing the aromatic substances to release their fragrance.

Direct burning incense: This variety does not require a continuous source of heat as a combustible substance or oxidiser such as charcoal powder is mixed into the ingredients. The incense is ignited and then the flame blown out, leaving an ember that causes the release of fragrance from the aromatic substances.

Incense is available in the following forms:a. Cored sticks: The ingredients are kneaded into a sticky dough by adding water, rolled onto a bamboo stick core, and dried. The Indian agarbatti is of this variety and falls into the direct burning category.

b. Solid sticks: The stick has no core and is composed entirely of incense mixture. This is of the direct burning type and is popular in Japan and Tibet.

c. Incense cones: Incense mixture is formed into small cones and dried. They are usually of the direct burning type.

d. Coils: Incense mixture is shaped into large coils. It is commonly used in China and South-East Asia.

e. Powders / pellets / granules: These are warmed using an external heat source to release their fragrance.

Introduction to Incense


Incense sticks or agarbattis in India are hand-rolled following a simple process, and requiring minimum tool usage. The raw materials for agarbattis or dhupkathis, are it is locally known in the north-eastern states of India, consist of a bamboo stick core and the masala, which is a mixure of powdered ingredients. The core of the incense stick is made of split, sliced and sized bamboo, and is of two types - a square section and a round section, each approximately 1.5mm-2mm and 3mm thick, and in lengths of either 8” (203.2mm) or 9” (228.6mm). The square sticks are made manually with ease; consequently, the greater part of the incense sticks manufactured here, have a core stick with a square cross section. Round sticks are supplied to Tihu by a factory based in Sonapur, near Guwahati.

The masala is a mixture composed of a binding agent, an oxidising agent and may or may not include the aromatic substance. Incense sticks made without the addition of the aromatic substance, are called raw sticks, and are scented by either dipping them into a solution containing the aromatic substances or by the spraying of the same onto the raw sticks. Popular aromas in India are sandalwood, jasmine, champa (magnolia), lavender and rose. Incense sticks manufactured in Nalbari are raw sticks, which are sold wholesale to buyers in Guwahati.

The binding agent is composed of the powdered leaves and bark from various local plants and trees, and the oxidising agent is charcoal powder. The powdered leaves and bark are collectively called jigat, which is a term originally used for the powered bark of the tree, Machilus macrantha. However, it seems to be used by the locals to describe the powders derived from other local plants and trees, such as teak (Tectona grandis), the tulsi (Ocimum tenuiflorum) and amar lati or bougainvillea (Cuscuta reflexa).

Incense making in Tihu, Nalbari

Sawing bamboo culm with a hacksaw

Lengthwise splitting using a ‘dao’

Sizing into sticks with a ‘katari’

Sawn off bamboo

Splitting along the plane using a ‘katari’

Sticks, finished and unfinished, bound in 1/2 kg bundles


Bamboo culm is sawed into lengths of 8” and 9” using a hacksaw and is then split lengthwise into eight pieces, using a an instrument called a dao, similar to a billhook. Each of these pieces are then sliced along the plane into into slices of 2mm to 3mm, using a small knife called a katari. The slices are held together in a stack, and, using the katari, further sliced into slivers of a cross section of approximately 2mm x 2mm, and lengths of either 8” or 9”. Once the sticks are cut, it moves into the next stage - rolling, known locally as leping, where a mixture of the powdered plant material and charcoal powder is rolled onto the stick.

The powdered mixture, comprising jigat powder and powdered bark and leaves of certain trees, is sold or supplied to the local units, where it is mixed with a proportionate quantity of water to form sticky dough. The dough is rolled onto the bamboo stick core with a dab of charcoal powder which acts as fuel to keep the stick burning. The rolling process is hand-done by the women of the units, on a small worktable with dimensions approximating 14”x 9”x 4”, on which a small amount of charcoal powder is also present. A quantity of the kneaded mixture is placed on the work-table, a portion is broken off and hand-rolled with one palm into a long, thin cylinder. A bamboo stick held in the other hand is placed on the table and the cylinder of masala is worked onto it. They are then laid to dry for a minimum of four to six hours, bundled into 1/2 kilogram packs and sold to the Bahumukhi Incense Stick Product company.

The units also produce bamboo sticks which they sell to the BISP. The company also employs it own staff for the above activities. In addition the BISP also owns a number of machines for the pulverising and powdering of the raw ingredients and for the cutting, slicing, slivering and sizing of bamboo. The charcoal is imported from Hyderabad, and powdered in the BISP factory.

Kneading powdered mix into a dough

Rolling the ‘masala’ onto a bamboo stick

Drying of the rolled sticks

Rolling the dough into a cylinder

Stick with the ‘masala’ rolled on

Tools for the splitting and sizing of bamboo


Manager: Mr. Dilip DakuaContact number: 88768 67620Date of visit: 15th, 16th, 18th of July, 2013

The Bahumukhi Incense Stick Product factory, established in 2009, is located in Tihu village, Nalbari dist., Assam. It is one of the initiatives of the Bahumukhi Pratibha Vikas Samiti, an NGO run by Bani Kalita, a Guwahati based businessman. Mr.Kalita also owns a bamboo round stick making unit in Sonapur area near Guwahati.The Bahumukhi Incense Stick Product (henceforth referred to as BISP) was the first to initiate the business of incense stick making in the area, in 2009. They supply raw incense sticks to buyers in Guwahati, Tejpur and Bangalore, and outsource most of their manufacturing to small home based units in and around nearby villages - Makhibaha, Palitana and Nathkuchi as well as to villages in Darang, Chirang and Baksa districts. They source raw materials for the agarbatti mix (called masala) locally or from Meghalaya, Hyderabad and the Assam-Bhutan border. Charcoal is sourced from Hyderabad. The grinding and mixing is done at BISP and supplied to local units. Once the masala is hand-rolled onto the sticks (a process known locally as ‘leping’) and dried, it is sent back to the BISP premises, where it is packed and sent out.

Unit 1 - The Bahumukhi Incense Stick Product company (BISP)

The signage for the ‘Bahumukhi Pratibha Vikas Samiti’, Tihu

Mr.Mahesh Kalita (L), Mr. Dilip Dakua (C)

BISP Rural UnitsMasala+bamboo+charcoal

Raw sticks


Podumi Debi, 40

Bijuli Pathak, 20

Nilima Dutta, 30

Sribimala Das, 45

Pranita Das, 25

Shankar and Kuladip

Rina Das, 40

Moni Kalita, 19

Tapan Goswami

Gitu Haloi, 19

Hirumoni Kalita, 17

List of regular employees


Observations Topic Possible design solutions

Product • Bamboo sticks are not clean - numerous exposed fibres• The application of masala along the length of the sticks is erratic and varying• Cracking of the applied masala during the drying process.

• Quality checks during the stick making process, to discard fibrous sticks• Mark area for coverage prior to rolling, perhaps by dyeing to a particular length• Correct proportion of ingredients, including water, to achieve best consistency• Use of trays to dry ready sticks in. Also drying in a shaded area away from direct sunlight will prevent excessive drying and consequent cracking

Process

Packaging

Storage

• Rolling technique used results in an uneven shaped incense stick. Also, the masala coats the palm very often, leading to further unevenness. • The surface of the worktable is coated with the masala at regular intervals, and is not cleaned frequently, causing stickiness and unevenly rolled incense sticks.

• As the BISP are wholesalers, finished sticks are bundled into half kg packs and tied with twine. Sacks of 40 kg are transported to Guwahati.• Cracking along the areas covered by the twine

• Storage of raw material: Most raw material is stored in a large shed with bamboo walls and an asbestos roof. Materials are stored close to the dirt floor, sacks spilling over on floor and designated areas for specific material.• Finished incense sticks are stored in the main work shed, along the walls, on sheets spread on the dirt floor.

• Can try method of rolling similar to that in Vietnam - by using a flat piece of wood instead of the palm of the hand. This will help maintain a regular surface and a better shape. Also, it requires very little expenditure. Training using this technique, if acceptable, can begin immediately.• Surface of worktable can be cleaned regularly - providing a scraper, such as metal sheet, will make this easier.

• In case of plans to enter the retail market, appropriate packaging and graphic design input, will be required• Use of a wider linear material such as a leaf prior to tying - this will help reduce the amount of force applied on a particular area, leading to cracking

• Need to store powdered raw material further off the floor. Can construct raised platforms for each type. This will automatically cause designated areas of storage for different materials. • Finished sticks can be stacked on raised and shelved platforms and not more than two or three bundles high. The current method of stacking upto 10-12 bundles high, causes cracking in the bottom most bundles.

Design Audit - Unit 1



Layout

Machinery

Research and Development

• Factory is situated on a large plot of land with separate sheds alloted for storage of raw material, large machinery, rolling of agarbattis and weighing. Other sheds are utilised for smaller or unused machinery, storage for material, cooking, eating and administrative areas. Open space in the building are also occassionally used for purposes of training

• Circular saws, pulverisers, bark cutters, bamboo sliver maker, square stick maker, stick sizer, stick polisher, laboratory equipment, vibro screen.

• Currently, none.

• The sequence of operations from delivery and unloading of materials, processing, assembly, packaging, leading and dispatch need to be identified, sequenced and adapted to the layout of the factory area, to best utilise the space available and streamline the manufacturing process.

• Current in-house machinery is adequate, unless they plan to automate agarbatti rolling process. As manual stick making is popular, some machines are infrequently used. However, when not in use, the machines need to be kept clean and in good working condition.

• As interest has been shown in retail, a study of agarbatti aromas and the scenting process is required, in order produce a finished product. Creation of a brand identity and appropriate packaging are indicated, as well as exhaustive research of the market, options for advertising and distribition and possible partners.

Workstations, Workspace and Ergonomics

• Workstations: No dedicated workstation. A small table of dimensions approximating 15”x 10”x 4” is used as a surface for the rolling of the agarbattis. The table is brought out and placed on the ground. The worker assumes a squatting or cross-legged position and proceeds of roll the agarbattis.• Workspace: The main workspace areas are the shed used for pulverising and powdering of raw materials and the workshed used for the rolling of the agarbattis, weighing and storage.

• Position assumed for rolling the agarbattis is difficult to sustain for long periods of time. Design of a workspace allowing for a sitting position such as a chair or a bench with an elevated table for rolling will help the worker’s posure as well as improve overall productivity.• Workers in the pulverising and powdering shed should be provided with protective masks. The workspace for the rolling of agarbattis is also utilized for the weighing, bundling, stacking and storage of finished agarbattis. Rolling of agarbattis need a dedicated area near the doorway, with adequate light and ventilation.


Finishing is not clean. Uneven application of masala along length of agarbatti

Can use wider band of materialto tie agarbattis

Twine has removed masala coating from the stick

Coating from previous rollingshould be removed periodically

Can use larger quantity of kneadedmasala to prevent delays

Need a trays to hold agarbattis and a dedicated drying area

Excessive drying causes cracks inthe masala coating

Agarbatti bundles, prior to being packed in a sack


Haphazard storage, damage to sacks, stored directly on floor made of earth.

Will get damp due to rains.

Poor storekeeping - lack of order. Need to store raw materials away from

machinery.


Auxiliary storage areas like this should be kept in order. Provision of shelves could control disorderliness

Waste material can be stored neatly for disposal and away from the main path

The path leading from the worksop to the exit. for convenience, workshop and store may be planned closer to exit.

Sticks stored on mat on floor and piled high, damaging sticks. Can use long shelves to store bundles.


Spaces like these are under-utilised. As there is sufficient natural light and a paved floor, it may be used as a workshed for the rolling process

Soaking tank for bamboo currently used as storage. such material can either be stored in the proper area or stacked neatly in the tank

Storage areas like these can have shelves for easy access of materials. Construction of these sheds should be sturdy and well protected from the elements


Can use trays for collection of powdered material as it exits the machines, to prevent spillage and reduce labour.

Bark cutters and pulverisers unused and covered with grime.

Vibro screen for sifting powders, covered with dust and material. Also placed in corner with inadequate lighting

Poor lighting, extensive unused space. Haphazard storage of materials. Space needs to be swept regularly.

Workshed for pulverisers, bark cutters and vibro screen


Narrow entrance to powdering and mixing shed. Other equipment clogging up already small entry area.

Poor cleaning practices

Workers in this area should be provided with masks.

List of machinery with costs incurred, installed at the factory.


Entrance to second factory shed, containing machines for slicing, splitting and polishing of bamboo culm into sticks.

Stick polishing machines. Not utilised to capacity as manual polishing in practice. Also manager states better results by the manual method.

Muffle furnaces in the lab for testing quality of imported charcoal.

Lab equipment should be in a separate room with some personnel trained in its usage and reading.


Machine for slicing split bamboo. However, manager syas that manual slicing is of better quality and is more profitable.

Square-core stick making machine. Infrequently used as manual method faster and cheaper.

As is shown, lighting conditions inside the shed are inadequate for the purpose.

Machine for cutting bundles of sticks to required lengths of 8” or 9”

Entrance to the workshed for the rolling of masala onto the bamboo stick cores.


Lighting inside is inadequate for the size of the shed. Need more points located above the workers and slightly to the front to prevent shadows falling onto the work area.

Weighing machine can be placed closer to worker. Table for levelling can be smaller and placed toward left. Here worker has to strain and reach across table.

Lack of spatial organisation. Also work area needs to be swept regularly to keep it clean.

Ready rolled sticks piled high along the perimeter of the shed, in damp and dark areas, with poor accessibility.

Posture strains neck and back, uncomfortable to maintain for the long durations required for rolling. Poor light causes considerable eyestrain.


Manager: Mr. D. SarmaContact number: 98641 20348Date of visit: 19th July, 2013

The Northeast Incense Powder factory, established in June, 2013, is located in Sonapur, near Guwahati. It is one of the initiatives of the Bahumukhi Pratibha Vikas Samiti, an NGO run by Mr.Bani Kalita. The factory was established with the intention of entering the round stick agarbatti market, and is equipped with round stick making machines, bamboo slicers, stick polishers, stick sizers, pulverisers and powdering machine. As the factory initiated operations very recently, it is not yet running to capacity, with an average daily output of a 100 kgs with two operational round stick machines. The round sticks produced here, are sent to TIhu and other areas, for the completion of the manufacturing process, by rolling the masala onto the sticks. According to the manager, Mr. D. Sarma, round sticks allow for better fixing of the masala and is more in demand by their buyers. The factory sources raw materials such as charcoal from Hyderabad and powders it in the facility. Other material such as leaves and bark are also locally sourced, powdered and send to the hand-rolling units.

Unit 2 - The Northeast Incense Powder Company

Mr.D. Sarma, Manager



Product

Process

Storage

• Exposed fibres on the bamboo sticks are cleaned using nails embedded in a length of wood instead of the polisher. • The polisher, according to the workers, does not function effectively enough.

• There is no catchment area for bamboo slices as they exit the machines. They lie scattered, making it difficult to collect.• Drying of sticks is a makeshift process - spread close to the ground, sometimes directly on the ground making it difficult to collect them.•.No safety procedures followed while using power cutting tools - circular saw is placed on uneven ground and operated. • Switch is 10’ feet away and saw is left running till switch is turned off

• Material is stored on areas on the factory floor free of machinery. All material is kept directly on the floor.• Sacks come into close contact with heavy machinery.• Sacks are stored close to the wall, flush with the gap between the brick level and the tin sheets. This may lead to wetting during the monsoon

• Use of better polishing aid such as steel wire brush with ergonomic grip.• Identification of a better quality polisher.

• Use of a flat tray or a high table as a catchment area will reduce time wasted in collecting slices.• Use of trays or racks to dry slices and sticks• Urgent need of safety precautions - circular saw to be placed on level ground, a guard for blade must be installed to prevent chances of serious accidents.• Switch must be within arm’s reach and placed in a position away from the blade of the saw

•. Must have dedicated storage area on factory floor.• Need to store material off the floor and away from the walls. Can construct raised platforms for each type - will lead to designated areas of storage for different materials. • Storage areas must have easy access, to aid in movement of material

Layout • Factory is accomodated in a large shed-like structure. One third is devoted to pulverising and powdering. Processsing of bamboo into round sticks occupies the rest. • Cutting of the bamboo culm into sections takes place in the open, uneven area outside the shed .

• The sequence of operations from delivery and unloading of materials, processing, assembly, packaging, leading and dispatch need to be identified, sequenced and adapted to the layout of the factory area, to best utilise the space available and streamline the manufacturing process.




Machinery


• Circular saws, pulverisers, bark cutters, bamboo sliver maker, round stick maker, stick sizer, stick polisher.

• Plan to initiate agarbatti rolling process in the future. • Plan to enter retail market.• Looking for ways and means of creating a brand and a viable marketing plan

• Current in-house machinery is adequate, unless they plan to automate agarbatti rolling process. However, the stick polishing machines may be reviewed for efficiency as they seem to be underused in BISP as well as in this factory

• Understand scents and the scenting process - also to locate scenting units or plan an in-house scenting unit.• Creation of a brand identity and appropriate packaging are indicated, exhaustive research of the market, options for advertising and distribition and possible partners• Plan product diversification for retail and export - production of cones, pellets, solid sticks, larger agarbattis• Can initiate research into products associated with incense, such as agarbatti holders and trays, and packaging and gifting ideas in natural material such as cane and bamboo or grass, and censers in brass or bell metal.

Workspace and Ergonomics

• Current placement of machines according to availability of space - no special though given to proper layout• Cutting of culm into smaller sections happens outside factory, in the open• No space for loading or unloading vehicle or covered storage for bamboo culms.

• Streamline layout of the workspace according to sequence of operations in the workflow.• Workers in the pulverising and powdering shed should be provided with protective masks. • A dedicated area for sawing and splitting of bamboo culm• A dedicated space or platform for temporary storage for loading and unloading material from vehicles.• Repair of road leading up to the factory


The factory shed

Splitting bamboo Splits will be fed into slicer for thinner slices

No blade guard

Walks away to switchoff machine

Chances of serious injury from spinning blade

Danger to head

Danger to arm


Bamboo slicer Slicer in action

Round stick maker in action

Round stick making machines

Table reqd here for catching of slices


Bundled sticks, awaiting cutting to required size

Bamboo stick polisher - indigenous manufacture. Infrequently used as cleaning of fibres is inadequate

Slices and round sticks

Can try a steel wirebrush with handle

Use trays or sheets for drying

May purchase better functioning polisher from the market

Loose fibres

Manual cleaning of loose fibres

Bundled sticks arecut to size


Pulveriser for powdering of charcoal

Unused stick polisher

Sacks encroach onto machine area.Dedicated storage area required

Dedicated and raised storage area required

Sacks stored near gap between walls

Storage directly on floor - can place material on raised platforms


Use tray for collection of waste

Again, storage of material impinges onto space near power machinery.

Workers should be provided with masks to prevent inhalation of bamboo dust.

Power machines have no on/off switch on the frame, causing blade to spin till power is cut off from the socket.

Can use a metal sheel, bent at a right angle, to contain round sticks as they exit the machine.

Protruding, uncapped rods, are a potential hazard.


Can place a tray to collectsliced bamboo

Waste should be stored in a container, for easy disposal Need to repair road leading

to factory shed.

Can construct a covered platform here, for storage of bamboo culms. Can also serve as a temporary storage for material, for ease of loading and unloading.

Infrequently used machinesblock space in middle of factory area

Poor access to stored material


Proprietress: Ms. Rekha DasContact number: 88220 65179Date of visit: 15th and 16th July, 2013

Gargi Dhupkathi Udyog (henceforth referred to as GDU), is a small agarbatti manufacturing unit under the Milan SHG, at Makhibaha village. The propreitor, Ms.Rekha Das, has constructed a small working area, screened with bamboo walls in the porch of her home, which serves as the working area for women from the village.The roughly 12’x 7’ space contains the work and storage area. Inspite of the space contraints, the work area is neat and clean. The GDU is mainly engaged in the application of the agarbatti masala to the bamboo stick cores. They also split and size the bamboo into sticks.

The unit is one of the job-workers for the BISP. Sticks and masala are supplied to them, they roll the masala onto the agarbattis and sell it back to the BISP. The BISP sells the powdered masala to the unit at Rs.30 per kg. Each kg of powdered masala, after being kneaded with water yields sufficient masala to roll four kgs of raw sticks, which are sold to the BISP at Rs.40 per kg. Sized bamboo stick cores are also supplied to the BISP at Rs.16 per kg. They also make a small quantity of agarbattis for retail in the local markets around the village. Of late, Ms Das has begun to experiment with scenting raw agarbattis, packaging them and retailing to local markets.

Unit 3 - Gargi Dhupkathi Udyog

The signage for the ‘Gargi Dhupkathi Udyog’, Makhibaha.

Ms. Rekha Das, proprietress, Gargi Dhupkathi Udyog, Makhibaha.


List of regular employees

No. Name of workers Age 1 Sabita Das 182 Niru Das 163 Sabita Haloi 404 Kakoli Kalita 205 Monica Das 356 Kamala Das 327 Purabi Das 208 Renuka Haloi 359 Bina Datta 4010 Sunita Das 2011 Gunumuni Das 1812 Gitika Haloi 2513 Lipika Haloi 2314 Rekha Das 35



Product • Neat, well-rolled sticks, however application of masala along the length of the sticks vary• Some cracking of the applied masala during the drying process.

• Mark area for coverage prior to rolling, perhaps by dyeing to a particular length• Correct proportion of ingredients, including water, to achieve best consistency• Dry sticks in tray, away from direct sunlight to control drying and prevent cracking

Process

Packaging

Storage

• Rolling technique used sometimes results in an uneven shaped incense stick. Also, the masala coats the palm very often, leading to further unevenness. • The surface of the worktable retains the sticky masala, causing unevenly rolled incense sticks.

• Coated sticks are bundled into 1/2kg packs, wrapped in paper and sent to BISP• Cracking along the areas covered by the twine• A small quantity of sticks are scented and packed in assorted boxes, bearing brand names of Bangalore based brands, and supplied to local retailers

• Raw material is stored in sacks, under a raised platform at one end of the work area• Coated sticks are stored on top of the platform

• Can try method of rolling similar to that in Vietnam - by using a flat piece of wood instead of the palm of the hand, as mentioned in the BISP report• Surface of worktable can be cleaned regularly - providing a scraper, such as metal sheet, will make this easier.

• Use of a wider linear material such as a leaf prior to tying - this will help reduce the amount of force applied on a particular area, leading to cracking• In case of plans to enter the local retail market, can develop a simple and inexpensive packaging, bearing name of unit. However they will require some guidance as awareness is low

• None - they have made the best possible usage of available resources• Can tie bundles with a wider linear material such as grass in place of twine. Twine scrapes the coating away




Layout

Machinery


• Work area is a small, bamboo walled shed approximately 12’x7’. About 2’x7’ of the further end of the shed is earmarked for the storage of raw materials and coated sticks.• All other activities from making of sticks to rolling and packing is managed in the remaining 10’x7’

• None. Basic hand tools such as the hacksaw, the dao and the katari used.

• Ms. Das has begun the scenting process using locally available solutions, which are sprayed onto the sticks.• Sticks are sold approximately 10 to a pack, in surplus boxes of other brands.

• The unit needs funds to build a larger work area. Current space is utilised in the best possible manner.

• Currently, no machinery required.

• The unit needs informed input into scenting as well as a supply of material and know-how.• Training in better rolling methods, better posture needed.• The proprietress could benefit from a short course in accountkeeping; they are unaware of exact expenditures.


• Small tables of dimensions approximating 15”x 8”x 4” are shared between two women for the rolling process; they sit cross-legged on the ground, bent over the tables.• Though cramped, the workspace is clean and well-managed. Newspapers spread on the packed earth ground provide an easy to clean area.

• Each worker needs her own table, which they are unable to arrange for due to a shortage of finances.• Urgently need a larger space - more women in the neighbourhood want to join up, but cannot be accomodated due to lack of space.• Given the finances, design of a workstation allowing for a sitting position such as a chair or a bench with an elevated table for rolling will help the worker’s posure as well as improve overall productivity.


The home compound which also houses the small workspace The workspace

Cramped working conditions

Poor ergonomics

Inadequate number of rolling tables


Neat and clean storage - best use of available facilities

Locally available liquid scenting agents - no quality assurance

Lack of proper branding and packaging

Lack of space to comfortably accomodate all activites


Proprietress: Ms. Gitanjali BhattaContact number: 95080 13502Date of visit: 15th and 16th July, 2013

Dhupkathi Making Udyog (henceforth referred to as DMU) is a small agarbatti manufacturing unit under the Food Processing Centre and Dhupkathi Making Udyog SHG at Khudra, Makhibaha village. A CFC has been constructed within the compund of Ms. Gitanjali Bhatta, the Secretary of the SHG, with the aid of state government schemes. The permanent structure consists of two large rooms with a covered porch. Of the two rooms, one is used for storage of raw material and as a workspace. The other seemed to be infrequently used.The CFC was constructed in 2012 by the District Rural Development Agency.The DMU is mainly engaged in the application of the agarbatti masala to the bamboo stick cores. They also split and size the bamboo into sticks and jobwork for the BISP. Sticks and masala are supplied to them, they roll the masala onto the agarbattis and sell it back to the BISP. They also make a small quantity of agarbattis for retail in the local markets.

Unit 4 - Food Processing Centre & Dhupkathi Making Udyog, Khudra, Makhibaha

The signage for the ‘Food Processing Centre and Dhupkathi Making Udyog’, Makhibaha. Ms. Gitanjali Bhatta, proprietress stands at the right.


List of employees involved in both, food processing and agarbatti making

No. Name of workers Age 1 Ranjita Bhatta 382 Gitanjali Bhatta 393 Monomoti Bhatta 454 Shilpi Bhatta 205 Panki Bhatta 206 Komola Debi 267 Sabitri Debi 458 Dalimi Debi 409 Nandita Barman 3510 Bhunita Debi 4511 Rani Sarma 4012 Gitanjali Barman 4013 Sangeeta Debi 3014 Anupama Debi 4015 Nirupama Debi 3516 Rita Debi 3517 Helentina Sarma 2018 Bhabita Debi 3519 Gita Das 3520 Mamoni Debi 4021 Rukmini Barman 3022 Hiran Barman 4023 Binita Barman 40



Product • Quality of rolled sticks is average - uneven application of masala• Cracking of the applied masala during the drying process.

• The women of this unit need more training in the rolling of the masala onto the sticks. • Correct proportion of ingredients, including water, to achieve best consistency• Dry sticks in tray, away from direct sunlight to control drying and prevent cracking

Process

Packaging

Storage

• Method of rolling consists of rolling out a long, very thin cylinder, then placing stick onto the table and rolling the cylinder onto the stick.Rolling technique used results in an uneven shaped incense stick. Also, the masala coats the palm very often, leading to further unevenness. • The surface of the worktable is extremely sticky due to repeated usage and wrong consistency of the kneaded masala.

• Coated sticks are bundled into 1/2kg packs, wrapped in paper and sent to BISP• Cracking along the areas covered by the twine• A small quantity of sticks are scented and packed in assorted boxes, bearing brand names of Bangalore based brands, and supplied to local retailers

• Raw material is stored in plastic bags in the work area, next to sacks of food material, causing chances of contamination• Coated sticks are stored in bundles in the work area

• Need training - the method used is not that followed in the other units. Hence quality of rolled sticks is poorer. • Can try method of rolling similar to that in Vietnam - by using a flat piece of wood instead of the palm of the hand, as mentioned in the BISP report• Surface of worktable can be cleaned regularly - providing a scraper, such as metal sheet, will make this easier.

• Use of a wider linear material such as a leaf prior to tying - this will help reduce the amount of force applied on a particular area, leading to cracking• In case of plans to enter the local retail market, can develop a simple and inexpensive packaging, bearing name of unit. However they will require some guidance as awareness is low

• As adequate space is available, can dedicate a small area with some shelves, to the storage of material, both raw and finished




Layout

Machinery


• A permanent Common Facility Centre with two large rooms and a porch, comprise of the workspace for both food processing and agarbatti rolling• Of these, one room is used for storage and manufacture; the second room appears to be mostly unused.

• None. Basic hand tools such as the hacksaw, the dao and the katari used.

• Ms. Bhatta has begun the scenting process using locally available solutions, which are sprayed onto the sticks.• Sticks are sold approximately 10 to a pack, in surplus boxes of other brands.

• Utilise both spaces, by dedicating a room each to agarbatti rolling and food processing, to avoid contamination of food material, by powders used for agarbatti rolling• Organise space of each room into activity specific areas - for storage, manufacturing, drying (on the porch) and storage of finished material

• Currently, no machinery required.

• The unit needs informed input into scenting as well as a supply of material and know-how.• Training in better rolling methods, better posture needed.• The proprietress could benefit from a short course in accountkeeping; they are unaware of exact expenditures.


• An assortment of tables, some small and one very large table, is shared between workers for the rolling process; they sit cross-legged on the ground, bent over the tables• The CFC is airy and well-lit by natural light, but poorly utilised, as mentioned in previous observations.

• Each worker needs her own table• Design of a workstation allowing for a sitting position such as a chair or a bench with an elevated table for rolling will help the worker’s posure as well as improve overall productivity.


Room 1 of CFC - used for storage of food products as well as rolling of sticks

Poor utilisation of available resources - too many people at one table

Room 2 of CFC - mostly unused

Poor ergonomics


Tools used in the processing of bamboo into sticks. From the left: the dao, katari, hacksaw, hammerStorage shed for cut bamboo

Small bowl makes kneading of the masala difficult Wrong rolling method - a very thin cylinder of the masala is being applied on to the stick, resulting in uneven and inadequate coating

Surface of rolling table is unclean. The stickiness results in poorly rolled products


Storage for raw sticks and bamboo stick cores

Covered porch or Room 2 can be used for storage of raw sticks

Scent is sprayed onto sticks - unequal coverage

Sticks are packed in plastic bags for local retail

Sticks stored next to sacks of food products, causing risk of contamination

Locally available liquid scenting agents - no quality assurance

Lack of proper branding and packaging


Contact person: Ms. Podumi Debi or Ms. Sewali DebiContact number: 84861 97849 (Podumi Debi)Date of visit: 15th and 16th July, 2013

The activities of Sauji SHG are bamboo stick making, goat farming, weaving of mekhala-chador and tailoring. Of the twelve women who are part of the SHG, only around three are actively engaged in bamboo stick making, of which, Ms.Podumi Debi is the most efficient and also works at the BISP.They possess power cutting tools and some machines for bamboo slicing but prefer to work manually as they say it is faster. Also, the power cutting tool consumes too much electricity for them to find of viable use.Ms. Podumi Debi wants to take up agarbatti rolling on a regular basis, the others are either unwilling or unsure. They are more interested in availing of loans to facilitate and bolster their tailoring activities.

No. Name of workers Age1 Podumi Debi 402 Sewali Debi 403 Pranita Debi 354 Aparajita Debi 355 Bhagyasri Debi 336 Phoolkumari Debi 377 Dipika Debi 408 Archana Debi 409 Anjumoni Debi 3310 Manju Debi 4011 Arpana Debi 3712 Namita Debi 30

Unit 5 - Saujhi Self Help Group

Bamboo sticks from the Saujhi SHG

Members of the Saujhi SHG. Ms.Podumi Debi is involved in the slicing of bamboo

List of employees of the SHG



Product • Cut and sized bamboo stick cores. The sticks are not completely trimmed of loose fibres• Rolling of masala onto the sticks, is undertaken in small quantities

• Core sticks can be cleaned better before dispatch to BISP. Use of a steel wire brush may aid in the process• Rolled sticks contain numerous loose fibres, which may be avoided by cleaning, as mentioned above

Process

Packaging and Storage

• Bamboo culms are sawed using a hacksaw, split with a dao, sliced and sized using a katari - all manual processes• The sizing process is achieved manually, by gathering all the slices, and cut with great speed into the required cross sections, using a katari• Rolling of masala onto sticks is the same as those followed in other units

• Sticks, both coated and uncoated, are bundled into 1/2 kg bundles and dispatched to the BISP

• Use of a rubber finger guard such as those found in Kerala will help prevent injuries

• Use of a wide material for tying of rolled sticks.

Machinery


• Circular saw, manual slicing and sizing machines are available to the SHG, but unused. All processes are manually executed

• Of the total agarbatti making process, the SHG is mostly involved in stick-making

• At present, the manual processes are adequate for the output of the SHG. A CFC, if constructed, can house the machinery

• Ms. Podumi Debi is interested in being involved in the rolling process at her village. More members are willing to be involved, if better remuneration is provided• Given the availability of good working skills with bamboo, members can be trained in the making of ancillary products of agarbatti making, such as ash stands, holders and bamboo packaging• Accounting know-how will be immensely useful to members

Workstations, Workspace and

Ergonomics

• No dedicated area - work happens in Ms. Podumi’s home• Those involved, sit cross-legged or squatting on the floor

• A straight backed position, achievable through use of a chair and table, or assuming a cross legged position with one’s back resting against a wall, or the use of a small stool for sitting, will ease pressure off the legs and back



The slicing of bamboo culm Slices are stacked in a pileA katari is applied along the length of the slice stack to make bamboo stick cores

Resultant sticks mostly of equal length, but unequal thicknesses

Unused machinery for bamboo stick making.

Sticks of all thicknesses are bundled

Loose fibres on rolled sticks

Stages and tools in manual stick making


Date of visit: 15th July, 2013

Rong JLSG is a Joint Liability Group sponsored by the State Institute of Rural Development, Guwahati and financed by the Assam Gramin Vikas Bank, Haribhanga, Nalbari. The unit is managed by three young entrepreneurs - Mr. Khanin Kumar Haloi, Mr. Pranjal Thakuria and Mr. Kishor Haloi.The unit, which aims to produce square, and later, round bamboo stick cores, is yet to begin operations. They are currently equipped with the machinery requisite for the production of square sticks only. The unit is housed in a four room building, of which, two are occupied. Circular saws, bamboo splitting machines, bamboo slicing machines, square stick makers and a stick polishing machine are currently the inventory of the unit. According to the members, one of the main contraints they face is an inadequate supply of electricity in the area. Once the unit is functional, they plan to supply the Department of Design at IIT, Guwahati with the sticks produced.

Unit 6 - Rong J.L.S.G

The young entrepreneurs of the Rong JLSG


Bamboo slicing machines

Bamboo splitting tool View of the unitCircular saw with safety guard

Tool for making of square section bamboo sticks

Circular saw and bamboo stick polisher


Varying lengths Varying lengths

Varying lengths

Cracking of masala

Uneven coating along lengths Uneven stick

thicknesses

Uneven coating along lengths

Cracked ends

Badly cracked ends

Loose fibres

Study of raw sticks from the Nalbari Cluster

Raw sticks from the Bahumukhi Incense Stick Product factory Raw sticks from the Food Processing & Dhupkathi Making Udyog, Khudra, Makhibaha

8”8”8”


Study of scented sticks from the wholesale market at Guwahati

Outer box and inner packet with branding by the Padma Perfumery Works, Bangalore. Contains 16 hand-rolled and scented incense sticks

Even lengths of 9”

Even coating along lengths

Well-finished ends

Clear target customer Branded inner packet

Clear branding

Even stick thicknesses

Excessive powder

9”


Interview with Mr. Bani Kalita


Mr. Bani Kalita, a Guwahati based businessman and former resident of Tihu, is the founder of the NGO, the Bahumukhi Pratibha Vikas Samiti (Reg No. NAL/246/C/70). The foray into the incense stick industry is a new venture, with the Bahumukhi Incense Stick Product (BISP) factory in Tihu. His other business interests include a coke making factory - the first of its kind in Guwahati, and a fire-brick making factory among other interests.

The round stick making factory, which beagan functioning in June 2013, is situated in his factory premises at Sonarpur, and he also plans to begin arrangements to enable the rolling process of incense stick making. Mr. Kalita is interested in entering the retail market for incense sticks and has toured the country to develop an understanding of the product and the availability of its varieties in India. He spoke about the difficulty of entering the retail market, given the intense competition in this sector, and the dominance of a few brands.

In the course of the interview, he aired his views and requirements, which are as follows:• Gathering more information on machinery that will facilitate incense stick making, especially machines that coat the bamboo core stick with the masala mixture. (At present, most of the machinery installed in his factories are from Dewas, Madhya Pradesh)• Instate better market linkages for the incense sticks produced by the Bahumukhi Incense Stick Product. He wants to increase production in the factories and net better prices for the raw sticks.• Increase productivity and enable generation of more employment for the people of Assam

• Conduct research into the scenting process of incense stick making, in order to provide a finished product• The development of a logo, packaging and a branding plan for the finished product

Mr. Bani Kalita, founder of the Bahumukhi Pratibha Vikas Samiti


Proposals for product development for incense sticks

• Dyeing the ends of the sticks in brighter colours• Dip dyeing upto a market point will serve as a guide for the rolling of masala• Can produce festival specific range of incense sticks using colours and scents

• Manufacture of incense cones• Raw materials and processes are similar to those of incense stick making• This adds another product to the existing repertoire

• Manufacture small accessories for incense sticks - such as a bamboo stand and ash collecting tray in one

• Conversion of the large amounts of waste bamboo, especially the nodes, into bamboo charcoal• Bamboo charcoal is popular product in South East Asian countries and lately European and South American countries, as it absorbs a number of air and water borne pollutants.

• Colourful packets of finished sticks can be retailed as a gifting item

• Introduce a range of incense sticks in different sizes


Proprietor: Mr. Arun BarmanContact number: 98543 19114Date of visit: 18th July, 2013

Maniram Bah-bet Udyog is a small unit in Kaithalkuchi Village, Nalbari. The expertise of the unit is in the making of products from cane and bamboo, and include furniture, lampshades, baskets, flower-pot holders and other small items of household use. Mr. Barman has been involved in the cane and bamboo handicraft industry for over 20 years, and participates in numerous exhibitions and trade fairs, notable those at Dilli Haat and Pragati Maidan, in New Delhi.In addition, he also retails locally from a shop at the nearby town of Barama, Nalbari. Though the products are sturdy, there has been no change in the design of the products for many years, leading to a dip in the demand for these products. He works out of home, through a small workspace in the yard and is aided in the work mainly by a younger brother. A large part of the production is sold through the exhibitions and fairs and finished products are stored in any unoccupied space in the house. Citing large expenses incurred in the transportation of the products outside Assam, Mr. Barman is working on furniture that can be packed into compact units - an example is a set of two chairs, a table and a basket, as illustrated in the images.

Unit 7 - Maniram Bah-bet Udyog

Mr. Arun Barman, proprietor, Maniram Bah-bet Udyog


Innovative stacking of products

Adequately covered storage of raw material Shortage of workspace Shortage of workspace

The unpacked stack - 2 garden chairs, 1 garden table and 1 basket

No change in designs

Lack of storage space

Lack of storage space

Excessive surplus stock

Innovative attempt at design of stackable product sets - good design direction


Proprietor: Mr. Kamini BarmanContact number: Date of visit: 18th July, 2013

Champak Bah-bet Udyog is owned by Mr. Kamini Barman, the elder brother of Mr. Anil Barman of Maniram Bah-bet Udyog. Also situated in Kaithalkuchi, the unit functions in a manner similar to Maniram Bah-bet.Cane and bamboo furniture and household items are manufactured and retailed through the common store in Barman town. Mr. Barman also participates in numerous exhibitions and trade fairs in New Delhi, Surajkund, Nepal and Bhutan, in addition to undertaking local orders.Like those of Maniram bah-bet, the designs available in the product range have remained static over the years. Mr. Barman says sales through exhibitions are not as good as they used to be, and consequently, the quality of the raw material he uses has deteriorated. According to him, customers bargain for lower and lower prices. Towards the end of an exhibition or trade fair, he sells his stock at a marginal profit, to avoid paying expensive transportation rates to bring stock back to his home. As a result of this, he has now begun to use cheaper cane and bamboo. He faces a problem of storage of unsold stock - all available space in his house is overrun with finished products; some are even suspended from the ceiling beams.

Unit 7 - Champak Bah-bet Udyog

Mr. Kamini Barman, proprietor, Champak Bah-bet Udyog


The home and the front yard which serves as a workshop

Workshop - scattered material, no designated space for material and manufacturing activities

Products suspended from the ceiling Products strored in the kitchen Excessive surplus stock Excessive surplus stock

No change in designs

Bulky designs - difficult to transport

Unrefined design detailing and poor proportions



Product • Sofa sets, chairs, armchairs, garden chairs, coffee tables, side tables, murrahs, lamp-shades and an assortment of baskets in different designs - the designs of the products have not been updated for years

• Update the current product range by introducing designs more in sync with current market requirements, both domestic and international

Process

Packaging and Storage

• Almost exclusively hand-made, through the processes of sawing, splitting, bending and joining, using traditonal hand-tools such as the dao and katari, as well as the hacksaw, hammers, nails, pliers and kerosene blow lamps.• Jigs, when used are fashioned out of hardened earth.

• Product units tied together suspended from ceiling beams or stacked in any free space indoors

• Use of metal jigs for consistency in bending of component parts• Introduction to more refined finishing techniques through workshops, for the master craftsmen

• Design of stackable or knock-down products, which can be stored in a minimum of space, also enabling ease in transport


• Currently, no change apart from what the craftsman innovates for himself.

• To instate a design, training and marketing cell that provides design updates, training in implementation of the same and marketing aid to the units for ready products.

Design Audit - Unit 7 and 8


Opportunity Areas Remedial design solutions

Technology, modernisation and collaboration • Scope for use of better tools, jigs and product finishing techniques• Collaboration with institutes dealing with bamboo research and product development for regular inputs into product design and processes. • Also important to initiate collaborations with agencies that aid in the marketing of new products• Smaller units in this area may be able to collaborate with agarbatti making units to create packaging using bamboo and cane

• Bamboo’s versatility and the artisans facility with the material can be adapted into products that find a place in the contemporary market aesthetic, while retaining the essence of its cultural roots• Explore options of collaborations with architects and furniture stores, to co-create products• A study of temperature variations on products and ways and means of controlling the effects (if any), to facilitate export of products with a guarantee of durability to other countries

• Though the quality of cane and bamboo work in the north-east region is exemplary, products tend to sell less as designs have become redundant. Fresh designs or a reinterpretation of existing designs is required to revive interest in cane and bamboo products

• Creation of an identity linking the quality of material used and craftsmanship to its provenance will help build value for the product• As the north-easters states of India possess remarkarable technical and aesthetic mastery of cane and bamboo, instating a brand highlighting these qualities will make buyers aware of the value and hand-crafted nature of the product

• Building a Common Facility Centre could aid all the units in the area in terms of infrastructure as well as improving communications• All training in techniques and the the execution of new products can be undertaken at the CFC

• By initiating the establishment of a body of design and marketing profesionals resposible for design development and marketing of the same to interested buyers• Identification of target markets and reinterpretation /redesign of products to suit them • Cane and bamboo furniture used in conjunction with other materials, such as a metal core structure to give it longevity and lightness, can be easily marketed in cities.• People on the move would prefer furniture that is light, easy to stack and durable

Research and development directions for future initiatives

Market and competition study for design advantage and distinction

Visual identity and branding from communication design point of view

Inter cluster communication

To create a visible impact and effectively develop capabilities of MSME

Observations and suggestions on the cane & bamboo units


Proprietor: Mr. Sanatan RajbongshiContact number: 88764 46168Date of visit: 18th July, 2013

• The artisan makes decorative products using bamboo roots, the form of which guide the product, which are various animals and fish• All products are hand-tooled and are executed by a single artisan and require finesse in terms of artistic ability and finishing. • The artisan has also crafted a very good likeness of Sri Bhupen Hazarika; similar products can be produced as promotional items for Assam tourism and stocked in areas of high tourist footfall such as Kaziranga• Tools include the standard hacksaw, dao and katari• Products are large and heavy. Scaling down the size will help purchasing, especially by tourists.• Exhibits products at local and state exhibitions. Better executed products highlighting the fauna of the state of Assam would liven up regular exhibitions, especially if displayed in a tableau• Creation of an identity linking the quality of material used and craftsmanship to its provenance will help build value for the product. • Small hangtags with information on the name, habits and local lore regardingthe animal would help capture the attention of potential buyers• At a manufacturing level, a CFC with machines especially for finishing techniques would infinitely help the end look of the product.• At the training level, a short workshop on sculpting tools and techniques will enrich the abilities of this self-taught artisan• At a macro level, the instatment of a purchase and supply chain to stores and exhibitions around the state and country will help get the products a better market base.

Unit 8 - Sangita Bamboo Root Zoo

Mr. Sanatan Rajbongshi, proprietor, Sangita Bamboo Root Zoo

Products are attractive but need refinement in the finishing

Sculpting inputs will greatly improve the forms

Well executed likenesses, but needs more refiniment in the finishing

Observations & Design Audit - Unit 8


Proprietor: Mr. Mahendra ChilContact number: 96783 57388Date of visit: 18th July, 2013

• The artisan used to make decorative products such as animals and fish, using bamboo roots, but has now almost ceased activity. He now runs a small grocery shop, sells petrol and rents out space for parking of two-wheelers• All products are hand-tooled require a lot more finesse in terms of artistic ability and finishing. • Tools include the standard hacksaw, dao and katari• Products are large and heavy. Scaling down the size will help purchasing, especially by tourists.• The artisan is self taught and needs a great deat of training to improve the look and finish of the products before they can be retailed successfully• Creation of an identity linking the quality of material used and craftsmanship to its provenance will help build value for the product. • Small hangtags with information on the name, habits and local lore regardingthe animal would help capture the attention of potential buyers• At a manufacturing level, a CFC with machines especially for finishing techniques would infinitely help the end look of the product.• At the training level, a short workshop on sculpting tools and techniques will enrich the abilities of this self-taught artisan• At a macro level, the instatment of a purchase and supply chain to stores and exhibitions around the state and country will help get the products a better market base.

Unit 9 - Sunita Cycle Stand

Mr. Mahendra Chil, proprietor, Sunita Cycle Stand

Poor finishing

Currently runs a store

Artisan needs training in sculpting techniques

Half finished products - currently discarded

Observation & Design Audit - Unit 9



Fancy bazaar, Guwahati is the main wholesale market dealing in goods of every conceivable variety. A large part of the raw sticks produced from the BISP is dispatched to merchants with warehouses or shops here, where they are further shipped to Bangalore, or undergo the scenting process and find their way into the local markets.Small shop owners dealing with incense sticks among other goods, directed me to Barooah Market, where the largest dealers were to be found.Here, four shops stocking incense sticks from a huge number of brands acted as wholesale merchants. They were unable or unwilling to provide any information about buyers of raw sticks and where the scenting process occurs; they say that all stock is sourced from Bangalore.

A survey of the brands revealed that:• Material was largely sold under Bangalore based brand names, with a certain quantity from Mysore as well as Ahmedabad• The wholesale market sells cartons of twelve boxes, containing 16-20 sticks each (approx. 192 sticks per carton) at rates varying from Rs. 150/- to Rs. 450/-• Competition in this segment is fierce. As the number of brands available is huge, a superlative distribution system is essential• Branding revealed target markets from very young children to urban young adults - praying and/or use of incense is promoted as a lifetstyle activity• Savvy companies are using characters from popular serials on T.V. as a means of promoting theit product

Survey of Wholesale Markets at Guwahati

The entrance to Barooah market

Shops stocking incense, among other items


Small wholesale dealer, main Fancy Bazaar area Wholesale dealer, Barooah market

Shops stocking incense, among other items Wholesale dealer, Barooah market


Agarbatti brands on display at the wholesale stores in Barooah market

Target customer - children.Inspired by a popular TV serial

Freebies to attract customers Higher end products expressed through the packaging

Brands on display at wholsale stores in Barooah market


Packaging displaying information about the places of manufacture

Brands on display at wholsale stores in Barooah market


• Poor quality - loose fibres, cracking of masala, varying thicknesses of rolled sticks, varying lengths, non-uniform application of masala along length, varying thicknesses of bamboo stick cores

• Need exposure to better quality products• Must improve quality for better prices• Better training required

PRODUCT

• Inadequate training in rolling methods and mixing of raw ingredients• No quality checks for consistency of product• Poor posture - lack of ergonomically designed tools and workstations• No awareness of quality standards• Poor infrastructure in terms of space availability and usage.• Lack of financial support• No knowledge of account keeping• Inadequate reimbursement for efforts• Interest in growth but poor awareness and lack of access to information

• The proprietor or master artisan needs to be trained well, so as to further improve the skills of her team• Member(s) to be trained in Quality Control• Observation of postures and workstations adopted in other cultures, and to implement the same• Courses in account-keeping, increased awareness of loans and schemes by the state governments, especially for women run businesses• Better reimbursement or standardisation of rates per kg of product• Periodic meetings by design/marketing agency for inputs and updates

UNIT

• No dedicated training establishment• Lack of trained labour; seasonal labour availability as all hands are required on the fields during planting and harvesting season• Fulfils requirement of first level of supply chain - rolling raw sticks. No scenting or packaging. Implementation of scenting process adds value to the product and will help fetch better prices.• Lack of a cohesive growth plan - can implement agarbatti rolling as a community building and upliftment exercise. Currently, small units jobwork for BISP, but due to inadequate reimbursements, they are attempting to retail in local markets• No tie-up with established brands or buyers.

• Establish a nodal agency for training and development• Fix rates per kg of raw and finished material• Initiate research into the scenting process - try to establish scents unique to the region as USP of the product

CLUSTER

Summation of observations and suggested measures

Observations

Observations

Observations

Suggestions

Suggestions

Suggestions


• No active steps to promote the use of items of local provenence in day to day lives - local craft emporia are stuffy, have poor displays and no local promotion.• Not much collaboration with private agencies / stores / online stores for marketing and sale of products

• Active steps to consolidate and promote local design by making it easier to access - set up of small weekly markets where artisans from all over the state can display products• Instate a small warehouse for storage of products• Initiate collaborations with local designers, stores, marketing and distribution agencies in the area• Promote the weekly craft markets as a tourist attraction

REGIONAL

• No promotion of the crafts and textiles of Assam and the North-Eastern states as a brand • No collaboration with private agencies / stores / online stores for marketing and sale of products• Craft emporia do not promote themselves. Also poor displays, often indifferent attitude to customers, unstreamlined payment system

• To promote the products of Assam and North-East as a dedicated brand• Emphasise quality, hand made nature of the products, durability and use of eco-friendly material• Initiate collaborations with designers, stores, marketing and distribution agencies and manufacturing industries in and outside Assam• Refurbish the craft emporia - instate good window displays, highlight and market products on a monthly basis, create interest among customers• Facilitate placement of special orders - for individuals or companies and ensure dates of delivery are met

NATIONAL

• No promotion of the crafts and textiles of Assam and the North-Eastern states as a brand • No collaboration with agencies / stores / online stores for marketing and sale of products• Not enough participation in international exhibitions and fairs• Poor research into ability of local material especially bamboo, to withstand temperature variations internationally• No interest in the creation of a well-designed and beautifully finished range of products for international buyers

• To promote the products of Assam and North-East as a dedicated brand• Emphasis on quality, hand made nature of the products, durability and use of eco-friendly material• Collaborate with Indian and international designers for creation of product specific designs, for example: a range of cane stools or bamboo curtains • Instate a research body for study of local materials - their durability, exploration of techniques of joinery, finishing techniques etc

INTERNATIONAL

Observations

Observations

Observations

Suggestions

Suggestions

Suggestions


• Easy availability of raw materials - bamboo for core sticks; also plant material for conversion into powders• Willing and self-motivated workforce• Easy training - almost anyone from a large age group bracket can find employment•Can work out of home• Initial investment can provide sustained returns once product quality is improved and proper marketing channels are set in place• Increasing demand in markets in Europe and the Americas as a product associated with spirituality

• To create a brand of agarbattis from Assam• Set up a scenting research and application centre that serves the district, provides know how and easy to use, ready made kits for scenting. Also creation of indigenous scents• Design a simple, minimal packaging and logo, high-lighting the state• Set up of a Common Facility Centre dealing with all bamboo craft activities in the district• Cooperation among units to co-create high demand products such as gift packs during festival seasons• Use by-products such as bamboo waste, to create useful products such as bamboo charcoal

• Lack of a cohesive and sustained plan for growth• Poor quality - total lack of awareness of quality standards• Inadequate training leading to products of inferior quality• Transportation - distance from main buying centres - Bangalore and Mysore - poor roads and heavy rainfall • Poor awareness of market trends and requirements• Lack of proper management• Absence of proper scenting scenting methods• No finished product and hence no branding• Unwillingness to work as a cohesive community, leading to profit of all concerned

• Huge amount of competition from competing brands in the south• Competition from machine made agarbatti making units• Irregular availability of labour • Lack of dedication and systematic application• Possibility of health issues later due to poor ergonomics and inhalation of raw powders

OPPORTUNITY THREAT

WEAKNESSSTRENGTH

SWOT Analysis


Suggestions on the improvement of the rolling technique

• Use of a planing instrument as shown in the image above - can be a piece of planed wood or a stiff metal sheet, with a handle.• Use of a larger and more elevated rolling surface - greater surface area allows enough space for raw powders and a higher elevation allows better posture

• Dyeing the bamboo stick cores evenly upto a measured distance along the length - this makes it visually attractive as well as demarcating the area of coverage using the masala

• The planing instrument allows for even and quick rolling• Use of a larger quantity of kneaded masala for the rolling process

• The planing instrument can also be used to neatly cut the top of the rolled stick to prevent unevenness as shown in the study of raw sticks from the cluster

The above screenshots are from an internet movie on incense stick rolling in Huè, Vietnam. The artisan sits in a kneeling position at her worktable with an elevation suitable to keeping the spine straight. The use of a planing instrument allows for rapid rolling of the sticks and the application of very

even coat of masala. The area to be coated is clearly indicated by the undyed portion of the stick. The surface comfortably accomodates a large amount of kneaded masala as well as the scented powder. In case of Nalbari cluster, this would be charcoal powder.


Suggestions for ergonomic worksations

The photographs demonstrate the positions adopted by rollers in Vietnam, one of the leading exporters of incense sticks. The table and bench allows for a comfortable posture as opposed to the crouching position followed by the rollers in Nalbari. The use of a sloped table surface prevents excessive bending of the neck, increases visibility of the work surface and allows for better control of the rolling process.

The worktable is also designed to accomodate powder and large amounts of kneaded masala. A large bamboo or cane tray is supported on the knees and acts as a space to keep the bamboo stick cores as well as rolled sticks. Once a sufficient number of sticks have been rolled, the worker can get up and place them to dry, also allowing her a chance to stretch her back and limbs.

Space for storage of powders

Tray for keeping sticks

1 workstation accomodates 2 people Comfortable posture

Rolling surface can be used to close storage when unused


• Intitute a design, training and marketing cell to oversee activities of the cluster in bamboo incense stick rolling as well as cane and bamboo furniture and products• Training of the trainers so as to impart better manufacturing processes to master astisans, who in turn can train the juniors• Concentration on improvement of product quality• Providing a quality standards manual to ensure products of uniform quality• Exploration of options provided for better and more ergonomic workstations• Initiate agreements with designers for product development modules every six months• Initiate tie-ups with established brands as a supplier of better quality raw sticks• Development of accessories in bamboo, that are resonant with incense sticks, ‘dhoop-daan’ and similar items, that can be retailed singly or as gift packs with incense sticks.

• Initiate research into the scenting process and implement the infrastructure required for the same in a Common Facility Centre in the district• Development of indigenous scents or those unique to the region• Creation of a logo and development of an eco-friendly, affordable and easy to implement packaging• Launching of the improved product in the local markets, through established stores, exhibitions and fairs• Small kiosks near places of worship to allow customers easy access to the product• Initiation of tie-ups with suppliers and stores outside the state• Tie-ups with established brands as a supplier of raw and scented sticks (for example, ITC’s Mangaldeep brand)

• Developent of marketing links at a national level for the brand• Congruent development of ties with larger brands for supply of raw and scented sticks• Initiate tie-ups with international stores, both online and physical, for retail of products• Establish a dependable and affordable logistics system for efficent delivery

In 6 months

In 1 year

In 2 years

Suggested Future Initiatives


No. Name of worker Address Contact number

1 Dilip Dakua Village PO Haribhanga 88768 67620 2 Tapan Goswami Village No. 2 Nathkuchi 82539 88472 3 Mahesh Kalita Village No. 2 Nathkuchi 98642 95953 4 Anup Baishya Village Nakhara 94359 74650 5 Biswa Kalita Village No. 2 Nathkuchi 88760 51613 6 Kuladip Kalita Village Nakhara 82538 22421 7 Rekha Das Village Barmakhibaha -8 Gitumani Haloi Village Barbari 88768 46636 9 Bejuli Pathak Village Niznamati 88766 65443 10 Pranita Das Village Bamunbari (Namati) 88223 76475 11 Dipamani Kalita Village Bamunbari (Namati) 88763 00696 12 Hirumani Kalita Village Niznamati 87618 23957 13 Munni Kalita Tihu, Ward No. 3 88763 94306 14 Nilima Dutta Village Makhibaha 95772 74496 15 Podumi Devi Village Patikara 84861 97849 16 Bhunita Goswami Village no. 2, Nathkuchi 82539 88472

List of people to visit - supplied by the DIC, Nalbari

List of bamboo stick and agarbatti workers under Bahumukhi Pratibha Vikas Samiti, Tihu, Nalbari


No. Name of beneficiaries Address Contact number Age Craft

1 Maniram Barman Village Kaithalkuchi 88224 51654 40 Cane and bamboo2 Dwijen Sarma Village Kaithalkuchi 98598 92206 45 Cane and bamboo3 Paresh Haloi Village Kaithalkuchi 98587 30098 47 Cane and bamboo4 Ramen Haloi Village Sathikuchi 98547 66814 38 Cane and bamboo5 Hemanta Barman Village Sathikuchi 98542 33715 35 Cane and bamboo6 Tilak Barman Village Sathikuchi 98590 38416 35 Cane and bamboo7 Jatin Barman Village Sathikuchi 95771 19175 33 Cane and bamboo8 Mahendra Chil Village Besimari 96783 57388 50 Cane and bamboo9 Arjun Baishya Village Gobardal 95770 23024 39 Cane and bamboo10 Sanatan Rajbongshi Village Besimari 88768 46168 40 Cane and bamboo11 Prasannna Barman Village Sathikuchi 95777 90526 32 Cane and bamboo12 Harin Rajbongshi Village Sathikuchi 90853 96817 29 Cane and bamboo13 Suman Barman Village Sathikuchi 95777 90526 - Cane and bamboo

List of handicraft artisans, Nalbari district

Name and address of MSME unit: Bahumukhi Incesne Stick Cluster (Under Bahumukhi Pratibha Vikas Samiti, an NGO, Registration no. NAL/246/C/70), Tihu Village, Dist, NalbarContact Person with designation and contact details: Mr. Dilip Dakua, office assistant and general overseer. Phone: 88768 67620Product range: Hand‐rolled raw incense sticksNature of work: Splitting and sizing of bamboo into sticks, hand‐rolling of agarbatti mix onto sticks and wholesaler of raw incense sticksTurnover: 7000 kg annually @ INR 60/‐ per kg = INR 4,20,000/‐Infrastructure set‐up: SSI unitEmployee strength: 50 (F‐32, M‐18)Date of visit: 15‐07‐13, 16‐07‐13, 18‐07‐13

Sl. no. Opportunity areas for design intervention Covered? Remarks

1 Product design, redesign, product development Y Scope for better quality products. Can introduce scenting process

2 Technology, modernisation and collaboration YResearch into better rolling of masala methods + automation of process indicated. Can collaborate with organizations providing training in scenting process as well

3 Research and development directions for future initiatives YIn the areas of scenting, brand development and packaging. Also development of small bamboo products for use with agarbattis

4Innovation in process and related areas for design intervention Y

Need to better the rolling process for more quality products. Also standardise the size of the bamboo sticks used

5 Workstation and tooling design Y

Study for more comfortable posture indicated while rolling agarbattis, perhaps a higher rolling table? Also no protective gear used while operating machines. Areas involving mixing of powders can enforce use of masks to prevent inhalation of fine powders and charcoal dust

6Market and competition study for design advantage and distinction Y

Thorough market analysis required if they want to step into retail. At present the local markets are flooded with agarbatti from Bangalore. Need to conduct research into which segment they want to enter in terms of retail

7 Training and skill upgradation, if any Y

Better training indicated, especially for units which job‐work for BISP. Can introduce a skill development program with better workstations and including visuals and movies as part of awareness of product quality

8 Ergonomic and environment factors YMore comfortable posture and more efficient working table required. Also better lighting inthe work areas

9Packaging, logistics and storage related design opportunities Y

Packaging reqd if they plan to enter retail. Storage is haphazard ‐ need to streamline, have dedicated areas for certain materials. Easy access to material and dry storage areas also indicated. Storage of finished goods is in the same space as the working area causing excess clutter.

10Infrastructure and capability enhancement from design perspective Y

Replan the factory to streamline the manufacturing process ‐ a sequential series of operations from the entry of raw material to exit of finished goods.

11 Exhibition / display design opportunities YCan participate in exhibitions of which there are a number every year. Can design appropriate and aesthetic props for display of the product

12Visual identity and branding from communication design point of view Y

Can develop an area appropriate branding and packaging ‐ highlighting the north east. Use of better quality raw material. Development of unique products ‐ all natural / unique scents / agarbatti + stands / gift sets.

13 Inter cluster communication Y Fairly good, with job‐workers in the area. However better training indicated

14To create a visible impact and effectively develop capabilities of MSME Y Covered in points 2, 4, 6, 10

15 To improve the process of manufacturing and productivity Y Covered in points 2, 5, 7, 10

16 To increase market share and profitability YBy introducing scenting, improving product quality and product packaging. Even in case of wholesale, product quality need improvement.

17To reduce rejections, wastages in material, process, resources and drudgery in labour Y Covered in points 8, 10

18To improve product manufacturability, servicability, manufacturing process, packaging, logistics operations etc. Y Covered in points 2, 10, 12

19To add value to the product or services concerned and increase their competitiveness Y Covered in points 3, 12

20

To create a positive difference to the MSME, either in absolute revenues (indicating higher profits) or in percentage terms Y Covered in points 2, 4, 6

Research into improving the rolling of agarbattis ‐they are currrrently rolled on a wood table using the flat of the hand. However on being shown a video of agarbatti rolling iVietnam, using a planed piece of wood, helped in the realization that a small intervention can have a large impact of the quality of the rolling of the agarbattisStrict quality controls and standarisation in size and thickness required.Need of better, more ergonomic workstations and comfortable working positions. Also cleaner, better lit and more organized working space will improve outputStudy of sequence of operations and accordingly reworking the factory layout to improve overall production. Also laying of a permanent flooring will enhance cleanlinessAmple scope for product development including finishing processes such as scenting and packaging ‐ need to initiate collaborations with organizations with know‐how in scentsand the scenting process. Product development in terms of size, colour, packaging and branding need to be worked out

Remedial design solutions suggested

Design Awareness Programme(Need Assessment Survey and Design Clinic Workshop)

Checklist for Design Expert(s) to conduct Need Assessment Survey

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The Bahumukhi Incense Stick Product factory, established in 2009, is located in Tihu village, Nalbari dist., Assam. It is one of the initiatives of the Bahumukhi PratibhaVikas Samiti, an NGO run by Bani Kalita, a Guwahati based businessman.Mr.Kalita also owns a bamboo round stick making unit in Sonarpur area near GuwahatiThe Bahumukhi Incense Stick Product (henceforth referred to as BISP) is the first to initiate the business of incense stick making in the area. They supply raw incense sticks to buyers in Guwahati, Tejpur and Bangalore. They outsource part of their manufacturing to small home based units in and around nearby villages ‐ MakhibahaPalitana and Nathkuchi as well as to villages in Darrang, Chirang and Baksa districts.They source raw materials for the agarbatti mix (called masala) locally or from Meghalaya, Hyderabad and the Assam‐Bhutan border. The grindingand mixing is done at BISP and supplied to local units. Once the masala is rolled onto the sticks, a process known locally as 'leping' and dried, it is sentback to the BISP premises, where it is packed and sent out.The BISP round stick making factory at Sonarpur is highly mechanised and has been in operation since June 2013. Hence no data was available regarding turnoveand other issues. However, a separate report on the machinery and processes is provided.

Sl. No. Topic Covered Remarks

1 Problems in product / process YLabour shortage. Production process not streamlined. Disorganized work areas. No dedicated area for drying of agarbattis

2 Problems in packaging / visual identity YNo dedicated visual identity ‐ they are wholesale manufacturers. Packaging is in form of 1/2 kg packs bound and wrapped in newspaper. Transported to Guwahati in sacks of 40kgs.

3Level of awareness of new processes / machinery Y

At factory level: Not high. No exposure to the internet. However the owner, Mr.Kalita is a savvy individual,keen on developing a strong marketing framework

4 General observationsMost productive months are between November‐April, the non‐monsoon months. Also, labour availability isbetter as this is a low period for agricultural activities.

5 Workstation and tooling details Y

Tools consist of a small wooden table usually 15"x10"x4" for the rolling. However, no set sizes. Stick making tools consist of a small wood‐handled knife called a katari. Manual cutting of bamboo with a hacksaw and splitting with a large wood‐handled knife called a 'dao'.

6 Ergonomic Issues YWorking position is squatting or cross‐legged on the ground. Though the workers claim no discomfort, the neck is craned downward for long periods of time.

7 Lighting in work areas YVery poor, 4 medium CFL lamps in a large shed. However, work is limited to the daylight hours between10 amto 4 pm max

8 Worker oriented facilities (Canteen / toilets) Y Canteen present. Toilets present9 Skilled / semi‐skilled labour Y Mostly semi‐skilled, with about two skilled hand rollers

10 Wages Y Did not divulge11 Gender distribution in workforce Y F ‐ 32, M ‐ 1812 General obsevations They train new employees in house as well as send trainers to other units in the state.

13 Raw materials YJigat powder, leaves/bark powder consisting of 'bagnal' bark, teak leaves, 'amar lata', wild tulsi, charcoal powder

14 Raw material procurement YJigat powder / leaves and bark powder: locally, Baksa and Chirang districts, Arunachal Pradesh. Charcoal powder : Hyderabad, Wood coal: Meghalaya. Bamboo: Locally. Transportation is by means of trucks

15 Method of purchase Y Agents, who supply them

16 Storage facilities Y Large bamboo walled and asbestos sheeted sheds. Adequate storage area. Unplanned means of storage.

17 Transportation details YAll movement of finished goods from the manufacturing unit is by road by tempos or trucks. Transport between village units and BISP is by cycle, motorbikes or tempos.

18In‐house facilities / indigenous innovations / collaboration within units Y

Machinery details: Pulverisers, Mixers, Round saws, Splitting and sizing machines, Polishers, Vibro screen (for sifting), Testing lab for quality of charcoal

19 Automation in manufacturing process Y Mostly in the pulverizing and mixing of raw materials and for cutting, sizing of bamboo20 Means of communication Y Phone21 Methods of quality control Y Small lab for charcoal quality testing, otherwise none observed22 General observations Factory layout needs to be better, storage is haphazard, general lack of cleanliness

23 Mode of selling product Y Wholesale only. Raw agarbattis supplied to buyers in Guwahati, Tejpur and Bangalore, Mathura24 Designated marketing person / agency Y None mentioned25 Electricity Issues Y Fluctuating supply. Cited as inadequate to run machines regularly26 Raw material procurement Y Locally, or through agents27 Labour Y Cite shortage of skilled labour28 Space Y No shortage of space. However very poor planning and utilization of it. 29 Government support Y None mentioned30 Mode of financing operations Y None mentioned31 Business development plans Y Interested in retail for domestic and export markets

32Willingness to collaborate with designer + other units for future initiatives Y

Interested in developing a brand identity and packaging. Mr.Kalita cites the requirement of a plan to launch abrand into domestic and international retail markets.

33 General observations Very competitive market. In case of venturing into retail, will need to acquire know‐how for scenting processes

Introduction to the MSME unit

Questionnaire for each unit visited

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Name and address of MSME unit: North East Incense Powder (Under Bahumukhi Pratibha Vikas Samiti, an NGO, Registration no. NAL/246/C/70)Contact Person with designation and contact details: Mr. D. Sarma. Phone: 98641 20348Product range: Round stick making. Nature of work: Splitting and sizing of bamboo into round sticks for agarbattis, pulverising and powdering of raw mateials and charcaolTurnover: In operation since June 2013, hence no indicationInfrastructure set‐up: SSI unitEmployee strength: 10Date of visit: 19‐07‐13


1 Product design, redesign, product development Y Plan to introduce rolling of agarbattis at a later date

2 Technology, modernisation and collaboration Y

Well equipped with requisite machinery for current processes. Can invest in machinery for applicaton of masala to agarbattis. Can plan on scenting process as well as packaging due to proximity to Guwahati.

3Research and development directions for future initiatives Y Covered in point 2


Need to create an area for drying of sized sticks. Also a catchment area or receptacle for sized slivers and sticks

5 Workstation and tooling design Y

Need to follow safety measures for operation of cutting tools. Tool is left in operation till switch which is about 15'away is turned off. Also use of masks during pulverising and powdering indicated

6Market and competition study for design advantage and distinction Y Covered in point 2

7 Training and skill upgradation, if any Y Better training in safe use of machinery indicated

8 Ergonomic and environment factors YDedicated areas needed for sectioning of bamboo. Currently it is done in the open on uneven ground using power cutting tools in a very unsafe manner


Can invest in a space for loading and unloading of materials outside the work area. Can dedicate a cordoned off space for storage of packed sticks.

10Infrastructure and capability enhancement from design perspective Y Plan factory layout according to sequence of operations

11 Exhibition / display design opportunities Y n /a


Can serve as a collection point for finished goods for packaging and boxing incase of foray into retail

13 Inter cluster communication Y Supplier of round sticks and raw material for masala to units in Nalbari and other districts

14To create a visible impact and effectively develop capabilities of MSME Y Covered in points 2

15To improve the process of manufacturing and productivity Y

Factory not functioning to capacity. Some machines underutilized and others unused due to a preference for processes by hand, esp in the splitting of the bamboo shoot sections

16 To increase market share and profitability Y By utilizing the factory to full potential

17To reduce rejections, wastages in material, process, resources and drudgery in labour Y Covered in point 10

18

To improve product manufacturability, servicability, manufacturing process, packaging, logistics operations etc. Y Covered in point 10

19To add value to the product or services concerned and increase their competitiveness Y Covered in points 3, 12

20

To create a positive difference to the MSME, either in absolute revenues (indicating highr profits) or in percentage terms Y Not applicable at this point as factory commenced functioning barely a month before

Since the factory has just commenced operations, it is a good time to rework the layout of the factory floor and streamline processes. Simple interventions like the inclusionof a receptacle for collection slivers and sticks as it exits the machines will help save time and improve productivity. A series of open shelves or raised platforms for drying of sticks will help in improving quality of the finished sticksEnforcement of safety measures while using power tools is a must.Strict quality controls and standarisation in size and thickness required.Can plan on a CFC for research and development into scents and the scenting process plus packaging. Proximity to Guwahati is a distinct advantage.




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Name and address of MSME unit: Gargi Dhupkathi Udyog functioning under the Milan SHGContact Person with designation and contact details: Ms. Rekha Das, Proprietor. Phone: 88220 65179Product range: Hand‐rolled raw incense sticks. The proprietor also owns a small handloom for the weaving of 'mekhala chador'Nature of work: Splitting and sizing of bamboo culm into sticks, hand‐rolling of agarbatti mix onto sticks. Jobworking for BISP as well as retailing to local markets around TihuTurnover: Approx. INR 3000/‐ per month x 12 = INR 36,000/‐ annuallyInfrastructure set‐up: Micro enterpriseEmployee strength: 14, all female, of which around 6‐7 people are working dailyDate of visit: 15‐07‐13, 16‐07‐13


1 Product design, redesign, product development Y Scope for development of better quality scented agarbattis for the local markets


At present, all work is done by hand from cutting of bamboo sections to rolling of the agarbattis. Collaboration happens in terms of buying raw material such as bamboo culms from within members of the GDU.

3Research and development directions for future initiatives Y Wants to develop a viable packaging for the local market


They can explore the rolling of agarbattis using a planed piece of wood for more even thickness of the agarbatti as well as better productivity

5 Workstation and tooling design Y Needs more worktables with better ergonomics


An attractive packaging in the local language might help as buyers can identify with it. However, it need to be verified through a survey in the area

7 Training and skill upgradation, if any Y Can do with some training as rolling process is slow. 8 Ergonomic and environment factors Y Needs better designed work tables


Not enough storage space. However what is there is well utilized and clean. Packaging material is in the form of ready made boxes bearing the identity of brands in Bangalore

10Infrastructure and capability enhancement from design perspective Y Needs more workspace and better organized work flow.

11 Exhibition / display design opportunities YCan participate in exhibitions of which there are a number every year. Design of appropriate packaging and aesthetic props for display of the product would help.

12Visual identity and branding from communication design point of view Y Covered in point 6

13 Inter cluster communication Y None, apart from the regular social contact

14To create a visible impact and effectively develop capabilities of MSME Y Covered in points 4, 6, 10

15To improve the process of manufacturing and productivity Y Covered in points 4, 5, 10

16 To increase market share and profitability Y Covered in point 6


18

To improve product manufacturability, servicability, manufacturing process, packaging, logistics operations etc. Y Covered in points 6, 10

19To add value to the product or services concerned and increase their competitiveness Y Better quality scents and better packaging

20

To create a positive difference to the MSME, either in absolute revenues (indicating higher profits) or in percentage terms Y

Covered in points 1, 4, 6, 10. In addition the unit would greatly profit from a short indroduction to basic accountkeeping

Research into improving the rolling of agarbattis ‐they are currrrently rolled on a wood table using the flat of the hand. May attempt rolling using a planed piece of wood for faster, better rolled agarbattis. It is a simple intervention not requiring any investmentBetter quality controls and standarisation in size and thickness required.Need of better, more ergonomic workstations and a larger workspace. Current facility is cramped. Development of a viable packaging solution




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Gargi Dhupkathi Udyog (henceforth referred to as GDU) is a small agarbatti manufacturing unit under the Milan SHG at Makhibaha village. The propreitor, Ms.Rekha Das hasconstructed a small working area, screened with bamboo walls in the porch of her home which serves as the working area for women from the villageThe roughly 10'x 6' space contains the work and storage area. Inspite of the space contraints, the work area is neat and cleanThe GDU is mainly engaged in the application of the agarbatti masala to the bamboo stick cores. They also split and size the bamboo into sticksthe unit is one of the job‐workers for the BISP. Sticks and masala are supplied to them, they roll the masala onto the agarbattis and sell it back to the BISP. They also make a smalquantity of agarbattis for retail in the local markets around the villageOf late, Ms Das has begun to experiment with scenting raw agarbattis, packaging them and retailing to local markets


1 Problems in product / process Y Inadequate infrastructure ‐ shortage of work tables for rolling process. They work two to a table.

2 Problems in packaging / visual identity YPackaging for the retail market consists of an assortment of boxes available from the market. The boxes bear the identities of manufacturers in Bangalore


Very poor. Dependant on the BISP for inputs, if any. Access to markets in Guwahati is limited due to the distance from the village.

4 General observations

Inspite of space and financial constraints, the quality of agarbattis rolled here is fairly good. Ms. Das is very keen on developing a simple and viable firm of packaging for her local market. She has already begun to produce and sell scented agarbattis


Tools consist of a small wooden table usually 15"x10"x4" for the rolling. However, no set sizes. Stick making tools consist of a small wood‐handled knife called a katari. Manual cutting of bamboo with a hacksaw and splitting with a large wood‐handled knife called a 'dao'.

6 Ergonomic Issues YWorking position in this unit cross‐legged on the ground. Though the workers claim no discomfort, the neck is craned downward for long periods of time.

7 Lighting in work areas YNone. Work happens only during the hours of 10 am to 3 pm, as this is the time the women are free of household chores.

8 Worker oriented facilities (Canteen / toilets) Y Workers travel from their homes which are within walking distance, therefore none necessary9 Skilled / semi‐skilled labour Y Mostly semi‐skilled

10 Wages Y Did not divulge, but mentioned a profit sharing mode of operations11 Gender distribution in workforce Y All female

12 General obsevations

Cramped workspace and shortage of tools. However, a fairly good quality product and propietor is motivated to improve conditions. The current workspace was constructed with a small loan and she is looking for anotherloan to enlarge the workarea. According to her, more ladies are keen to join but are hampered by lack of space.

13 Raw materials Y The powdered masala mix, charcoal powder, bamboo sticks

14 Raw material procurement YCharcoal powder and masala powders supplied at a cost of INR 30/‐ by the BISP. Sticks made in‐house and alsosold to the BISP at INR 16/‐ per kg

15 Method of purchase Y Direct from BISP

16 Storage facilities YAn elevated area of 3'x2' at the further end of the workspace. Rolled agarbattis are dried outside theworkspace perimeter

17 Transportation details Y Cycles and motorbikes

18In‐house facilities / indigenous innovations / collaboration within units Y Initiating the scenting process for sale in local markets

19 Automation in manufacturing process Y None20 Means of communication Y Phone21 Methods of quality control Y Badly rolled agarbatties are re‐rolled. Otherwise, none observed

22 General observationsMasala bought at INR 30/‐ per kg suffices to roll 4kg of agarbatti. They supply rolled agarbattis to BISP at INR 40/‐ per kg

23 Mode of selling product Y Small retail market. Otherwise, jobworks for BISP24 Designated marketing person / agency Y None mentioned

25 Electricity Issues YFluctuating supply. However work happens during daylight hours and there is no electrically operated machinery present

26 Raw material procurement Y Locally and from BISP27 Labour Y No shortage of interested workers. However, they require a certain amount of training28 Space Y Acute shortage of space29 Government support Y Looking for financial support in terms of investment or a loan

30 Mode of financing operations YSelf or generated by the selling of the agarbattis. Wants to expand but unable to do so due to severe financialconstraints

31 Business development plans Y Interested in developing a local retail presence

32Willingness to collaborate with designer and other units for future initiatives Y Willing to work with a designer. Not keen on collaboration with other units as perceived as competition

33 General observationsAcute shortage of financial support hampering any growth plans. The proprietor would greatly benefit from a short course in basic accountkeeping



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Name and address of MSME unit: Food Processing Centre and Dhupkathi Making Udyog, Khudra, Makhibaha, PO Makhibaha, Assam 781375Contact Person with designation and contact details: Ms. Gitanjali Bhatta, Secretary. Phone: 95080 13502Product range: Hand‐rolled raw incense sticks and food products such as Assamese 'pitha', laddoos and namkeenNature of work: Splitting and sizing of bamboo culm into sticks, hand‐rolling of agarbatti mix onto sticks. Jobworking for BISP as well as retailing to local markets around TihuTurnover: Unaware as keep no account books or are unwilling to answer. Infrastructure set‐up: Micro enterpriseEmployee strength: 23 women in the SHG of which about 6 work dailyDate of visit: 15‐07‐13, 16‐07‐13


1 Product design, redesign, product development Y Scope for development of better quality scented agarbattis for the local markets


At present, all work is done by hand from cutting of bamboo sections to rolling of the agarbattis. Collaboration happens in terms of buying raw material such as bamboo culms from within members of the GDU.

3 Research and development directions for future initiatives Y Wants to develop a viable packaging for the local market


They can explore the rolling of agarbattis using a planed piece of wood for more even thickness of the agarbatti as well as better productivity. However training is needed as workers are slow.

5 Workstation and tooling design Y Needs more worktables with better ergonomics


An attractive packaging in the local language might help as buyers can identify with it. However, it need to be verified through a survey in the area

7 Training and skill upgradation, if any Y Needs training as slow and quality of product poor to middling8 Ergonomic and environment factors Y Needs better designed work tables

9Packaging, logistics and storage related design opportunities Y Adequate space, but poor usage. Quite unplanned

10Infrastructure and capability enhancement from design perspective Y Needs more worker training and better organized work flow.

11 Exhibition / display design opportunities YCan participate in exhibitions of which there are a number every year. Design of appropriate packaging and aesthetic props for display of the product would help.

12Visual identity and branding from communication design point of view Y Covered in point 6


14To create a visible impact and effectively develop capabilities of MSME Y Covered in points 4, 6, 10

15 To improve the process of manufacturing and productivity Y Covered in points 4, 5, 1016 To increase market share and profitability Y Covered in point 6


18


19To add value to the product or services concerned and increase their competitiveness Y Better quality scents and better packaging

20


Covered in points 1, 4, 6, 10. In addition the unit would greatly profit from a short indroduction to basic accountkeeping

Research into improving the rolling of agarbattis ‐they are currrrently rolled on a wood table using the flat of the hand. May attempt rolling using a slaned piece of wood for faster, better rolled agarbattis. It is a simple intervention not requiring any investment. More training for workers requiredSecretary Ms.Bhatta needs to make better use of the facilities provided. No shortage of space, but haphazard usage of it and general unmotivated attitude.Better quality controls and standarisation in size and thickness required. Need of better, more ergonomic workstations.Development of a viable packaging solution




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Dhupkathi Making Udyog (henceforth referred to as DMU) is a small agarbatti manufacturing unit under the Food Processing Centre and Dhupkathi Making Udyog SHG at Khudra,Makhibaha village. A CFC has been constructed within the compund of Ms. Gitanjali Bhatta, the Secretary of the SHG, with the aid of state government schemes. The permanentstructure consists of two large rooms with a covered porch. Of the two rooms, one is used for storage of raw material and as a workspace. The other was not in useThe CFC was constructed in 2012 by the District Rural Development Agency.The DMU is mainly engaged in the application of the agarbatti masala to the bamboo stick cores. They also split and size the bamboo into sticks and jobwork for the BISP. Sticksand masala are supplied to them, they roll the masala onto the agarbattis and sell it back to the BISP. They also make a small quantity of agarbattis for retail in the local markets


1 Problems in product / process Y Inadequate training and poor usage of space.

2 Problems in packaging / visual identity YPackaging for the retail market consists of an assortment of boxes available from the market. The boxes bear the identities of manufacturers in Bangalore



4 General observations Poor usage of available space and lack of training.


Tools consist of a small wooden table usually 15"x10"x4" for the rolling. However, no set sizes. Stick makingtools consist of a small wood‐handled knife called a katari. Manual cutting of bamboo with a hacksaw and splitting with a large wood‐handled knife called a 'dao'.

6 Ergonomic Issues YWorking position in this unit cross‐legged on the ground. Though the workers claim no discomfort, the neckis craned downward for long periods of time.

7 Lighting in work areas YSingle bulb. However, work happens only during the hours of 10 am to 3 pm, as this is the time the womenare free of household chores.

8 Worker oriented facilities (Canteen / toilets) Y Workers travel from their homes which are within walking distance, therefore none necessary9 Skilled / semi‐skilled labour Y Mostly semi‐skilled10 Wages Y Did not divulge, but mentioned a profit sharing mode of operations11 Gender distribution in workforce Y All female 12 General obsevations Very haphazard work area. Needs to be organised

13 Raw materials Y The powdered masala mix, charcoal powder, bamboo sticks

14 Raw material procurement Y

Charcoal powder and masala powders supplied at a cost of INR 55/‐ by the BISP. This may be an inaccurateand inflated price as GDU mentions masala powder at INR 30/‐ per kg. Sticks made in‐house and also sold to the BISP at INR 16/‐ per kg. However, according to Ms. Bhatta, they buy sticks, if required, from BISP at INR 25/‐ per kg

15 Method of purchase Y Direct from BISP16 Storage facilities Y Adequate but poorly used17 Transportation details Y Cycles and motorbikes

18In‐house facilities / indigenous innovations / collaboration within units Y Initiating the scenting process for sale in local markets

19 Automation in manufacturing process Y None20 Means of communication Y Phone21 Methods of quality control Y Badly rolled agarbatties are re‐rolled. Otherwise, none observed

22 General observationsUnplanned work areas leading to poor utilisation of space. No methods of accounting. Conflicting accountsof profits

23 Mode of selling product Y Small retail market. Otherwise, jobworks for BISP. Sells a box of 10 agarbattis for INR 5/‐ locally24 Designated marketing person / agency Y None mentioned

25 Electricity Issues YFluctuating supply. However work happens during daylight hours and there is no electrically operatedmachinery present

26 Raw material procurement Y Locally and from BISP27 Labour Y Workers require a great deal of training for better quality of agarbattis28 Space Y Ample but poorly used

29 Government support Y Have received support for construction of a permanent structure serving as a Common Facility Centre30 Mode of financing operations Y Self or generated by the selling of the agarbattis. 31 Business development plans Y Interested in developing a local retail presence

32Willingness to collaborate with designer and other units for future initiatives Y Willing to work with a designer. Not keen on collaboration with other units as perceived as competition

33 General observations General lack of planning



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Name and address of MSME unit: Sauji SHG, Village Jalkhana (Patikara), PO Jalkhana, Districy Nalbari, Assam 781374Contact Person with designation and contact details: Ms. Seuli Debi or Ms. Podumi Debi Das. Phone: 84861 97849Product range: Nature of work: Splitting, slicing and sizing of bamboo culm into sticks for agarbattis for sale to the BISP, goat farming, weaving and tailoringTurnover: Approximation ‐ 70kg per week x 52 weeks = 3744 kg per year x INR 16/‐ per kg = INR 59,904/‐ . This is assuming they work through the year. The actual amount may be much lower.Infrastructure set‐up: Micro enterpriseEmployee strength: 12, all female, of which only Podumi debi is actively engaged in this activity. She is also on the payroll of the BISPDate of visit: 15‐07‐13, 16‐07‐13


1 Product design, redesign, product development Y Scope for rolling of agarbattis for sale to the BISP and the local market

2 Technology, modernisation and collaboration YAt present, all work is done by hand. They possess a power tool for cutting and two machines for slicing which are infrequently used

3Research and development directions for future initiatives Y Some of the ladies want to take up the activity of rolling the agarbattis


They can explore the rolling of agarbattis using a planed piece of wood for more even thickness of the agarbatti as well as better productivity

5 Workstation and tooling design Y At present none as all the cutting is hand done using a hacksaw, dao and katari.

6Market and competition study for design advantage and distinction Y At present can supply cut sticks to other local manufacturers in addition to the BISP

7 Training and skill upgradation, if any YMembers can be trained in the rolling process, also in making of small bamboo artifacts for sale with agarbattis

8 Ergonomic and environment factors Y

Ample bamboo available around the village. Ergonomically, the workers say the position they emply is comfortable. However the use of a low stool may provide a posture more comfortable for work

9Packaging, logistics and storage related design opportunities Y Output is sent on an almost daily basis to BISP

10Infrastructure and capability enhancement from design perspective Y Covered in point 7

11 Exhibition / display design opportunities Y None at present

12Visual identity and branding from communication design point of view Y None at present


14To create a visible impact and effectively develop capabilities of MSME Y

Instate other profit making activities such as rolling of agarbattis and other small bamboo artifacts

15To improve the process of manufacturing and productivity Y covered in point 14

16 To increase market share and profitability Y covered in point 14

17To reduce rejections, wastages in material, process, resources and drudgery in labour Y

Ideally by making use of the tools available. However, the members claim faster results by hand

18

To improve product manufacturability, servicability, manufacturing process, packaging, logistics operations etc. Y covered in point 14

19To add value to the product or services concerned and increase their competitiveness Y covered in point 14

20


covered in point 14. In addition, a short course in account may be of immense help in any future endeavours

At present certain members of the SHG are involved solely in making of bamboo sticks for BISP. Venturing into rolling of the agarbattis may be a source of added income




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The activities of Sauji SHG are bamboo stick making, goat farming, weaving of mekhala‐chador and tailoring. Of the twelve women who are part of the SHG, only around threeare actively engaged in bamboo stick making, of which one, Ms.Podumi Debi is the most efficient and also works at the BISPThey possess power cutting tools and some machines for bamboo slicing but prefer to work manually as they say it is faster. Also, the power cutting tool consumes too muchelectricity for them to find of viable use.Ms. Podumi Debi wants to take up agarbatti rolling on a regular basis, the others are either unwilling or unsure. They are more interested in availing of loans to facilitate andbolster their tailoring activities.


1 Problems in product / process Y All manual ‐ from sectioning the culm to slicing and sizing. 2 Problems in packaging / visual identity Y Not applicable as they produce only part of the final product



4 General observationsMs. Podumi Debi is very skilled in the slicing and sizing of the bamboo sticks. Long practice has given her an astonishing degree of deftness in the process.

5 Workstation and tooling details Y Tools consist of a hacksaw, a dao and a katari. Power cutting tool and others are available but unused6 Ergonomic Issues Y Working position is either squatting or cross‐legged. Seem to have no issues7 Lighting in work areas Y Work takes place in the living area of Ms. Podumi Debi and only in daylight hours.

8 Worker oriented facilities (Canteen / toilets) Y Workers travel from their homes which are within walking distance, therefore none necessary9 Skilled / semi‐skilled labour Y Mostly semi‐skilled, except Ms.Podumi Debi who is highly skilled

10 Wages Y Did not divulge, but mentioned a profit sharing mode of operations11 Gender distribution in workforce Y All female

12 General obsevations

More women would be interested in joining the work if there was better incentive. As such the work is quitelabour intensive and few are wiiling to take it up full‐time. They also seek a better price for the bamboo sticks supplied to BISP ‐ they want INR 20‐25 per kg.

13 Raw materials Y Bamboo culms14 Raw material procurement Y Locally or from Ms. Podumi Debi15 Method of purchase Y Covered in point 14

16 Storage facilities Y Same area as the workspace. Output is not stored for long, but supplied on an almost daily basis to BISP17 Transportation details Y Cycles

18In‐house facilities / indigenous innovations / collaboration within units Y None

19 Automation in manufacturing process Y None20 Means of communication Y Phone21 Methods of quality control Y Odd sized sticks are discarded. Effort is made to keep size to the coorect lengths of 8"and 9"22 General observations One bamboo culm costs INR 80/‐ and yields approximately 12 kg of sized sticks

23 Mode of selling product Y Jobworks for BISP24 Designated marketing person / agency Y None mentioned25 Electricity Issues Y Fluctuating supply. However work happens during daylight hours.26 Raw material procurement Y Locally27 Labour Y Need motivation and incentive to engage in this activity28 Space Y No dedicated space29 Government support Y None mentioned30 Mode of financing operations Y Self31 Business development plans Y Some members interested in engaging in the rolling process

32Willingness to collaborate with designer and other units for future initiatives Y Willing to work with a designer.

33 General observationsNo account keeping makes it diffilcult to estimate any profit or loss. A system of accounting might help convince other members of the monetary gain in participating in the activity



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Name of unit No. Name of workers Age

Gargi Dhupkathi Udyog 1 Sabita Das 182 Niru Das 163 Sabita Haloi 404 Kakoli Kalita 205 Monica Das 356 Kamala Das 327 Purabi Das 208 Renuka Haloi 359 Bina Datta 4010 Sunita Das 2011 Gunumuni Das 1812 Gitika Haloi 2513 Lipika Haloi 2314 Rekha Das 35

Dhupkath Making Udyog of 1 Ranjita Bhatta 38Khudra Makhibaha 2 Gitanjali Bhatta 39

3 Monomoti Bhatta 454 Shilpi Bhatta 205 Panki Bhatta 20

6 Komola Debi 267 Sabitri Debi 458 Dalimi Debi 409 Nandita Barman 3510 Bhunita Debi 4511 Rani Sarma 4012 Gitanjali Barman 4013 Sangeeta Debi 3014 Anupama Debi 4015 Nirupama Debi 3516 Rita Debi 3517 Helentina Sarma 2018 Bhabita Debi 3519 Gita Das 3520 Mamoni Debi 4021 Rukmini Barman 3022 Hiran Barman 4023 Binita Barman 40

Bahumukhi Incense Stick Product 1 Podumi Debi 402 Sribimala Das 453 Rina Das 404 Gitu Haloi 195 Bijuli Pathak 206 Pranita Das 257 Mani Kalita 198 Hirumoni Kalita 179 Nilima Dutta 30

Seuji SHG 1 Podumi Debi 402 Sewali Debi 403 Pranita Debi 354 Aparajita Debi 35

5 Bhagyasri Debi 336 Phoolkumari Debi 377 Dipika Debi 408 Archana Debi 409 Anjumoni Debi 3310 Manju Debi 4011 Arpana Debi 3712 Namita Debi 30

List of workers under each Agarbatti making unit visited

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List of people supplied by the DICC, Nalbari

No. Name of worker Address Contact number1 Dilip Dakua Village PO Haribhanga 88768 676202 Tapan Goswami Village No. 2 Nathkuchi 82539 884723 Mahesh Kalita Village No. 2 Nathkuchi 98642 959534 Anup Baishya Village Nakhara 94359 746505 Biswa Kalita Village No. 2 Nathkuchi 88760 516136 Kuladip Kalita Village Nakhara 82538 224217 Rekha Das Village Barmakhibaha8 Gitumani Haloi Village Barbari 88768 466369 Bejuli Pathak Village Niznamati 88766 6544310 Pranita Das Village Bamunbari (Namati) 88223 7647511 Dipamani Kalita Village Bamunbari (Namati) 88763 0069612 Hirumani Kalita Village Niznamati 87618 2395713 Munni Kalita Tihu, Ward No. 3 88763 9430614 Nilima Dutta Village Makhibaha 95772 7449615 Podumi Devi Village Patikara 84861 9784916 Bhunita Goswami Village no. 2, Nathkuchi 82539 88472

No. Name of beneficiaries Address Contact number Age Craft 1 Maniram Barman Village Kaithalkuchi 88224 51654 40 Cane and bamboo2 Dwijen Sarma Village Kaithalkuchi 98598 92206 45 Cane and bamboo3 Paresh Haloi Village Kaithalkuchi 98587 30098 47 Cane and bamboo4 Ramen Haloi Village Sathikuchi 98547 66814 38 Cane and bamboo5 Hemanta Barman Village Sathikuchi 98542 33715 35 Cane and bamboo6 Tilak Barman Village Sathikuchi 98590 38416 35 Cane and bamboo7 Jatin Barman Village Sathikuchi 95771 19175 33 Cane and bamboo8 Mahendra Chil Village Besimari 96783 57388 50 Cane and bamboo9 Arjun Baishya Village Gobardal 95770 23024 39 Cane and bamboo10 Sanatan Rajbongshi Village Besimari 88768 46168 40 Cane and bamboo11 Prasannna Barman Village Sathikuchi 95777 90526 32 Cane and bamboo12 Harin Rajbongshi Village Sathikuchi 90853 96817 29 Cane and bamboo13 Suman Barman Village Sathikuchi 95777 90526 ‐ Cane and bamboo

List of handicraft artisans, Nalbari district

List of bamboo stick and agarbatti workers under Bahumukhi Pratibha Vika

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Name and address of MSME unit: Maniram Bah‐bet Udyog, PO Kaithalkuchi Village, Thana Belsor, Nalbari districtContact Person with designation and contact details: Arun Barman, Proprietor. Phone: 98543 19114Product range: Lamps, furniture and small decorative items in cane and bambooNature of work: Manufacture of cane and bamboo products, retail through stores or direct orders from clientsTurnover: Not divulgedInfrastructure set‐up: Micro enterpriseEmployee strength: 3‐5Date of visit: 18‐07‐13


1 Product design, redesign, product development YDesign of products has remained static ‐ no noticable change over the years. Need inputs in design of products for the contemporary market


Scope for use of better tools, jigs and product finishing techniques. Collaboration with institutes dealing with bamboo research and product development will be useful for regular inputs into product design and processes. Also important to initiate collaborations with agencies that aid in the marketing of new products. Smaller units in this area may be able to collaborate with agarbatti making units to create packaging using bamboo and cane

3 Research and development directions for future initiatives Y

Bamboo's versatility and the artisans facility with the material can be adapted into products that find a place in the contemporary market aesthetic, while retaining the essence of its cultural roots. Can also explore options of collaborations with architects and furniture stores, to co‐create products

4Innovation in process and related areas for design intervention Y More finesse in joinery and finishing techniques needed

5 Workstation and tooling design YWork sitting cross‐legged or squatting on the ground. Tools: hacksaw, dao, katari, kerosene blow lamp, pliers


Though the quality of cane and bamboo work in the north‐east region is exemplary, products tend to sell less as designs have become redundant. Fresh designs or a reinterpretation of existing designs is required to revive interest in cane and bamboo products

7 Training and skill upgradation, if any Y In the areas of finishing of products and use of jigs

8 Ergonomic and environment factors YOrganizing of workspace with all tools within reach, and designated areas for specific activities (such as use of the blow lamp) will speed up the pace of work.


Can explore possibilities of stackable products. Currently, ready products are stored all through the artisan's home as there is no large storage area.


Organizing of workspace with all tools within reach, and designated areas for specific activities (such as use of the blow lamp) will speed up the pace of work.

11 Exhibition / display design opportunities Y

Participates in exhibitions and fairs at Dillihaat and trade fairs in Pragati Maidan. A long term collaboration with a designer / architect / retailer would aid the craftsmen through regular inputs on new requirements in the marketplace.


Creation of an identity linking the quality of material used and craftsmanship to its provenance will help build value for the product. As the north‐easters states of India possess remarkarable technical and aesthetic mastery of cane and bamboo, instating a brand highlighting these qualities will make buyers aware of the value and hand‐crafted nature of the product

13 Inter cluster communication YModerate. Building a Common Facility Centre could aid all the uits in the area in terms of infrastructure as well as improving communications


By initiating regular design collections, which are shown to retailers and receipt of orders for the same.

15 To improve the process of manufacturing and productivity Y Covered in points 2, 7, 816 To increase market share and profitability Y Covered in points 2, 3, 11


18To improve product manufacturability, servicability, manufacturing process, packaging, logistics operations etc. Y Covered in point 8, 9, 11

19To add value to the product or services concerned and increase their competitiveness Y Covered in points 1, 2, 11

20


By initiating the establishment of a body of design and marketing profesionals resposible for design development and marketing of the same to interested buyers. The

Identification of target market(s) and reinterpretation or redesign of products to suit the target market(s). Cane and bamboo furniture used in conjunction with other materials,such as, a metal inner structure to give it longevity and lightness can be marketed especially in cities. People on the move would prefer furniture that is light, easy to stack anddurable. As mentioned in point 12, promoting the products of the north‐east especially in cane and bamboo as a brand with certain qualities of finesse and durability will help capturethe attention of potential buyers. A careful study of extreme temperatures on cane and bamboo products and ways and means of controlling the effects (if any) should be done. This will enable export ofproducts with a guarantee of durability to other countries.




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Name and address of MSME unit: Champak Bah‐bet Udyog, PO Kaithalkuchi Village, Thana Belsor, Nalbari districtContact Person with designation and contact details: Mr.Kamini Barman, Proprietor, Phone: Product range: Lamps, furniture and small decorative items in cane and bambooNature of work: Manufacture of cane and bamboo products, retail through stores or direct orders from clientsTurnover: Not divulgedInfrastructure set‐up: Micro enterpriseEmployee strength: 5 Date of visit: 18‐07‐13


1 Product design, redesign, product development YDesign of products has remained static ‐ no noticable change over the years. Need inputs in design of products for the contemporary market


Scope for use of better tools, jigs and product finishing techniques. Collaboration with institutes dealing with bamboo research and product development will be useful for regular inputs into product design and processes. Also important to initiate collaborations with agencies that aid in the marketing of new products. Smaller units in this area may be able to collaborate with agarbatti making units to create packaging using bamboo and cane

3 Research and development directions for future initiatives Y

Bamboo's versatility and the artisans facility with the material can be adapted into products that find a place in the contemporary market aesthetic, while retaining the essence of its cultural roots. Can also explore options of collaborations with architects and furniture stores, to co‐create products

4Innovation in process and related areas for design intervention Y More finesse in joinery and finishing techniques needed

5 Workstation and tooling design YWork sitting cross‐legged or squatting on the ground. Tools: hacksaw, dao, katari, kerosene blow lamp, pliers


Though the quality of cane and bamboo work in the north‐east region is exemplary, products tend to sell less as designs have become redundant. Fresh designs or a reinterpretation of existing designs is required to revive interest in cane and bamboo products

7 Training and skill upgradation, if any Y In the areas of finishing of products and use of jigs

8 Ergonomic and environment factors YOrganizing of workspace with all tools within reach, and designated areas for specific activities (such as use of the blow lamp) will speed up the pace of work.


Can explore possibilities of stackable products. Currently, ready products are stored all through the artisan's home as there is no large storage area.


Organizing of workspace with all tools within reach, and designated areas for specific activities (such as use of the blow lamp) will speed up the pace of work.


Participates in IITF Pragati Maidan, Surajkund Handicrafts Fair. Has participated in exhibitions sent to Nepal and Bhutan. A long term collaboration with a designer / architect / retailer would aid the craftsmen through regular inputs on new requirements in the marketplace


Creation of an identity linking the quality of material used and craftsmanship to its provenance will help build value for the product. As the north‐easters states of India possess remarkarable technical and aesthetic mastery of cane and bamboo, instating a brand highlighting these qualities will make buyers aware of the value and hand‐crafted nature of the product

13 Inter cluster communication YModerate. Building a Common Facility Centre could aid all the uits in the area in terms of infrastructure as well as improving communications


By initiating regular design collections, which are shown to retailers and receipt of orders for the same.

15 To improve the process of manufacturing and productivity Y Covered in points 2, 7, 816 To increase market share and profitability Y Covered in points 2, 3, 11


18To improve product manufacturability, servicability, manufacturing process, packaging, logistics operations etc. Y Covered in point 8, 9, 11

19To add value to the product or services concerned and increase their competitiveness Y Covered in points 1, 2, 11

20


By initiating the establishment of a body of design and marketing profesionals resposible for design development and marketing of the same to interested buyers. The

Identification of target market(s) and reinterpretation or redesign of products to suit the target market(s). Cane and bamboo furniture used in conjunction with other materials,such as, a metal inner structure to give it longevity and lightness can be marketed especially in cities. People on the move would prefer furniture that is light, easy to stack anddurable. As mentioned in point 12, promoting the products of the north‐east especially in cane and bamboo as a brand with certain qualities of finesse and durability will help capturethe attention of potential buyers. A careful study of extreme temperatures on cane and bamboo products and ways and means of controlling the effects (if any) should be done. This will enable export ofproducts with a guarantee of durability to other countries.




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Name and address of MSME unit: Sangita Bamboo Root Zoo, PO Kaithalkuchi, Village Besimari, Nalbari districtContact Person with designation and contact details: Mr. Sanatan Rajbongshi. Phone: 88764 46168Product range: Artifacts carved from bamboo rootsNature of work: Artifacts carved from bamboo roots and a small grocery storeTurnover: Not divulgedInfrastructure set‐up: Micro enterpriseEmployee strength: 1Date of visit: 18‐07‐13


1 Product design, redesign, product development YArtisan makes decorative products using roots of bamboo. The form of the roots guide the products, which are various animals and fish

2 Technology, modernisation and collaboration Y All products are hand‐tooled and are executed by a single artisan

3Research and development directions for future initiatives Y

Though interesting, the products require more finesse in terms of artistic ability and finishing. The artisan has also crafted a very good likeness of Sri Bhupen Hazarika on a section of bamboo. More items like these can be produced as promotional items for Assam tourism and stocked in areas of high tourist footfall such as Kaziranga

4Innovation in process and related areas for design intervention Y Better quality products/artworks with the incorporation of functions.

5 Workstation and tooling design YAll products are hand‐tooled and are executed by a single artisan. Tools include the standard hacksaw, dao and katari


Currently, all products are large and heavy. Scaling down the size will help purchasing, especially by tourists.

7 Training and skill upgradation, if any YTraining in refining the forms of and better finishing of the product in addition to having a variety of sizes would make them much more desirable

8 Ergonomic and environment factors Y Artisan works seated on the ground with his hand tools.


Packaging consists of wrapping with newspaper. All storage is in the workshed. Once products have been refined, the artisan needs a way of supplying these to the market. One example could be small design offices which aid with design inputs as well as form a suppply chain to stores in and around the state.

10Infrastructure and capability enhancement from design perspective Y Covered in points 3, 6, 9


The artisan exhibits his products at local and state exhibitions. Better executed products highlighting the fauna of the state of Assam would liven up regular exhibitions, especially if displayed in a tableau


Creation of an identity linking the quality of material used and craftsmanship to its provenance will help build value for the product. Small hangtags with information about the name and habits of the animal depicted help capture the attention of potential buyers

13 Inter cluster communication Y None



Certain degree of machining in the prepation of the bamboo roots for shaping as well as use of buffing machines in the finishing processes



18


19To add value to the product or services concerned and increase their competitiveness Y Covered in point 12

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To create a positive difference to the MSME, either in absolute revenues (indicating higher profits) or in percentage terms Y Covered in points 3, 6, 9, 11, 12

Improvement in the crafting and finishing as well as incorporation of smaller sizes in the design repertiore. In addition, since most of the products represent animals and fish, the inclusion of some information and some local lore regarding them will capture the imagination of potential buyers.At a manufacturing level, a common CFC with machiners especially for finishing techniques would infinitely help the end look of the product.At the training level, a short workshop on sculpting tools and techniques will enrich the abilities of this self‐taught artisanAt a macro level, the instatment of a purchase and supply chain to stores and exhibitions around the state and country will help get the products a better market base.




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Name and address of MSME unit: Contact Person with designation and contact details: Mahendra Chil. Phone: 96783 57388Product range: Artifacts carved from bamboo rootNature of work: Artifacts carved from bamboo root, a small grocery store, selling of petrol, renting of space for parking of two‐wheelersTurnover: Not divulgedInfrastructure set‐up: Employee strength: 2Date of visit: 18‐07‐13


1 Product design, redesign, product development YArtisan makes decorative products using roots of bamboo. The form of the roots guide the products, which are various animals and fish

2 Technology, modernisation and collaboration Y All products are hand‐tooled and are executed by a single artisan

3Research and development directions for future initiatives Y

The artisan has all but given up on the activity. He and his son, the other member of the team, require training in order to produce products of a salable quality

4Innovation in process and related areas for design intervention Y Needs extensive training in order to better the form and finish of his products

5 Workstation and tooling design YAll products are hand‐tooled and are executed by a single artisan. Tools include the standard hacksaw, dao and katari

6Market and competition study for design advantage and distinction Y Needs extensive training in order to better the form and finish of his products

7 Training and skill upgradation, if any YTraining in refining the forms of and better finishing of the product in addition to having a variety of sizes would make them much more desirable

8 Ergonomic and environment factors Y Artisan works seated on the ground with his hand tools.


Packaging consists of wrapping with newspaper. All storage is in the workshed. Once products have been refined, the artisan needs a way of supplying these to the market. One example could be small design offices which aid with design inputs as well as form a suppply chain to stores in and around the state.

10Infrastructure and capability enhancement from design perspective Y Covered in points 3, 6, 9


The artisan exhibits his products at local and state exhibitions. Better executed products highlighting the fauna of the state of Assam would liven up regular exhibitions, especially if displayed in a tableau


Creation of an identity linking the quality of material used and craftsmanship to its provenance will help build value for the product. Small hangtags with information about the name and habits of the animal depicted help capture the attention of potential buyers

13 Inter cluster communication Y None



Certain degree of machining in the prepation of the bamboo roots for shaping as well as use of buffing machines in the finishing processes



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19To add value to the product or services concerned and increase their competitiveness Y Covered in point 12

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To create a positive difference to the MSME, either in absolute revenues (indicating higher profits) or in percentage terms Y Covered in points 3, 6, 9, 11, 12

Improvement in the crafting and finishing as well as incorporation of smaller sizes in the design repertiore. In addition, since most of the products represent animals and fish, the inclusion of some information and some local lore regarding them will capture the imagination of potential buyers.At a manufacturing level, a common CFC with machiners especially for finishing techniques would infinitely help the end look of the product.At the training level, a short workshop on sculpting tools and techniques is required to better the abilities of the artisanAt a macro level, the instatment of a purchase and supply chain to stores and exhibitions around the state and country will help get the products a better market base.




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Bamboo Incense Stick Cluster, NalbariDesign Clinic Workshop Report

December 06 to December 12, 2013

by Mridul Mitra

Design Clinic Workshop Report for Bamboo Incense Stick Cluster, Nalbari | 2013 | Mridul Mitra, Design Consultant | Email: [email protected]

Introduction to the workshop

Day 1 - December 06, 2013







Logo

Rubber Stamp

Packaging

Booklet

Image Gallery

The Artisans

Acknowlegdements

Credits

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Contents

Design Clinic Workshop Report for Bamboo Incense Stick Cluster, Nalbari | 2013 | Mridul Mitra, Design Consultant | Email: [email protected] 3

The Design Clinic Workshop is the second module of the Design Awareness Programme organised by the DCS-MSME. Data collected during the Need Assessment Survey of the cluster, through interactions with the artisans and personal observations, was evaluated to formulate cogent activities for the workshop.The SHGs in the cluster largely produce blank incense sticks supplied in bulk to the resident NGO, the Bahumukhi Prathibha Vikas Samiti, which in turn, sells it to wholesale buyers in Guwahati and Bangalore.

In a commendable self initiave, some of the SHGs have commenced sale of agarbattis in small quantities, to the local market. However, certain issues were noted by me in the NAS, which I will set down briefly as follows:

• Lack of quality in the incense sticks produced• Use of unbranded scenting chemicals and lack of awareness of the chemicals used• Lack of awareness of the use of colour in incense sticks• Pachaging of the sticks in surplus boxes of other manufacturers.• Lack of any kind of branding showing the provenance of the incense sticks.

With these points in mind, my approach to the workshop activities consisted of 4 main areas:

• Exercises and methods to improve the quality of the product, and introduce a degreee of standardisation.• Methods of value addition to the product through an introduction to scenting techniques and the use of colour. Also, introducing the concept of products allied to the use of incense sticks, such as incense stick holders, using locally available bamboo.• Introduction to the concept of packaging, using locally available materials.• Developing a simple logo, to be used by the cluster at large, but also flexible enough to allow details of the manufacturer to be mentioned.

To further the above aims, I prepared a few demonstration kits prior to the commencement of the Workshop:

1. A hand drawn booklet, with information in Assamese, on simple procedures to follow in order to improve quality of incense sticks.2. An assortment of incence products including coloured sticks, solid sticks, and incense cones, sourced from markets in Ahmedabad, for the artisans to explore.3. Prototypes of incense stick holders with appropriate finish to be shown to the artisans for development.4. Samples of perfumes and chemicals, used in the scenting of incense sticks, along with dyes used to add colour to the finished sticks.

Introduction to the Workshop Planned Workshop activities

Demonstration Kits prepared


A presentation on incense sticks, and allied products and accessories, was made to facilitate an awareness amongst the artisans, of the possibilities in simple design development.It also helped them visualise products they would create during the workshop, thus making the process of creating the product easier.

Dec 06, 2013

Opportunities for Improvement

Improvement in quality of agarbattis through:+ better quality of sticks+ standardisation of lengths+ even coating of masala

Accessories Sold with Incense

Activity 1: Presentation on incense Activity 2: Distribution of Booklet

The booklet was distributed amongst the artisans, who were asked to go through it. An interactive session ensued where the diagrams were explained.

Day 1

Slides from the presentation

Excerpts from the booklet

Artisans reading the booklet


The incense products were laid out on a table and the artisans were invited to gather around and examine them for quality, and use them personally. This helped them develop a hands-on understanding of the types of products available; how they should look, feel and smell; how they were packed; and finally how to use them.

The projector was used to show the artisans short videos on the methods of rolling incense sticks followed by the Vietnamese. Three ‘rolling paddles’ were distributed amongst the three groups, for use on the next day.In addition, a video on the scenting process and one on how to make incense cones was also shown.

Activity 3: Hands-on use of products Activity 4: Videos on incense making

Artisans exploring the products A presentation on incense making

Stills from videos on incense rolling


The artisans, who had divided themselves into three groups, were asked to prepare a large batch of masala per batch. Once the correct consistency was achieved, the process of rolling agarbattis was begun, using the rolling paddles. Though the artisans agreed that the resultant incense sticks were smoother and of more uniform cross-section, they preferred rolling by hand, as this was the common practice. However, they kept the paddles, saying that they would continue to practise in their free time.

A few grams of orange dye was diluted in water in a clean plastic cup. As per the booklet, all the artisans, dipped a bunch of fresh cut bamboo sticks into the dye and allowed the sticks to sun-dry. The coloured part indicated the length of the stick to be covered in the incense masala. It also provided a visual contrast to the dark agarbattis. The ready agarbattis, with the ends dyed orange, were laid out to dry in the sun.The artisans also experimented with hand-made incense cones, after seeing a video the previous day. Using the actual product during the interactive demonstration, also piqued their interest. The cones were set to dry, in order to test them, the next day.

Activity 1: Activity 2:

Dec 07, 2013Day 2

Using the ‘rolling paddle’ Making of incense cones


Images of Day 2:

Kneading of the agarbatti masala

Sticks with ends dyed, set out to dry

Early experiments set out to dry

Dyed and rolled agarbattis


As the artisans showed a lot of interest in the making of coloured agarbattis, the first activity was the application of wood-dust, dyed green, orange and golden-brown, onto the masala coated agarbattis. As the charcoal agarbattis do not hold colour easily, the artisans were asked to roll the battis in a small amount of charcoal and immediately coat the still damp agarbattis in the coloured wood dust. These were given a final roll and set out to dry. The artisans made agarbattis in three sizes - 41/2”, 9” and 12”.

The second session involved an introductory session on the types of scents commonly used in the business (mogra, sandalwood, chameli and gulab). The opened bottles were passed around and all the artisans smelt them.They were told about the base chemical, locally called the DP chemical (di-ethyl phathalate). The commonly followed proportion of 1 part scent concentrate to 4 parts DP chemical was shown. The resultant mixture was sprayed onto the agarbattis of the previous day, using a manually operated spray bottle, with a nozzle. The agarbattis were then placed in narrow plastic bags, 10 pieces to a bag, to preserve the scent. After the demonstration, the groups measured and mixed their own scents, and applied it to freshly rolled blank agarbattis.

Activity 1: Making coloured agarbattis Activity 2: Scenting of the agarbattis

Dec 08, 2013Day 3

Rolling coloured agarbatties Learning to apply an even coat of colour


Images of Day 3:

Fresh rolled sticks in assorted colours, kept to dry

Group interactions speeded up the process of learning Artisans quickly learnt to mix their own colours


The artisans were given a demo on creating simple packaging using different coloured art paper. The basics of cutting the paper to size, creasing for neatness and use of adhesives, was explained to them. Papers were rolled into cylinders, which were used to contain packes of 10, 20 or more agarbattis. The artisans were asked to choose a colour for each group, to maintain a uniform look. As part of a simple branding exercise, print-outs of the logo were used as labels on the packages.

The artisans were asked to closely examine the developed samples and replicate them, using the local bamboo. They were shown how to cut the bamboo in the manner best suited for the bamboo incense stick holder. Shaping of the ends was demonstrated. Each group was asked to make three bamboo agarbatti holders of lengths 5”, 10”, and 13” each. Each piece was sanded to even out the surface and prepare it for a finishing coat of clear lacquer.

Activity 1: Packaging (Part I) Activity 2: Bamboo accessories (Part I)

Dec 09, 2013Day 4

Working in groups helped the artisans learn from each other Some artisans possessed good bamboo working skills


Images of Day 4:

Packaging in progress

Artisans enjoyed experimenting with different coloured papers

Splitting bamboo to form the agarbatti holders

Measuring and cutting the holders for different sizes of agarbattis


The second stage of packaging introduced the artisans to the use of art paper and cellophane paper. Each group was asked to prepare 1 bundle (containing 20 sticks) each of agarbattis of lengths 41/2”, 9” and 12”. The agarbattis were first sealed in plastic bags. The bundles were rolled in a cylinder of coloured art paper and then given a final roll in coloured cellophane paper, available from the local stationery store. Each group selected set of colours and create the packaging for all three sizes of sticks. Print outs of the labels were distributed to all the groups, and they were shown how to neatly affix them to each package.

The bamboo agarbatti holders, were prepared for lacquering. The artisans were shown how to apply a smooth and even coat of lacquer using a soft piece of cloth. Each group proceeded to coat their products with lacquer and set them in the sun to dry.

Activity 1: Packaging (Part II) Activity 2: Bamboo accessories (Part II)

Dec 10, 2013Day 5

Preparing the first roll with art paper Lacquered bamboo agarbatti holders drying in the sun


Images of Day 5:

Gargi Dhupkathi Udyog chose blue as their group colour

Lakhimi OBC Dhupkathi Udyog chose yellow packaging

Artisans learning to apply lacquer onto the bamboo holders

Checking for unlaquered spots


The logo developed for agarbattis made in the Nalbari area was realised in the form of a rubber stamp. The artisans were invited to use the stamp and were shown how to achieve a neat imprint. They practised using the rubber stamp and cutting out the resultant print on a long strip of paper, which could be wound around the agarbatti package, to achieve a belly-band.

The artisans were shown how to combine the bamboo incense stick holder into a gift pack, by placing one packet of packed agarbattis into the hollow core, and using a paper strip bearing the logo and other details as a belly band. They repeated the exercise with their own agarbattis, packed the previous day. They also filled in details such as the name of the organisation, contact numbers, quantity of sticks and price per unit, in the space provided in the stamped label.

Activity 1: Using the logo in stamp form Activity 2: Creating a Gift-pack

Dec 11, 2013Day 6

Learning to use the stamp of the logo

Packed agarbatties are placed into the bamboo holders


Images of Day 6:

Learning to apply even pressure onto the stamp

Cutting out a paper belly-band with the logo

Three sizes in bamboo holders for different sized sticks

Packed agarbattis in assorted sizes


For the final display, the artisans were asked to collate all the material and products they had used and produced, in simple chronological order, on three separate tables. In addition to myself, external consultants Ms. Jutika Baruah and Mr. Dibakar Choudhury; Ms. Nilufar Sheikh from DCS-MSME, NID; Mr. Bhuiyan, the ex-General Manager, DIC, Nalbari; and Mr. Dibakor Thakuria, the Extension Officer, DIC, Nalbari formed the examining panel.

Ms. Jutika Baruah and Mr. Dibakar Choudhury spoke about the importance of marketing and packaging respectively; Ms. Nilufar Sheikh shared inputs on costing; and Mr. Bhuiyan spoke about various development schemes offered by the government, and methods of availing of them.

Display of products and discourses by external consultants

Dec 12, 2013Day 7

The last day of the workshop Artisan groups display their new products on tables


Images of Day 7:

External consultant explaining marketing techniques

Artisans on the final day of the workshop

The rubber stamp with the logo and manufacturer details

With the Lakhimi OBC Dhupkathi Making Udyog group


Logo

Nalbari DhoopHandmade Agarbattis

Manufactured by

....................................Makhibaha, Tihu

Nalbari Dist., AssamPhone: ..............................

Qty : .................Price : ...............


As mentioned in my observations during the NAS, it would be beneficial to the agarbatti artisans of Nalbari to retail their products under a common name and logo. This would:

• Help local buyers identify a product made in their neighbourhood .• Help connect the product to the area of manufacture, in case of participation in state-wide and nation-wide handicraft fairs.• Promote better craftsmanship among the stakeholders by promoting a sense of ownership in the brand.

The logo logo developed is• Simple• Has a traditional flavour, reminiscent of architectural decorative elements.• Can be represented in a single colour to minimise replicating costs

Advantages of a rubber stamp:• Reduces repeated printing costs. • Is flexible in terms of use, ie, can be used on most papers.• Can be used to create labels and belly-bands of different sizes.• Can be used with various colours of inks to creat distinct ranges.• Easy to use • Can be made locally

The label bearing the logo and manufacturer’s details

The final logo


Manufactured byGargi Dhupkathi Udyog

Makhibaha, TihuNalbari Dist., Assam

Phone: 08822065179Nalbari Dhoop

Handmade Agarbattis

Manufactured byGitanjali Dhupkathi Udyog



Handmade Agarbattis

Manufactured byRONG J.L.S.G



Handmade Agarbattis

Gargi Dhupkathi Udyog


Makhibaha, TihuNalbari Dist., AssamPhone: 08822065179

Manufacturers of scented and unscented agarbattis

Lakhimi OBC Self Help Group



Manufacturers of pitha, laddoo Manufacturers of agarbattis

Mili-Juli Dhupkathi Udyog




Gitanjali Dhupkathi Udyog






RONG J.S.G & Incense Stick Industry Manufacturers of raw sticks, and scented and unscented agarbattis

Manufactured by

....................................Makhibaha, Tihu


Qty : .................Price : ...............


Manufactured by

....................................Makhibaha, Tihu


Qty : .................Price : ...............


Manufactured by

....................................Makhibaha, Tihu


Qty : .................Price : ...............


Manufactured by

....................................Makhibaha, Tihu


Qty : .................Price : ...............


Manufactured by

....................................Makhibaha, Tihu


Qty : .................Price : ...............


Manufactured by

....................................Makhibaha, Tihu


Qty : .................Price : ...............


Manufactured by

....................................Makhibaha, Tihu


Qty : .................Price : ...............


Manufactured by

....................................Makhibaha, Tihu


Qty : .................Price : ...............





Nalbari DhoopHandmade AgarbattisNalbari Dhoop

Handmade AgarbattisMade in


Phone ......................................

Name .....................................


Made in Makhibaha, Tihu

Nalbari Dist., Assam

Phone ..................................................

Name ..................................................

Size and colour iterations of the logo


Rubber Stamp of Logo

The common rubber stamp bearing the logo and space for the contact details of the manufacturing group was developed in Guwahati. It can be used to create labels and belly-bands, or can be used directly on agarbatti boxes, if required.

Different coloured inks can be used to distinguish across product ranges. For example:• Black ink for the standard black scented agarbattis.• Blue ink for coloured agarbattis.• Red ink for special categories such as neem infused agarbattis, to be used as mosquito repellants.• In the absence of coloured inks, art papers in selected colours can be used to create a colour code.

The artisans can easliy replicate the stamp in the nearby town of Tihu, where there are a number of shops dealing with rubber stamps. They can then come to a consensus on the colours, and adhere to the finalised colour code.

The rubber stamp and the impression of the same on blue art-paper


Practice sessions on usage of the stamp

Stamp iterations

Belly-bands created using the stamp

The final stamp on ivory art-paper


The artisans currently use ready-made boxes bearing the names of other brands, to retail in the local market. It is not possible for them to develop boxes bearing their name and logo, as manufacturers of these boxes require bulk orders, which is not a feasible financial investment for these micro units. The packaging solution, therefore, was developed using locally available materials and keeping the cost at a minimum.

It consists of the following:• A plastic pouch to contain agarbattis (currently in use by the artisans)• A cylinder of art paper - white or any other colour• An outer wrapping of coloured cellophane paper• A belly-band bearing the logo, details and address of the manufacturer.

Advantages:• Materials are easy to source • Cost effective as are they commonly available and a single sheet of paper can be cut to size and used for numerous packs• Easy to learn • Can be used for any size of agarbatti in any quantity

Packaging


Bamboo agarbatti holder

Cellophane and art paper cylinder

Belly-band with logo and manufacturer’s details


Packaging

Packaging with belly-band placement options


The complete gift pack: paper and cellophane wrapped agarbattis + bamboo agarbatti holder


Booklet


Image gallery

Original products of the cluster - unscented and raw bamboo sticks

Demo kits for scenting and colouring Dip-dyeing the ends of the sticks


Mixing a batch of coloured powder

Initial attempts at rolling coloured agarbattis

Coloured powder set out to dry

Repeated practise led to marked improvement in quality


Glimpses of workshop activities

Image gallery


Glimpses of workshop activities


Product variety and quality at the end of the workshop

Agarbattis laid out to dry

Image gallery


Stages in packaging development - from newspaper to a labelled product

Colours explored in the packaging process


The Artisans

Members of the Gargi Dhupkathi Udyog, Nalbari


Members of the Gitanjali Dhupkathi Udyog, Nalbari


The Artisans

Members of the Lakhimi OBC Dhupkathi Udyog, Nalbari


Members of the Rongh J.S.G. Incense Stick Industry, Nalbari


Acknowlegdments

The Design Clinic Workshop for the Bamboo Incense Stick Cluster at Nalbari, offered me the opportunity to be part of, and witness, the benefits of design intervention at a micro level.

I was helped in this endeavour by a wonderful team of people: Ms. Nilufar Sheikh, Project Officer of the North-East, DCS-MSME and Mr. Rabha, Officer, DCS-MSME, who have stood by to provide invaluable help at every step; Mr. Dibakar Thakuria, Extension Officer, DIC, Nalbari, who presence and participation, helped knit the workshop together; Mr. Rabha and Mr. Medhi of IIE, Guwahati for their support; and Mr. Ashim, for his cheerful help and support, for each day of the workshop.

My gratitude to all the artisans of the cluster, whose energy, enthusiasm and entrepreneurial spirit to learn, made the workshop a wonderful experience.

And finally, I would like to thank the DCS-MSME team at NID, especially Mr. Shashank Mehta, Mr. Ashok Mondal and Mr. Kirti Parmar for guidance and support at every step of the project.


Credits

Page 4 (image on bottom left)http://ecx.images-amazon.com/images/I/414IBAdE5CL._SL500_AA300_.jpg

Page 5http://www.youtube.com/watch?v=o6Eql9UV3EYhttp://www.youtube.com/watch?v=ezaPuUMAMxUhttp://www.youtube.com/watch?v=ezaPuUMAMxU

Page 24 & 25Photographs by Rachita Sareen

Page 32 & 33Booklet designed and illustrated by Mridul Mitra

bamboo incense stick cluster, nalbari

Documents