pilot project on improving manufacturing of...
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PILOT PROJECT ON IMPROVING MANUFACTURING OF EFFICIENT RURAL COOKSTOVES
This volume is a product of the staff of the International Bank for Reconstruction and Development / The World Bank. The findings, interpretations, and conclusions expressed in this paper do not necessarily reflect the views of the Executive Directors of The World Bank or the governments they represent. The World Bank does not guarantee the accuracy of the data included in this work. The boundaries, colors, denominations, and other information shown on any map in this work do not imply any judgment on the part of The World Bank concerning the legal status of any territory or the endorsement or acceptance of such boundaries.
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The material in this publication is copyrighted. Copying and/or transmitting portions or all of this work without permission may be a violation of applicable law. The International Bank for Reconstruction and Development / The World Bank encourages dissemination of its work and will normally grant permission to reproduce portions of the work promptly. For permission to photocopy or reprint any part of this work, please send a request with complete information to the Copyright Clearance Center, Inc., 222 Rosewood Drive, Danvers, MA 01923, USA, telephone 978‐750‐8400, fax 978‐750‐4470, www.copyright.com. All other queries on rights and licenses, including subsidiary rights, should be addressed to the Office of the Publisher, The World Bank, 1818 H Street NW, Washington, DC 20433, USA, fax 202‐522‐2422, e‐mail [email protected].
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Table of Content Activity 1. Develop and test production technologies and techniques to
increase productivity and rate of stove production ..............................6 1.1. Clay Mixing ..........................................................................................................6 1.2. Stove body moulding ..........................................................................................7 1.3. Carving ................................................................................................................8 1.4. Drying (the second step drying)..........................................................................9 1.5. Firing..................................................................................................................10
Activity 2. Development of standards for production of the NKS and kiln
firing .....................................................................................................15 Standard finalization ................................................................................................17 Monitoring/implementation of standards ..............................................................17
Activity 3. Pilot production facility........................................................................19 Activity 4. Train producers in management and marketing .................................21 Baseline NKS production..........................................................................................21 Model Production Facility ........................................................................................22 4.1. Participatory Assessment for Planning & Introduction of the Scenario.......22 4.1.1. Divide the production into steps and valuation of the steps ..............23 4.1.2. Daily payment based on the quantity of the achieved production step 23 4.1.3. Money saving .......................................................................................24 4.1.4. Selling the stove from one ware house ...............................................24
4.2. Training to potters ........................................................................................24 4.2.1. Production techniques.........................................................................25 4.2.2. Book keeping........................................................................................25 4.2.3. Finance management ..........................................................................25 4.2.4. Stock management ..............................................................................25
Activity 5. Evaluation of the options for introduction of the improved
manufacturing of the NKS Stoves. .......................................................27 5.1. Improvement the micro‐enterprise..............................................................27 5.2. Improvement the family scale production ...................................................29 5.3. Projection of production capacity ................................................................29
Activity 6. Preparation of a plan for scale – up of production..............................31 Appendix 1. ..................................................................................................................33 Appendix 2. ..................................................................................................................36
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Background In the late ‘90 GERES‐Cambodia introduced the efficient “New Lao Stove” (NLS). The NLS technology is based on a model from Thailand and saves 22% of firewood or charcoal compared to the TLS. The NLS which is by far the best wood and charcoal burning stove presently produced in about 20 production centres in the main populated provinces in Cambodia, is durable and has a good appearance. In 2002 GERES‐Cambodia with the support of the EU trained TLS producers to manufacture the efficient NLS and undertook a publicity and sales campaign. This resulted in gradual adoption in urban markets even though the price of the stove is around $3.5 compared to the TLS price of $1.5. The NLS is now used by more than 40% of urban households and the monthly production is 25,000 stoves or 300,000 per year. The dissemination of the NLS in rural villages is however very low with major reasons the relatively high price and lack of distribution network that reaches villages. The development of Neang Kongrey Stove on 2001 was merely due to a need to supply low cost improved cook stove (ICS) to rural areas. The New Lao Stove, though it is durable and very efficient, most rural families cannot afford to purchase the NLS. To respond to the need, GERES developed the NKS by incorporating some important parameters of NLS and considering:
• NKS can be used either for charcoal or firewood • The main raw materials of the NKS are fine clay and coarse clay, as the
material used to produce traditional stoves • Skills of traditional stove producers are more than sufficient to produce the
NKS • NKS fits to the common traditional stove carriers operated by traditional
stove distributors The World Bank – ESMAP/DfID Cambodian SMEs in Decentralized Energy Services Program provided support to pilot trial the introduction of efficient cookstoves into rural Cambodia and on the basis of this a strategy for a National Efficient Cookstove Program for rural Cambodia was formulated. Through the pilot trials 3,000 efficient Neang Kongrey Stoves were sold in rural villages. The fuel saving of the Neang Konrey Stove (NKS) was very much appreciated by households and also the shorter cooking time and smoke reduction. Women who run village grocery shops and tried to sell the NKS were interested in continuing selling the stove but identified quality issues, and the need for a larger size NKS. A Model Production Facility has been established to address these issues and will be used as the basis for setting up production facilities at strategic locations throughout Cambodia to achieve effective dissemination of the stove. To address the problems found during the pilot dissemination, the quality, durability of the stove and production capacity the World Bank ESMAP/ASTAE Program provided technical assistance to GERES‐Cambodia to develop a “Model Production Facility for the Efficient Neang Kongrey Stove”. The Facility includes mechanized clay mixing, improved moulding techniques and kiln firing. The aim is to increase the
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production capacity of the NKS and produce a high quality stove, pay fair wages for stove producers who are mainly women and to keep the cost of the stove low to ensure it is accessible to all households including the poor.
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Activity 1. Develop and test production technologies and techniques to increase productivity and rate of stove production
At present the stoves are produced completely by hand and affect to the quality, durability of the stoves and production capacity & reliability. Introduction of alternative forming technology and modern kilns to potters in Kampong Chhnang is aimed to improve the quality, durability of the stoves and production capacity. 1.1. Clay Mixing The clay, that is obtained by collecting from its source (hill or river bank) or delivered by a supplier, is usually soaked in a pit to allow the water to spread evenly throughout the lump. This wet clay is then mixed with non‐clay material that acts as filler to reduce plasticity and shrinkage. Fillers may also increase the porosity and lower the bulk density of the fired body, depending on the firing temperature. Common practice of traditional potters of Kampong Chhnang is to mix the lump of wet clay with non‐clay material (usually fine sand from river bank) or coarse clay from the hill. Traditionally, the potters of Kampong Chhnang mix the clay and non‐clay material by kneading. After kneaded, the mixture is kept for a few more days to reach certain plasticity. Kneading a 1 m3 mix of clay requires 6 man‐hours and if hiring a person the cost to knead is 10,000 KHR (US$ 2.5) for 0.5m3 or 20,000 KHR (US$ 5) for 1m3 At the Pilot Production Facility, clay mixing improvement was made by introducing a mechanical clay mixer, which has been utilised by 8 NLS production centres since the last two years (costs US$ 850/unit). This mechanical mixer can assure a homogenous clay mixture and reduce the burden of the kneading. The capacity of the introduced clay mixer is 1m3 per hour.
Picture 1: The mechanized clay mixer To mix 1m3 of clay, requires one working hour of an operator and one litre of diesel fuel which costs US$ 1.25; US$ 0.75 for the diesel fuel and 2,000 KHR (US$ 0.5) one man hour.
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With the kneading cost of KHR 10,000 (US$ 2.5) to get 0.5 m3, the mechanical clay mixer can produce 2 m3 of ready mix clay. The clay mixer consists of frame with two shafts, one shaft with 5 blades that sinks into the cylindrical metal tank and fixed by 5 bearings and one pulley. The other shaft is fixed by 3 bearings with 2 pulleys. The diesel engine is fixed and it is connected to the mixing shafts by pulleys. The detail drawings of the clay mixer are given in Appendix1. 1.2. Stove body moulding The most common way to form traditional stoves in Kampong Chhnang is “hand building” technique; a lump of clay mixture is placed on a fixed pole and pulled it up from the centre to form a basic hollow shape. Once the walls are the right thickness, coils of clay are added (when necessary) to the top to build it up to the correct size. To finalize the form, the walls are beat from outside using a wooden bat and countered by a round and flat stone from the inside. The final product is a cylinder with a bottom.
Picture 2: A potter is throwing clay with a simple pottery wheel An important note: traditionally potters of Kampong Chhnang do not use pottery wheels to throw the clay but instead the potter moves in a circle around a fixed pole while the hands are working with the clay (pulling or beating). Only a few potters utilizing pottery wheel that was introduced by the collaborative pottery improvement project of GTZ, JSRC, PRASAC and ICRDP (1996/97). The pottery forming technique does not fit to produce improved cook stoves that require standard quality and regular product dimension. To achieve standard form and dimension of the stove body, in 2004 GERES introduced a set of tools in producing the Neang Kongrey Stove. The tools consist of an external mould and a set of rotating trimming blade (called jigger‐jolly in India). The consideration to select and introduce this technique was:
• No external power is required to operate this tool, but manual
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• The cost of the tool is US$ 25 and it is quite affordable by potters • Requires minimum maintenance, i.e. wash it with water, dry it up and paint
with used engine oil to prevent from rusting • Local workshops with basic technical skills can produce the tools • All parts can be easily calibrated and the calibration cost is affordable
There was an intention to use a hydraulic press mould to make the stove body but the hydraulic press technique was;
• Require external power (electricity) to run the hydraulic pump • The investment cost of the hydraulic press is quite high (more than US$
300/set) and not suitable for family scale production • It requires sophisticated workshop with high precision to produce the whole
set • Needs special skills to maintain the parts, i.e. oil pump, hose, joints and
connectors, hydraulic shaft, etc… • It requires specials training to operate the equipment
A study done earlier found that the speed to mould a stove body using a hydraulic press requires an average of 1 minute and using the jigger‐jolly requires 2.6 minutes. Time wise, the hydraulic press is more productive in moulding but it is not the only principal step in the whole of NKS forming. 1.3. Carving After moulding the stove body is dried under the shade to reduce the moist in the body until it is firmed (it is called the first step drying). In dry season the drying takes about 6 – 8 hours and in rainy season it can take up to 24 hours. When the stove body is firmed enough (but remain soft enough to be cut with the carving knife), the rim of the body is carved to make three pot rests. Further step is to cut the rim for the fuel entrance and cut the lower part of the body for the primary air inlet. No special tools are used in carving but adopting the traditional tools commonly used in forming the Traditional Lao Stove. The production speed achieved by newly trained potters (per unit) at the Pilot Production facility after three months training and in comparison with a NKS producer (skilful) in Kdey Tnaot Village) is: Table 1: Speed of production steps achieved by trained potters
Production steps Newly Trained Skilful Potter
Moulding the stove body 10.14 mins 2.6 mins Carving 23.12 mins 16.57 mins Cutting 2.39 mins 1.79 mins Grate moulding 0.48 mins n/a Grate punching 6.60 mins n/a
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Therefore, even hydraulic moulding is much faster than the moulding work using jigger‐jolly, the determining factor of production capacity is the carving ‐ that at least it requires 17 minutes. Moulding the final form of NKS body requires special moulding technique. The inside shape of the NKS and the thickness of clay are two factors that ordinary press mould or extruding technique cannot do. GERES tried to find an appropriate compression and blow moulding technique but the technologies do not support stove moulding because of:
• The texture of clay is too rough, the plasticity and elasticity is too low • The clay cannot be easily cured and stabilised ‐ like polymer, rubber, resin or
other composite materials that can be stabilised by heat • The internal shape of NKS is categorised as complex; a hollow with outward
bulging on the inside walls. The foreseen possibility is to apply a combination of compression moulding and collapsible mould. However this technology is not cheap and requires more time to validate the technology of "one press to final product" moulding. 1.4. Drying (the second step drying) The body of Neang Kongrey Stove are thicker than the body of other traditional stoves (Siam Stove, Lao Kampong Chhnang, etc…) the people usually make and needs a lot more time to dry. Drying process is quite crucial as most of the shrinkage takes place during the second step drying and not later when it is fired. If the stove body are allowed to dry unevenly stresses are set up within the stove because of the uneven shrinkage that results. If the stress becomes too great, cracks form can be seen immediately or can be seen later after firing. It is therefore important to dry the stoves as slowly as possible. Potters in Kampong Chhnang usually keep and dry the stove body under the house. In the dry season, the ground under the house is quite dry and quickly absorbs the moisture of the stove body, while in the rainy season the condition is totally the opposite. As the stoves are spread on the ground, the one in the middle are not exposed to the air as the one on the outside. To facilitate the second drying properly, the project introduced three rows drying shelf attached to house posts and drying pallet. The pallets are used to put the stove body, two stoves in each pallet. The pallets are stacked on the shelf. To dry the stove under the house with the space of 6 m X 6 m (common house size, 36 m2) can accommodate 300 units of stoves. Three rows shelf of 15 meters long and 1 meter wide (15 m2), which occupy less than a half of the space under a house can accommodate the same number of stoves.
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Drying the stove on the shelf is not faster than putting the stove below the house, but there are some advantages:
• Easy to control the drying by installing draperies (made of used rice bag) to prevent from direct sunlight and wind.
• Each and every individual stove body is exposed to the same room humidity and temperature
• The drying will not be affected by the moisture of the ground, never too fast or too slow.
• Prevented from animals (chicken, dogs, pigs) stepping on the un‐fired stove body
Before loading to the kiln for firing all the stoves are directly exposed to sunlight to assure that the body is dry enough to be fired. The sun drying usually takes 2 hours. 1.5. Firing The firing of stoves needs to be done in the same way as the drying ‐ slowly and steady in an appropriate time. As the NKS body is thicker than the traditional stoves, the firing needs longer time to permits the remaining water content to slowly leave from the centre of the clay. If this stage goes too fast, the water may turn into steam and build‐up enough pressure that breaks or causes crack the side of the stove body. Picture 3: Stacking the stove for bonfire (L), igniting the fire (R)
Traditionally the stoves are fired on an open space (on the yard). A layer of wood is laid on the ground, then the stoves are piled up above the wood and are covered with biomass (rice straw, palm leaves, etc…). The fire is lit from the four sides of the pile and gradually more biomass is added from the four sides of the pile. The whole firing process usually takes about 4 to 5 hours. This technique is knows as bonfire.
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Chart 1: Temperature in a bonfire Temperature in the middle of the bonfire (A0) can reach up to 851
oC, which is quite sufficient to fire stove body. At this temperature vitrification (when silica first melts followed later by the clay particles) begins, though with clay containing a lot of iron and in a reducing atmosphere (shortage of oxygen). When melting they stick together forming a strong brittle material. A gentle and gradual temperature increment from its starts to the end is crucial. Though the temperature in the hearth of the bonfire is quite high but occurred only for about 90 minutes and was not sufficient to completely vitrify the thick body of the NKS. The temperature on the side of the pile (B0), (C0) and (D0) is quite low to reach vitrification point (diagram below shows the position of the thermocouple probes). All probes to measure the temperature in the bonfire were positioned a half height of the bonfire pile, 60 cm from the ground. Probe A0 is exactly in the centre of the pile. Probe B0, C0, and D0 were installed 15 cm from the side of the bonfire. Temperature recording was taken once in every 30 minutes, started 10 minutes after the ignition.
Temperature of Bonfire
0
100
200
300
400
500
600
700
800
900
1 2 3 4 5 6 7 8 9 10 11 12 13 14Time - in hours
temp
erat
ure
in o C B0
D0
A0
C0
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Picture 4: Position of the probe in the bonfire To control gradual temperature increment, a simple kiln is introduced to the potters. The kiln is made of brick, 4 meter width and 2 meter length. The height is 1.3 meter. The kiln can accommodate 312 units of NKS. This kiln costs US$ 300 and can be used for 10 years with minimum maintenance. The temperature in the centre of the kiln (A1) reached above 800
oC after 25 hours of firing and stayed above 800oC for 3.5 hours with the highest temperature was 871oC. On the points close to the kiln walls, the temperature did not reach 800oC but stayed at above 700oC for at least six hours.
1.8 meter
1.8 m
eter
1.2 m
eter
D o
A o
B o
C o
A o D oB o C o
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Chart 2: Temperature in the kiln Drawing below shows the placement of thermocouple probes to measure the temperature in the kiln.
Picture 5: Position of the probes in the kiln
B 1 D 1
A 1 C 1
C 1D 1A 1B 1
4 meter
2 met
er1.3
met
er
Temperature of the kiln
0
100
200
300
400
500
600
700
800
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1000
1 8 15 22 29 36 43 50 57 64 71 78 85 92 99 106 113 120 127 134 141 148Time - in hours
Tem
pera
ture
in o C B1
D1
A1
C1
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All probes are positioned a half of kiln height, 65 cm from the kiln floor. Probe A1 is exactly in the kiln centre. Probe B1, C1, and D1 are installed 10 cm from the wall. Temperature recording was taken once in every 30 minutes. Different firing temperature and temperature increment behaviour of the bonfire and the kiln indicated in the strength of the stove body to resist from mechanical pressure. The pressure resistant test done in the Institute of Technology of Cambodia (ITC), Department of Civil Engineering resulted that the stoves fired in the kiln are slightly stronger than the stoves fired in the bonfire. Table 2: Comparison of pressure strength
Fired in the bonfire Fired in the kiln Breaking point Breaking Point Sample no. in kN in kg
Sample no. in kN in kg
A1 13.00 1,325.2 B1 25.60 2,609.6 A2 22.50 2,293.6 B2 32.50 3,312.9 A3 20.00 2,038.7 B3 34.50 3,516.8 A4 28.70 2,925.6 B4 14.10 1,437.3 A5 20.40 2,079.5 B5 24.50 2,497.5 A6 32.90 3,353.7 B6 28.80 2,935.8 A7 20.00 2,038.7 B7 17.50 1,783.9 A8 21.00 2,140.7 B8 25.00 2,548.4 A9 30.00 3,058.1 B9 19.60 1,998.0 A10 24.00 2,446.5 B10 34.00 3,465.9 Min 13.00 1,325.2 Min 14.10 1,437.3 Max 32.90 3,353.7 Max 34.50 3,516.8
Average 23.25 2,370.0 Average 25.61 2,610.6
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Activity 2. Development of standards for production of the NKS and kiln firing The production of the NKS based on the design developed in 2001 and started to get the market by 2003/04. Many potters produced the NKS to fill the demand but the production was not properly attended and the potters producing the NKS did not follow the dimension of the original design. Potters who were interested to produce the NKS copied the moulds from a trained potter and modify it by themselves according to the size they want to produce. There are at present no standards that producers must meet and monitoring of standards. As a result the NKS available in the market now is smaller than the original dimension (see table below). GERES will finalise the standards of the NKS (propose it to the Council of Minister for ratification, publish the standard manual and promulgate the standard) with support of the Office of Industrial Standard of Cambodia of the Ministry of Industry Mines and Energy. In addition to the NKS physical standards, the production line and procedures will be included. These will be introduced together with technology aids to facilitate adherence to the standards. Table below shows the dimension of the original NKS design and the incorrect design, the smaller and larger. Table 3: NKS dimension ‐ the original, smaller and larger size
Dimension of the NKS in mm. Parameter
Original Smaller Larger 1 External Ø of top rim 260 253 280 2 Internal Ø of top rim 210 202 245 3 Pot rest width 50 40 60 4 Pot rest height (from the rim) 10 16 11 5 Ø of the combustion chamber 180 160 184 6 Ø of the grate hole 16 15 18 7 Grate thickness 40 18 38
8 Width of the firewood door (top)
140 143 150
9 Width of the firewood door (bottom)
110 130 145
10 Height of the firewood door 70 48 55 11 Height of the primary air inlet 50 43 55 12 Width of the primary air inlet 120 110 112
The incorrectness of dimensions proportion has somehow affecting the performance of the stove because the important parameters do not assure proportional mixture of air and fuel to produce optimum combustion. The small size NKS somehow disappointed the users because the small size NKS could not generate the expected power as if it was the standard.
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Report on "Gender Assessment: Gender Mainstreaming Energy Planning Project recommends that larger size of NKS is demanded to cook rice for large size family (more than 5 people) and smaller size NKS for smaller families (less than 5 people). GERES is still finding the optimum dimension (diameter and depth of firing chamber, primary air inlet) of the smaller and larger NKS to be validated by the mid of 2009. The new NKS size variance will also be included in the standard.
Picture 4: Size of cooking pot compares to the size of NKS: The NKS is slightly too small for the pot (left), The NKS is OK for the pot (right) and the user added a rim to adapt the small size of cooking pot To facilitate and assure the standard adherence since the very first step of production line, the potters were trained to understand the standard and able to read technical drawing. In practice the potters were trained to use templates and moulds. NKS standard was presented in a simple way to potters participated the training program by showing a technical drawing, a physical sample of a NKS and was demonstrated in front of the potters. The NKS production training also mentioned the importance of the moulds set (outer stove body mould, inner body, and grate) as tools to follow the standard dimension as shown on the drawing below. The potters were also introduced to the draft of NKS standard guidebook, where dimension, production procedure and series of tests to justify the quality product are explicitly written. The concept of standard dimension is not easily understood by potters who learn pottery technique by inheriting from their parents and never had experiences producing pottery wares with low tolerances of dimension and quality (raw material preparation, production, and firing). The mindset that the shape is the most important has to be corrected.
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Standard finalization The standard of NKS that has been submitted to the Office of ISC of the MIME, is being assessed by the director of ICS and discussed thoroughly in two rounds by a working team consists of GERES technician and ISC officers since October 2008 . The draft standard will be submitted to the Council of Minister for ratification that may take long time (NLS standard has been submitted on the early 2008 but not ratified yet). There were a few points to be considered before setting‐up and promulgate the standard:
• A standard monitoring and enforcement infrastructure shall be established at national level;
• Licensing and authorization mechanism shall be developed along with technology transfer plan;
• Identify and inventory traditional stove producers in Cambodia to have a benchmark on target to achieve (quantity, outreach, prioritised area, etc…)
Monitoring/implementation of standards Preliminary conclusion was that the standard shall be promulgated as a voluntary standard and shall be reviewed annually to decide the appropriate time to amend it and promulgate it as a mandatory standard. To monitor standard adherence, GERES collaborates with the Office of ISC of the Department of Industry of MIME to set‐up a monitoring system. The initial monitoring and standard implementation plan was:
• On the early stage, GERES will train DIME staffs on ICS dissemination, NKS standard (NLS will be included) and standard monitoring protocol (4 months).
• DIME will do the monitoring in the province accompanied by GERES technicians to implement the protocol (8 months)
• After 12 months DIME is expected to fully responsible to the monitoring and standard implementation and GERES will keep providing technical back‐up to DIME.
Coordination meeting with the officers of Provincial Department of Industry, Mines and Energy (DIME) was planned for 20 March 2009 (after rescheduled for two times) but it has been postponed by the ISC to 01 April 2009. The agenda of the meeting is to set a plan to identify and inventory of potters in 17 provinces1 (number of the microenterprises, type of stoves produced, capacity,). Result of the identification and inventory will be presented on the next coordination meeting in May 2009 (the date will be confirmed) and develop a map of stove
1 Kg. Cham, Kg. Thom, Kg. Speu, Kg. Chhnang, Pursat, Battambang, Siem Reap, Banteay Meanchey, Takeo, Kampot, Kep, Sihanoukville, Prey Veng, Svay Rieng, Kandal, Kraches, Stung Treeng
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producers in Cambodia. Based on the map, monitoring system and standard implementation plan will be determined by considering the concentration of potters in a few provinces, and scattered potters in the other provinces.
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Activity 3. Pilot production facility A pilot production facility was established in Bahn Chkool Village, Kampong Chhnang, as a centre where the individual producer of NKS may access information, technical supports, facilities, warehouse and necessary trouble shoots. The Pilot Production Facility was established by GERES and managed by a technician, a facilitator and an assistant technician. The objective of the establishment is to facilitate about 30 potters interested to produce NKS in the area to learn to organize themselves to collaborate with each other. In considering the technical related issues, the collaboration is aimed to unite them and to enable them to:
• Share production facilities that improve the production quality and reduce their main burden in the production (clay mixer, firing kiln, and warehouse);
• Set‐up a micro‐finance mechanism that allows them to get regularly a small amount of daily income from the completion of the agreed production step (moulding, carving, cutting, grate production, and assembling);
• Manage a proper production recording to allow the disbursement of fund based on the completion of the agreed production step;
• Learn production management by involving themselves voluntarily as the administrator (two people each period of two weeks) taking care of raw material, production, finance, disbursement of the money to the peers, stock of finished product and sales of the NKS. Each person works overlapped with the partner for two weeks;
• Build their capacity and awareness to have a better bargaining power before the middlemen;
In addition to the technical and management purposes as above, the pilot production facility is developed to be a centre point for the potters ‐ who are mainly women ‐ to develop and revive their social virtues. The voluntary based collaboration will be institutionalized in the near future when each of them are ready and understood the perceived benefit of the collaboration. Currently the "association" is lead and accompanied by a GERES facilitator. While practising the NKS production in the Pilot Production Facility, the potters are also learning step by step practical and simple management. The potters are expected to establish the organisation structure and run the "association" on their own by the end of 2009 and from the social development point of view, the development of potters' organisation is to bring the potters back into a strong and solid social bond. The potters producing the NKS are mainly women, who do not have similar level of decision making in the traditional Cambodian society. Organising women into an association gives each of them an equal opportunity to get peer support and create a sub‐culture based on a common interest ‐ the production of NKS and be able to conform to the traditional culture, values and virtues. The ultimate goal is to give a proper understanding to potters on the correct conception of women (potters) in social order and create an internal control system and mechanism.
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With regard to the technical and social purposes mentioned, GERES allocated some fund to construct a pilot production centre on a land of 1,175 m2 in Bahn Chkoul village. The centre consists of the following buildings: Table 4: List of buildings at the Pilot Production Facility and its' floor size no. Building Size in m Cost (US$) 1 Clay stock, including two soaking pits 4 X 5 350 2 Coarse clay stock 4 X 5 350 3 Clay mixer platform (occupy space in the
corner of building 5) 1,5 X 2.5 300
4 Grate punching shelter 4 X 7 1,500 5 Moulding and carving shelter 14 X 7 3,400 6 First step drying platform and stock
platform of dried unfired stove 12 X 5 2,700
7 Assembling shelter to assemble the stove body and the grate
12 X5 2,700
8 Kiln 6 X 6 2,600 9 Rice husk warehouse 10 X 5 2,750 10 Warden house 5 X 4 1,200 11 Toilet 2.4 X 2.4 950 18,800
Currently GERES keep managing this pilot production facility until all the potters in the area are ready to take over and manage it properly. Continuous accompaniment for a period of two years is still necessary. To promote the NKS production strategy, construction of the centre shall follow similar principal but the construction specification might be adjusted to locally available material and affordability of the potters.
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Activity 4. Train producers in management and marketing The training was initiated by gathering interested potters and facilitates them to assess the existing practices of NKS production. The participatory assessment indicated and decided the need of the participating potters to improve their production and to get a better income. Baseline NKS production GERES‐Cambodia trained 24 NKS producers (11 potter on May 2003 and 13 potters on February 2004) as mentioned earlier, from the trained producers, currently only 7 who produce NKS regularly. In addition there are 23 more NKS potters producing NKS, but not in regular basis, and they copied the mould form the trained producers. From the 30 identified NKS producers, only 11 are actively producing NKS. The average monthly production capacity by 11 active producers was 390 units (in 2007) and 500 units (in 2008). The capacity is relatively low compare to the market demand that is now much higher. The potters produced the NKS based on order received from middlemen. The working rhythm to produce the NKS did not correspond to their real capacity and far from efficient. The common daily activities pattern of NKS production was: Table 5: The most common NKS production pattern
Day Activity
0 assumption ‐ Received payment from the NKS sales, 60 units @ 2,200 KHR = 132,000 KHR (approx US$ 33)
1 Purchase the raw material ‐ clay (or coarse clay), sand, rice husk, straw ‐ then soaked in a pit
2 Knead the clay and sand, then keep the lump covered
3 Moulding the stove body (20‐30 units)
4 Moulding the stove body (20‐30 units)
5 Carving the stove (15‐20 units) and making the grate (30)
6 Carving the stove (15‐20 units) and making the grate (30)
7 Carving the stove (15‐20 units)
8 Drying the stove
9 Drying the stove
10 Firing in the morning and assembling in the
22
afternoon (60 units)
11 Assembling the rest and sell the stove
The average cycle of 11 days (sometimes 12 to 13 days) as above is usually repeated twice a month. Therefore the maximum production capacity for a family is 100 ‐ 120 units Based on the production of 120 units per month (in two cycles), the profit margin is: Table 6: Profit of a common individual family producing NKS Investment: I m3 clay & coarse clay2 8,000 KHR 2.0 USD Labour cost for kneading of 1 m3 10,000 KHR 2.5 USD Fuel for firing (wood & straw) 60,000 KHR 15.0 USD Total Investment 78,000 KHR 19.5 USD
Income: From selling the 120 NKS @ 2,200 KHR 264,000 KHR 66.0 USD
Profit enjoyed in one month 186,000 KHR 46.5 USD The net profit shall be considered as monthly income, which is about 6,200 KHR of 1.55 USD per day. The average production and cash flow of potters as above was considered discouraging and many potters considered giving up NKS production temporarily but produce other pottery products instead because the production was not profitable, except larger families that can employ the members. To respond to the need to improve the production speed, regularity and cash flow, this pilot project offered to the potters a new scheme of NKS production that provide more regular income. Model Production Facility 4.1. Participatory Assessment for Planning & Introduction of the Scenario In the very beginning, all potters interested to produce NKS were gathered in a facilitated meeting and were exposed to an improved concept on NKS production. Including in the exposed concept is a small amount of seed money to allow them to manage the provision of labour cost to the potters involved in the program to get regular income and to share the production risks. The scenario is done by fragmenting the NKS production into several production steps and valuation of each agreed production step. : 2 1 m3 of clay and coarse clay can produce 240 units of NKS
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4.1.1. Divide the production into steps and valuation of the steps Instead of getting paid per produced batch in the Pilot Production Facility the production of the NKS is divided into 8 working steps with clear and quantifiable deliverables. Each step is valued based on the time, skills and labour intensity, comprising: Table 7: List of agreed steps and values in NKS production
no. Products / deliverable payment
in KHR/unit
note:
1 Mixing the clay and the sand (or coarse clay) and firing costs
700
Including in the cost are • raw material, • diesel fuel • mixing operator cost, • fuel for firing, • firing operator cost
2 Mould the stove body 200 Based on the number of the moulded stove at the end of the working day
3 Mould the grate 50 Based on the number of the moulded grate verified at the end of the working day
4 Punch the holes on the grate
150 Based on the number of punched grate and verified at the end of the working day.
5 Carving and installing the pot‐rests
400
Based on the number of stove body that are carved and verified at the end of the working day
6 Cutting the firewood gate and primary air inlet + drying
100 Number of the carved stove body that are cut
8 Assembling the stove body and the grate to final product
300 Number of assembled stove into final product
4.1.2. Daily payment based on the quantity of the achieved production step The aim of the valuation is to allow each and every potter joining the program to be paid based on the verified outcome by the administrator at the end of the working day. (see 3. Pilot Production Facility)
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Example 1, in a day a potter do: Moulding stove body 40 pcs @ 200 KHR 8,000 KHR 2.0 USD Moulding grate 40 pcs @ 50 KHR 2,000 KHR 0.5 USD Total income of the potter in the day 10,000 KHR 2.5 USD Example 2, in a day a potter do Carving stove body 20 pcs @ 400 KHR 8,000 KHR 2.0 USD Cutting stove 20 pcs @ 200 KHR 4,000 KHR 1,0 USD Punching grate 20 pcs @ 150 KHR 3,000 KHR 0.75 USD Total income of the potter in a day 15,000 KHR 3.75 USD The same potter might receive different amount of payment in the next day depend on the variation of the product outcome. The average daily income of the 10 trained potters (after three months training) at the NKS Facility is between 2,900 KHR to 4,200 KHR (0.73 USD to 1.05 USD), and the highest income is 13,500 KHR (3.375 USD) 4.1.3. Money saving Total production cost of the NKS is 1,900 KHR per unit, and the selling price is 2,200 KHR per unit. The margin of 300 KHR belongs to the potter and will be received by the potter on the day when the stoves are sold. However, the potter will not receive it in cash but saved in a saving account (individual saving account in the name of particular potter). The money saved in the bank (ACLEDA) can only be withdrawn after deposited for one year. The saved money shall be considered as additional profit to the potters. 4.1.4. Selling the stove from one ware house All the final NKS produced on the day are recorded by the administrator in charge and stored in a ware house following first‐in‐first‐out principal. The administrator organises the sale of the NKS to the middlemen. Instead of dealing with several individual producers, the middlemen deal with only a warehouse. This system allows proper recording of the sale to know the number of NKS sold on a particular day. 4.2. Training to potters At the end of the participatory meeting and based on the offered scenario as above, all potters agreed to realize their need into practical actions. To select the first batch of potters to join the training GERES decided to draw‐straw to all the meeting attendances because the pilot production centre can accommodate maximum only 10 potters while there are more than 20 interested potters. Based on the need and the existing skills of the potters, the training consists of:
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4.2.1. Production techniques In the training all potters learned how to mould the stove body using a jigger‐jolly, using a pallet to dry the stove, arrange the pallet on a shelf for drying, carving, drying, making the grate and assembling. Basically, all potters have known the technique quite well but they did not have sufficient knowledge to manage the production to optimise their time and effort so they may get optimum daily income from the production as elaborated as above. 4.2.2. Book keeping Book keeping training was done through "learning by doing" by assigning two potters for two weeks period to practice administrative works to record the realization of NKS production every day. The composition of two potters was changed every one week to allow all potters to work in partnership with all the peers. The attainment record of the day was the baseline to calculate the amount of "profit" to be received in the afternoon and the "costs" to be paid to the group (in this stage GERES acts as and on behalf of the group to receive the payment and manage the supply; mixed clay and firing service). 4.2.3. Finance management Training on finance management was taken place along with the book keeping training. The assigned pair shall also responsible on the payment to their peers; collect the money to be deposited in the saving account (individual saving account) and for paying the services provided by the group (mixed clay and firing service). Each individual potter shall "pay" to the service provider based on the quantity of produce and sold NKS in the period. 4.2.4. Stock management The assigned pair was also learning how to plan the correct clay to mixture to suffice the supply the need of their peers, how to contact and place the order for rice husk, fine clay and coarse clay. The "administrator" of the week should also contact and inform distributors on the NKS availability in the planned date. On the date of the transaction, the assigned pair shall also be responsible to record the quantity of NKS went out form the warehouse. The training has been taking place for three months and able to encourage the potters to do paper works, which they never experienced before. The other benefit of the training is that:
• The potters (all are women) were gradually encouraged and regaining their confidence and no longer feel inferior before their neighbours in the village because now they can write, fill the forms, work with simple administration;
• The spirit to take care of and serve to others were nurtured among the potters participating the training
• Social barriers amongst potters that sprouted from a notion that the other families producing NKS in the village are competitors were gradually fading
26
away and they started to bring up partnership and collaboration with the other NKS producers.
• The potters were able to manage to work as usual but gaining daily income.
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Activity 5. Evaluation of the options for introduction of the improved manufacturing of the NKS Stoves.
At present the NKS are produced in Kampong Chhnang province in household industry scale and a few in micro‐enterprise scale. The production capacity is varied from 100 units to 500 units per month. Besides production capacity, there are some other aspects that distinct the family scale and micro‐enterprise scale production: Table 8: Aspects influencing NKS production; Microenterprise & Family no. Production aspects Micro‐Enterprises Family scale
1 Capacity per month Minimum 500 units Ranging from 50 – 100 units
2 Labour Employ paid labour Unpaid labour, mostly women
3 Production facility Specially constructed, often separate from the house
Within house plot
4 Production flexibility
Can be extended and scaled‐up
Limited and highly depended on family size
5 Capital investment Bankable, mostly get loan from MFI
Limited, mostly get loan from money lender
6 Raw materials Supplied by providers Partly supplied but mostly are collected
7 Production regularity
Regular and reliable, usually able to fulfil the order on time
Less regular and reliable in fulfilling the order
8 Applied production technology
Intermediate technology, systematic
Traditional technology, mostly unsystematic
Different methods shall be applied to develop and improve the NKS production by micro‐enterprise and families. 5.1. Improvement the micro‐enterprise Improvement to micro‐enterprises that have been producing the NKS requires less effort, though the following aspects shall be well attended. Labour skill improvement: to up‐grade the labours to understand and follow the standard and able to operate semi‐mechanised equipment Supervision and control system: regular control system shall be introduced to minimise product defaults and to assure all the products correspond to the standard. Production chain management: proportional production steps, from moulding to assembling to avoid over‐loaded and/or under‐loaded works of the labour Workshop and its facilities: shall correspond to the production chain to prevent mixing‐up of two or more different tasks in the same platform.
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The workshop and its facilities to be promoted shall not be exactly similar to the Pilot Production Facility constructed by GERES in Bahn Chkoul (see Activity ‐3, Table 4: List of buildings at the Pilot Production Facility and its' floor size), but follows the principal of the Pilot Production Facility. To have similar facility for family scale the most important facility is:
‐ Ready mixed clay stock: to assure continuous supply of mixed clay (20 m2) ‐ Moulding platform: spacious enough for the potters to mould the stove body
and the grate (20 m2) ‐ Drying area: that allows stove body drying (first and second drying) in shelves
as well as on the drying floor (30 m2) ‐ Assembling platform and temporary stock: to facilitate installation of the
grate and keep the final product before the sale (30 m2) Those facilities can utilize the existing space under the house. If the space is not available, to construct those facilities of about 100 will require US$ 500 – US$ 800 with less cost material (bamboo poles, leaf roofing and hardened dirt floor). The facility can support the production of 600 – 800 units per month. Clay mixing machine and kiln for firing the stove (and grate) shall be procured and managed by the association or group of potters to reduce the investment cost of each family. For micro enterprises who like to produce the NKS, can use the existing facility producing traditional stoves or construct new facilities as in the Model Production Facility but with less cost material (bamboo poles, leaf roofing and hardened dirt floor). Construction cost of about US$ 5 – US$ 8 per square meter floor. To produce 2,000 – 2,500 units NKS per month, it requires about 400 m2 and shall have a unit of clay mixer (US$ 850) and a unit of kiln of 4m length, 2 m width and 1.3 m height (US$ 250). Safety and sanitation: the working place shall be well ventilated, well lighted, prevented from animals and the floor shall be free from sharp objects and the surrounding shall be neat free from stagnant water (especially during rainy season). Financial management: introducing a simple book keeping that links to other records of production management (raw material, labour, maintenance, final product, sales, etc…) to have a clear financial status. Proper book keeping will support the micro‐enterprise to access additional capital (when needed) from a bank or MFI Integrated training to improve those aspects requires active participation of the owner/manager for at least 6 months. Except in a few districts of Kampong Chhnang, Kampong Cham and Battambang Province, stove micro enterprise is usually the only one in the district (solitaire).
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Training to stand alone enterprise needs to specially allocate trainer only for the particular enterprise and emphasise on micro‐enterprise and business development. To be economical, high production capacity (minimum 2,000 units per month) of the particular enterprise is important. 5.2. Improvement the family scale production As a production unit, a family has some limitations (see table above) that cannot be easily adjusted. However, family producing cook stoves usually resides in pottery areas where many other potters doing similar activities. Strategy to improve family scale production is by setting up pilot production facility or a centre where interested potters can come and learn to improve the production as mentioned in Activity 3 (Pilot Production Facility) and Activity 4 (Train producers in management and marketing) 5.3. Projection of production capacity The current Pilot Production Facility managed to produce about 600 units of NKS per month. Assuming that every 3 months, the facility can train 10 potters, in a year the facility able to train 40 potters. After one year 1, the 40 potters from surrounding village and trained by the production facility can produce at least 2,400 units of NKS per month. Kampong Chhnang Province is a special case where more than 1,200 potters producing various pottery wares. However, in Kampong Chhnang at least there are 3 more clusters of potters interested to produce NKS; Khsam, Kdey Tnaot and Andong Russey. Establishing 3 more production facilities in those clusters can multiply the NKS production to more than 7,000 units per month. Training to family scale potteries, as experienced by GERES in 1998‐2000, can upgrade family scale production to micro‐enterprises (5 from 23 families trained on NLS production) with total production about 5,000 units per month. Combination of family scale production (supported by 4 production facilities) and 3 new microenterprises, Kampong Chhnang itself can produce about 13,000 units per month (conservative estimation). Production projection of the entire provinces in Cambodia is based only on the 17 provinces where potters and traditional stove micro enterprises exist. Table 9: List of provinces, potential NKS production units and capacity of production per month (in NKS units per month) at the end of year 1 after the training finished
Production facilities Micro‐enterprises no. Province
# cap/mo # cap/mo 1 Kg Chhnang 4 8,000 4 8,000 2 Kg Speu 2 4,000 1 1,000
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3 Kg Cham 2 4,000 1 1,000 4 Kg Thom 1 1,000 5 Pursat 1 1,000 6 Battambang 2 2,000 7 B Meanchey 1 1,000 1 500 8 Siem Reap 1 1,000 1 500 9 Prey veng 1 1,000 1 500 10 Svay Rieng 1 1,000 1 300 11 Kracheh 1 2,000 1 500 12 Stung Treng 1 500 1 500 13 Takeo 1 1,000 1 500 14 Kampot 1 1,000 15 Kandal 1 1,000 1 500 16 Kep 1 500 17 Sihanoukville 1 500 Potential production capacity 21 28,500 16 15,800
Total estimated NKS production capacity right after the training is 44,300 units and is expected to reach about 90,000 units per month by the end of year 4. The number of production facilities (to cover family scale pottery production) and micro enterprises to be developed in each mentioned provinces is to be discussed and confirmed by DIME staffs of the 17 provinces that will have a coordination meeting on 01 April 2009.
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Activity 6. Preparation of a plan for scale – up of production A plan will be prepared to meet the production required for the estimated market demand for broad scale introduction of the NKS Stove in rural areas. A plan to implement a National Efficient Cook Stove Program has been formulated by the MIME and assisted by the WB‐ESMAP. The program is aimed to support the promotion of NKS to rural families in the 17 prioritised provinces as listed in the table 9 (see previous activity). The National Program would lead the efforts to bring efficient cookstoves to all of the 2.1 million rural households and make major contribution to reduce the negative impact of smoke on the health of woman and children, lessening the time to collect wood or cost of firewood for cooking. The proposed target is to disseminate 1 million efficient cookstoves over a four year project period which is equivalent to 50% of the 2.1 million rural households in Cambodia. Fuelwood saving after year 4 is estimated to be 600.000 tons or 1 million tons of CO2. By the end of year 4 a sustainable private sector infrastructure would be in place which could expand the market to 2.1 million efficient cookstoves or one stove for every rural household. With a 2 year stove life this level of production would need to be sustained to meet replacements requirements. The estimated cost of the 4 year National Program is 3.5 million dollars or $3.5 per household. This can be compared to the annual carbon credits that could be generated by the distribution of 1 million efficient stoves per year (by the end of year 4). At an estimated price of $6 per ton this could generate 6 million dollars or $6 per household per year. The carbon credits could be utilized for a program to reduce the increasing demand for fuelwood by supporting major areas of need such as tree planting for firewood and efficient charcoal production using improved charcoal kilns. In Cambodia the present household demand for wood is more than 4 million tons per year and there is an increasing demand by industries. Present charcoal production to only supply Phnom Penh is 100.000 tons per year which mostly comes from Kampong Speu and is progressively collected from more distant national forested areas. Such a program would not only benefit households and industries but also the many very poor families in the illegal wood energy supply chain.
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Appendices
33
115013
00
200
937
Scale 1:20Unit: mm
700
416
756
1025
4.42
313
.62
64.
52
334
Appendix 1.
Fig. 2 Angle frame (A) Fig. 3 Axle (B)
Fig. 4 Pulley with Axle (C) Fig. 5 Bearing (D) Fig. 6 Frame with Engine
38 mm
1300
mm
34
67.50 degree
190 mm
450
mm
11 m
m
90 degree22.50 degree
38 mm
1200
mm
6 m
m
49 mm
600
430
348
4.42
3
13.6
26
4.52
Fig. 7 Mixing Tank (E)
Fig. 8 Axle with Blades (F)
Fig. 9 Pulley fixed with Axle (G)
35
Middle upper polyScale : 1:10
80 mm
60mm
26 m
m
2.80
mm
11m
m
6 m
m
4.60
mm 39 mm
19 mm16
0 m
m 19 m
m
3.74 mm
16 mm
5.6 mm
2.60 mm
24 mm
130
90
4
2.605.6016
136
8.40
20
Fig. 10 Pulley fixed to Axle (H)
Fig. 11 Pulley fixed to differential Box (I) Fig. 12 Pulley fixed to differential Box (J)
36
Appendix 2.
Material : Production :
Size :Optimized pot size :
Specification : Price in producer level :Price in retailer level :
Main users : Fuel :
Fuel saving :Dissemination :
Baked clayStove artisans21.7 cm height 26 cm diameter21 cm to 24 cm or diameterPortable (weight approx 5 kg)2,200 riels (US$ 0.55)5,000 riels (US$ 1.25)Targeted for rural & peri-urban familiesCommercial fuelwood22% (with fuelwood)Commercialization
Characteristics
120o
2 cm5 cm
AA
26 cm21 cm14 cm
11 cm18 cm
12 cm
19.5 cm
16.5 cm
5 cm
4 cm
7 cm
20 cm 21 cm
Grate consists of 37 holes,diameter of each hole is
1.8 cm
A - A view
Minimum pot diameter = 21 cm
Maximum pot diameter = 24 cm
B
B
B - B view