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“Bell & Brass metal work losing its shine in Odisha”.…a survey conducted by the Industry-Institute Partnership Cell &

Department of Management Studies.

Konark Institute of Science & Technology,

Bhubaneswar.

Introduction.

The metal handicrafts reached a high level of perfection during the reign of Ganga

Dynasty from 11th century onwards. The royal patronage brought extensive

popularity of the products and in course of time the craft began to grow in range

and variety. These kings developed a special liking not only for construction of

magnificent palaces and towering temples but also for patronizing figure arts and

econometric in metal and stone as well. From the level of few domestic types of

equipment which originally constituted the limited field of industry, it spread in

various directions of utilitarian and ritualistic fields. And finally it trickled down to

the households of well-to-do and common man of the society which leads to a

flourishing market of the metal crafts.

The excellence and universality of the products created opportunities for extensive

extra territorial markets. The bell metal products of Orissa found a regular market

in the neighboring state of West Bengal and other areas besides meeting the

growing demands at home. The industry was prosperous when raw materials were

available abundantly and the competitions from other industries were less

pronounced. But, lack of innovation and professionalism paves way to variety of

problems ranging from raw material to marketing of products in the competitive

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market environment, especially that gradually emerged after independence of

India.

Bell metal is a hard alloy used for

making bells and related instruments, such as cymbals. It is a form of bronze,

usually approximately 4:1 ratio of copper to tin (e.g., 78% copper, 22% tin by

mass). Bell metal ore is a sulfide of tin, copper, and iron called stannite (the

chemical formula is Cu2FeSnS4) bell metal was used for the casting of

bells Functional bells, with the intention of producing sound, are usually made by

casting bell metal, a high-copper alloy of bronze, with approximately a 4:1 ratio of

copper to tin (78% copper, 22% tin).

Brass metal is any alloy consisting primarily of copper, usually with zinc. In some

cases, copper with tin is considered a type of brass, although this metal historically

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has been called bronze. It is a substitution alloy atoms of the two constituents may

replace each other within the same crystal structure. Brass is used for decoration

for its bright gold-like appearance; for applications where low friction is required

such as locks, gears bearings, doorknobs, ammunition casings and valves; for

plumbing and electrical applications; and extensively in brass musical

instruments such as horns and bells where a combination of high workability

(historically with hand tools) and durability is desired

Brass & Bell Metal in Odisha.

Metal craft is perhaps the single mostimportant craft in terms of the number of

artisans engaged in its practice as in its close links with the daily lives of the

people of the State. The craft is practiced by the people of the Kansari caste who

can be broadly described as black smiths while a particular variety, dhokra, is

practiced mainly by sithulias. The largest concentration of the former is Kantilo in

Nyagrah and Balakati in Khordha ,Bhuban in Dhekanal district although fairly

substantial numbers are also found in Cuttack, Ganjam,Sambalpur, Bolangir,

Jajpur&Balsoredistricts of Odisha.

Details of Bell Metal Cluster in Odisha.

Sl.No.Name of

theDistrict

Name of theCluster

Name of theCraft

No. of craftpersons (approx.)

1 BolangirTarava

Brass&Bellmetal

70

Binika Brass 60

4

&Bellmetal

2 JajpurLaxminagar

Brass&Bellmetal

110

BaidyarajpurBrass

&Bellmetal500

3 Dhenkanal

BhubanBrass

&Bellmetal300

IndipurBrass

&Bellmetal80

Reamal Metal ware 318

4 Cuttack BhatimundaBrass

&Bellmetal400

5 Ganjam

BelgunthaBrass

&Bellmetal60

PatrapurBrass

&Bellmetal70

JagamohanBrass

&Bellmetal60

6 NayagarhKantilo

Brass&Bellmetal

500

KhalisahiBrass

&Bellmetal100

7 Khordha

MuktapurBrass

&Bellmetal140

RathijemaBrass

&Bellmetal300

BaichuaBrass

&Bellmetal400

BalakatiBrass

&Bellmetal500

8 Sambalpur RengaliBrass

&Bellmetal300

9 BalasoreRemuna

Brass&Bellmetal

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SimuliaBrass

&Bellmetal50

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Out of the above clusters, we have visited Bhuban & Indupur villages of

Dhenkanal district and the Baidyrajpur cluster of Jajpur district on 22.02.2015,

04.03.2015 & 02.05.2015 respectively. And the scenario remains almost same in

the three villages. The detail report is hereby given for a ready reference.

The Co-operative Society of Bell & Brass Metal at Baidyarajpur.

The workshop is called sala or shed and consists of a platform with a block of

stone for the floor on which the beating is done, a heating furnace or bhati, a raised

verandah with a local lathe for polishing. Tools used are hammers and anvils,

pincers, hand drills, files and scrapers. The heating furnace with a crucible is

fanned by a blower with leather bellows although of late the craftsmen have started

using mechanical blowers.

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The Crafts men in Bhuban are engaged in melting the raw materials.

The process consists of preparation of the material by melting the required

materials in the crucible and then placing the molten metal into an earthenware

container. After the molten metal sets, it is taken out and after repeated hammering

and beating is given the desired shape.

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The artisans are engaged in moulding activities.

The major items manufactured in the beating process are plates or 'thali', deep

round containers called Kansa, small containers called 'gina' (tumbers), water

containers called gara and buckets or 'baltis', large cooking utensils and storage

vessels called 'handi', various types of pots and pans, ladles or chatu, perforated flat

cooking spoons etc. While the above mentioned are items used in cooking and

eating there are also a number of items used for puja or worship. Of these most

important of course, is the ghanta or the gong and thali for offering of the food to

the deities.

Prof.(Dr.) P. Padhi, Principal, KIST discussing with the governing body members of the Baidyarajpur

Cluster.

Particulars of community associated with the craft:

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The community associated with the making of bell metal wares in Orissa is

Kansari. The Kansari is an artisan caste in the socio cultural hierarchy of Orissa.

As metal smiths, they specialize in bell metal, brass and copper and manufacture

different kind of non-ferrous metal wares. In Orissa, the communities practicing

different non-ferrous metal wares constitute a caste cluster. The caste/community

that practices with the work of bell metal is known as Kansari and that a copper is

known as Tambera. There are also other copper and copper alloy metal craftsmen

like the Kharuda (brass bangles) etc.The Kansaris are widely known for their work

in bell metal and brass. They earn their livelihood primarily as Brass and Bell

Metal smiths. Through this, they maintain their own age old metal craft tradition.

(Dr.) Payodhar Padhi, Principal, KIST discussing with the Artisans at Indupur, Dhekanal.

Number of households engaged in the craft in the state

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In absence of any comprehensive survey of the bell metal craft in the state it is

difficult to obtain the exact number of household engaged in the craft in the State.

However, as per the Ambedkar Hastashilp Vikas Yojana (AHVY), Ministry of

Textile, Govt. of India, it is revealed that the state has about 15000 artisan and

SHGs families with a production base of about one hundred crores rupees per

annum. And out of it about 3000 families are engaged in Brass and Bell Metal

craft.

Prof.(Dr.) Payodhar Padhi, Principal, KIST discussing with the Artisans at Bhuban, Dhekanal.

No of Dependents.

The bell metal artisans are mostly tribal-people. The metal-crafts sector plays a

vital role in providing employment to our rural population. In India there are about

three million handicraft artisans and most of them are working in metal sector.

These metal artisans display inherent creativity and play a significant role in

protecting the traditional art and culture of our nation.

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Different Bell Metal Products:

The bell metal handicraft objects manufactured by different artisan household

under survey are Thali (Plate or Tray) ,Thalia (Saucer of quarter plate) ,Kansa or

Bela , Tatia or big Gina (Cup) , Small Gina or Small Bati (Small Cup), Parasa, Bell

, Ghanta (Gong),Jhanja , Kubuji and Gini etc. And among the temple accessories,

cymbals (Jhanja), Gini, Ghanta, Ghanti, Chakra, Trisula etc.

Products made off brass & bell metal available at the Baidyarajpur Cluster.

Raw materials:

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The raw materials used can broadly be classified into two categories i.e. the

Primary and the Secondary.

a) Old utensils made of brass metal b) old utensils made of bell metal.

The copper ware and coal used as raw materials.

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The Primary raw materials include various kind of metals, both in pure and alloyed

forms are Copper, Zinc, Tin, Bell metal (alloys of Copper & Tin), Brass (alloys of

copper & zinc), German silver (alloys of nickl, copper and zinc) and Tau (alloys

of copper and zinc). The secondary raw material includes Soldering materials,

Resin, Polishing material and fuel.

However, the joblessness of the craftsman over a long period is primarily due to

the scarcity of raw materials, which is one of the major problem areas in this

traditional industry. The mahajans (the middle man) procures the brass sheets from

a re-melting, re-rolling mill as long as the prices were affordable to them. But with

raw material prices rising, they have stopped their procurement, and the

consequence of which the artisans are without work and income. On the other side,

the artisans cannot bypass these middlemen (mahajans) and buy raw material

directly themselves as these suppliers enjoy monopoly power in the factor market.

On the basis of procurement, the tools can be broadly classified into two types

i.e.indigenous and imported. The former includes those which are made either by

themselves or by the local ironsmith/carpenter, according to their specification and

on order, whereas, the latter includes those designed and manufactured using

machines, standardized and available in hardware shops.

Health Problems

Different private companies (for example Reliance General Insurance) have givenhealth promises to all the crafts men of this cluster, but everything goes in vein.

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The precarious health conditions of the crafts men in Baidyarajpur village.

The crafts men showing the health cards provided by the different companies having no benefit.

Technology.

It is observed that the all members of the Baidyarajpur Co-operative Society areusing the traditional technology for the purpose.

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The melting furance

The finishing activites being under taken at the Sala (Workshop)

Since the Brass and Bell Metal industry is household based, it does require huge

amount of capital investment.However, the capital is required for acquisition of

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tools and equipment, purchase of raw material and to bear costs involved during

the manufacturing process including the fencing charges.

Socio-economic background of the craftsmen.

Having interaction with the artisans at Baidyarajpur.

All most all craft enterprises are family owned. The owner and other family

members are the Manager, operator, marketer, technician and negotiator. There is

hardly any qualified people recruited from outside.

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One of the Sala (workshop) worstly affected by the Cyclone.

As a result no fresh idea came up and the process of manufacturing remained

traditional. One needs to understand that there are several functional areas in an

enterprise where qualified and experienced persons are required. The level of

awareness of the entrepreneurs, especially in technical and marketing areas, is not

as high as it should be. Low level of education and inability to communicate in

English has created a major problem for them.

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Prof (Dr.) P. Padhi & Prof.(Dr.) V. S. Murty, Distinguished Prof. of KIST, narrating theproblems of craft industry to the Media.

However, the traditional artisans have expertise only in this craft and limited scope

for alternative livelihood in one hand and their poor socio-economic condition,

the lack of schooling in most cases, and virtually no exposure to the outside world

on the other have left them vulnerable and unable to find a way forward on their

own.

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Socio-economic & environmental conditions.

The short-term effects is metal fume fever, symptoms of which occur four to

12 hours after exposure and include chills, thirst, fever, muscle ache, chest

soreness, coughing, wheezing, fatigue, nausea, and a metallic taste.

Welding smoke also can irritate the eyes, nose, chest, and respiratory tract

and cause coughing, wheezing, shortness of breath, bronchitis, pulmonary

edema (fluid in the lungs), and pneumonitis (inflammation of the lungs).

Gastrointestinal effects, such as nausea, appetite loss, vomiting, cramps, and

slow digestion, also have been associated with welding smoke.

An exclusive interview of the craftsman at their workshop (Shala).

Some welding fume components and welding processes can be especially

dangerous in a short period of time. Cadmium in welding fumes can be fatal

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in a short time. Ultraviolet radiations given off by welding reacts with

oxygen and nitrogen in the air to form ozone and nitrogen oxides, which are

deadly at high doses, irritate the nose and throat, and cause serious lung

disease.

Studies show that welders and those involved in brazing, soldering, and

metal cutting have an increased risk of lung cancer and possible larynx and

urinary tract cancer.

Other health problems that appear to be related to welding include heart

disease; skin diseases; hearing loss; chronic gastritis (stomach

inflammation); gastroduodenitis (stomach and small intestine inflammation);

and stomach and small intestine ulcers.

Problems of Technology

In the present era of globalization, liberalization & privatization, the Indian

brass and bell metal industry, which is the most important components of the

metal craft, is facing tough competition in the emerging manufacturing

scenario due to its conventional indigenously developed technology in

producing the traditional types of brass and bell metals Products.

As a result, the artisans are opting for alternate employment for survival and

the brass and bell metal artisan skills continue to decline and almost appear

to be moving towards extinction in some of the clusters/areas and hence it

necessitates product diversification, design development, technology up

gradation, proper market exploitation etc.

Sales and marketing

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The products are marketed within India.

The products are marketed through traders/dealers and agents.

There is no export till date recorded from this cluster but if the products are

diversified to decorative items on line with Moradabad cluster there will be

potential for export.

Marketing The Baidyarajpur cluster meets the order of the local markethaving no access to the national or international demand. However, the turnover the cluster is ten lacs to 15 lacs. (approx.)

Finance problem

Finance has been a problem for the craftsmen. Due to the illiteracy, ignorance and

poor family background of entrepreneurs they are compelled to work on job work

basis for Mahajans who purchases raw material i.e. Brass and Bell metal and give

it to the artisans on piecemeal basis. Although some banks are ready to provide the

financial assistance but these tiny units are accustomed to work on job work basis

and not making efforts to borrow the money from financial institutions.

Working Capital Requirement.

Total demand for the working capital is Rs.50, 00,000/-. However, the Baidyrajpurcluster has put demand of Rs. 6, 00, 000/- but the government has sanctioned onlyRs.2, 60,000/-

Human Resource Development.

All most all bell metal clusters in Odisha are providing no training facilities to the

craftsmen.. The skill and the technique involved in the process of manufacturing

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and repairing is done through the traditional method. Even R&D institutes and

quality testing laboratories are non-existent in this industry.

Infrastructural facilities

As is mentioned above most of the units are set up in their houses and therefore

there are no working sheds or suitable infrastructure available with them.

Business Development Services

Lack of business development services is also another big problem for the

development of craft industry. There is no technical training institutions, no R&D

laboratory, no management institutions, no testing facility, no marketing expertise,

no design development institutes available at all most all clusters in Odisha.

These problems are being discussed by Prof.(Dr.) P. Padhi, Principal, KIST with Mr. K. C.Sahoo-the representative of The Samaja- the Oriya Daily- in front of the foundry at Bhuban.

Institution involved in the development of clusters:

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The Government departments which have direct/indirect stake in the cluster butcertainly can play a very significant role for the overall growth of the cluster are:

Brass & Bell metal Co-operative Societies

District Industries Centre

Small Industries Service Institute

Small Industries Development Bank of India (SIDBI)

Directorate of Handicraft and Cottage Industries

Craft Council of India (CCI)

Khadi& Village Industries Commission (KVIC).

Regional Research Laboratory (RRL)

Small Industries Service Institute (SISI),

Directorate of Handicraft and Cottage Industries, Government of Orissa

Orissa Cooperative Handicraft Corporation Ltd.

National Bank for Agricultural and Rural Development (NABARD)

National Small Industries Corporation (NSIC)

Export Promotion and Marketing (EPM), Government of Odisha.

However, in spite of the various schemes announced by the different agencies, the

artisans have not been taken into confidence by the administration. The artisans are

unaware of the projects and schemes of the government and hence the benefits are

not trickled down to the craftsman. Thus the problems like scarcity of raw material,

obsolete technology, lack of marketing support, poor background of the

entrepreneur and their enterprise, lack of financial support and absence of

networking among cluster actors are the biggest threats to the development of this

industry.

Employment Generation

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The artisan workshop is able to create more employment opportunities because of

its labour intensive technology. Statistics shows that every artisan firm needs 4/5

labour for melting, casting, scrapping, welding, grinding and buffing activities in

the production process. In addition to this, there are also some indirect

employments like raw-material suppliers, machine suppliers, traders, marketing

agents etc. But due to the current downward tendency of this industry, the State of

Odisha is losing thousands of employment opportunities every year.

However, the factors, which hampered the development and growth of craft sector

in Odisha, can be summed up as

Fixed mind-set to change of products and processes and cater to market.

Lack of awareness on new manufacturing technologies and best practices,

collaborative work and other options existing outside.

Non-availability of institutional facilities for product design, new processes

and other technical support services to manage technological change and

financing of this process on continuous basis.

Lack of communication and interaction with handicrafts and other brass and

bell metal artisan enterprises of the other states like West Bengal, Uttar

Pradesh, Madhya Pradesh & Bihar, etc.

Very small size of manufacturing entities in comparison to their counterparts

in other states.

Absence of cooperation amongst brass and bell metal artisan enterprises

countrywide.

Thus the Key areas in which the strategic interventions are needed are:

1. Technology up gradation

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2. Networking among cluster actors

3. Skill Development Practical training for Diversification of products

4. Marketing support for products

5. Raw material support

6. Common facility Centre.

Suggestions.

In the month of February & March, 2015 We have paid a visit to Bhuban &Indipur of Dheknal district and came across with the no of artisans and theirprolonged problems. This has also been published in The Samaja on 26th Feb,2015.

The news published in The Samaj, dt. 26th Feb, 2015.

However, on the basis of interaction with the artisans of Bhuban, Indipur andBaidyarajpur, we can suggest the following for the development of the bell & brassmetal industry.

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To assess the problems of the bell metal craftsman facing as of now and to

categorize the problems in to engineering and management and formulate

solutions accordingly.

To created innovative design such that the works process will be more

productive, cost effective and less hazardous.

To enquire into alternate design for bell metal currently available in the

market, may be in India or abroad. The designs related to antiques, crafts, art

etc.

For infrastructure development, a Common Facility Centre (CFC) has to

be developed where improved machines will be installed.Facilities for

mechanization of material testing, sheet cutting, sheet rolling, sheet pressing,

product design and development, pattern making, packaging, etc. can be

done here.

Training programmes for product diversification with modern technology

should be organized at the cluster level.

To understand or explore modern/ innovative market avenues for solving the

market/distribution problems.

Project funds should be used for establishing a proper market network to

help artisans to market their goods directly without middle-men.

In this era of globalization, the marketing activities of the crafts man needs

to be integrated in order to capture both Factor market & Product market.

Govt. must develop a long-term cooperation and partnership programme to

provide international support to the craftsman. Motivation, awareness and

exposure of artisans to role of new technology, innovations and

technological options for enhanced productivity and sustained growth must

be carried out at the administrative level.

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Thus, it is concluded that all the above mentioned problems should be addressed

properly at the grass root level, so that all the 3000 artisans families in Odisha will

get benefit from the projects of the different agencies.