Chandigarh BDS Cluster

— An innovative approach adopted in the MPC Cluster

The fasteners industry is the most prominent manufacturing sector of Chandigarh, with over 450 units manufacturing different kinds of fastener products such as cold forged nuts, machine screws, self-tapping screws, rivets, bolts and nuts, special screws with washers, and hex bolts. The Chandigarh fasteners cluster caters to the demands of consumers all over India including general industry, automobile manufacturers, railways and government departments dealing in towers and transmission. Machines like cold header, threading machines, slotting machines, and hot forged headers are used for manufacturing the fastener products.

The diagnostic study conducted by the project revealed that the fasteners industry faces an acute shortage of skilled and semi-skilled labour, which poses a severe hindrance to the growth of the industry. The bulk of the workers in the fastener manufacturing units are migrants from Bihar and U.P. With the successful implementation of employment generation schemes like National Rural Employment Guarantee Scheme (NREGS) in these states, the inflow of migrant workers to Chandigarh has considerably reduced, worsening the plight of the fasteners industry.

The problem is compounded by the fact that the fasteners industry does not have an organized system and related infrastructure in place for training workers. Most of the training is imparted in the traditional manner, which is informal, sub-standard and time-consuming. Industry stakeholders have for long voiced the demand for an industry-led training programme that is customized to meet the skill-set requirements of the manufacturers.

Considering this vital and immediate demand of the fasteners industry, the TERI project team envisaged introducing an innovative model of training wherein the industry itself would be involved in imparting training.  The idea was taken up with the industry stakeholders and after due deliberation, the following approach was finalized.

• The focus of the training initiative would be on using a ‘hands-on’ approach to equip raw workers with skills such as heading, threading & rolling, and tooling. The trainee-workers would be mentored by a senior trainer in order to ensure the effectiveness of the learning
• The hands-on training sessions would be supplemented with theory sessions so that trainees would be able to understand the principles behind various operating techniques.
• Emphasis would be placed on preventive maintenance and care of the machines.
• The facilities of existing units would  be leased to train the candidates
• The participating fasteners units would facilitate placements for the newly trained workers upon their successful completion of training.

In order to mentor the training programme, the project identified Access Consultancy Services (ACS), a Chandigarh-based business consulting firm specializing in skill development and marketing services.  Machines were arranged on lease from two fasteners manufacturing units in Chandigarh who were motivated to participate in the programme. The training curriculum was designed with the active participation of all the stakeholders and faculty from the local Industrial Training Institute (ITI).

It was decided that prospective trainees would be mobilized from among the unemployed youth in the rural areas in and around the MPC cluster. Accordingly, ACS along with the project team mobilized the candidates (mainly dropouts from Class 5 to Class 10) from the rural areas around  Chandigarh and Panchkula. All candidates belonged to the low-income categories. ACS arranged for a competent subject-expert to provide theoretical training and a trained foreman to provide the hands-on training. The machines for training were leased from units during their ‘off- time’ and the evening hours so as not to hamper normal production schedules.

The hands-on practical training constituted around 75% of the instruction, while 25% comprised theory. The candidates were trained in small batches of 8–10 on machines like header, turning machines, slotting machines etc.; the ratio of trainees to machines was 1:5.  Efforts were made to ensure that trainees operated the machines individually with the guidance of the instructor. This had them gain confidence in machine operation and enabled them to operate it on their own after finishing the programme. Trainees were also given inputs on various shop-floor quality aspects and on preventive maintenance of the machines.

So far, 45 candidates have been trained in operating fastener manufacturing machines and successfully placed in over 15 units with salaries varying from `3750/- to `4500/- per month. Mr. Rathour, President, Chandigarh Screw Manufacturers Associations (CSMA) is excited at the success of the training programme. He observes:

“Shortage of skilled workers has always been an issue with manufacturing units. With regular poaching happening, it also bred bad relations. This training programme has shown how in a short period the industry can internally start to address this issue of worker shortage. These trainees are also more aware of maintenance and upkeep of machines, which is very good for the factory. The industry is grateful to TERI-SIDBI project for starting an initiative like this and Access Consultancy Services for successfully executing the skilled worker training programme which has been a tremendous success.”

Ramesh Kumar, a Class 6 dropout and an unemployed youth, was trained under this skill development programme. Upon successfully completing his training, he was placed in MSM Engineering Works, much to his delight, He says, “The training has changed my life, I am now a skilled worker with a regular job. My family income has gone up by 50%!”

In this backdrop, it is felt that this skills development programme will become self-sustaining as the employment and career advancement opportunities are its main motivators. Existing workers in the industry have started to urge their unemployed friends and relatives to join the training programme; also, the industry and the BDS provider (ACS) are keen to carry forward the initiative. Mr. Deepak Sharma of ACS says, “There is a requirement of over 1000 skilled and semi-skilled workers in the fasteners industry of Chandigarh and the industry is willing to continue this initiative. TERI should keep playing this positive catalytic role, till this initiative becomes totally self sustaining.”