Globalisation required that hitherto supported SSI units become stronger in terms of product quality and productivity so that they can compete globally. With this aim the Government of India in support of the State government set up a tool room at Vatva, Ahmedabad. Germany, a country with repute for excellence in mechanical engineering has provided technical support. The Indo German Tool Room popularly known as IGTR provides assistance to industries, particularly the Small and Medium Enterprises (SME) sector by way of development of dies and moulds, consultancy in modern production technology and training. The training activity has assumed great significance in this transition phase when the nation is marching to become super power. The large manpower has to be trained to handle latest technology. IGTR plays major role in this area. It trains about 2500 to 3000 trainees per year and gainfully employs them.

From school dropouts to post graduate engineers, IGTR trains them in CAD, CAM and CAE as well as CNC technology. The socially disadvantageous section is given this training free. The tool room trainees are in great demand in industries. It is all because of IGTR's motto to provide "Trained and day one productive, cultured manpower". IGTR is now expanding in this area of training and is adding up Rapid Product Development, Rapid Prototyping and Rapid Product Testing using latest computer technology both as service to SME and training. This will enable SME to launch highly reliable products with greater confidence. Mr V S Swadia is the General Manager of IGTR Ahmedabad. Mr Swadia is a Graduate in Production Engineering and PG in Management with 33 years of professional experience He has worked in reputed organisations like ABB, Telco (now TATA Motors), Klockner Windsor and others. He has been with this tool room since 14 years and heads the organisation since the last 6 years. He also has acquired professional training in many fields including that abroad. Mr Swadia was kind enough to answer a few posers from IPF. Excerpts:

What are the services and facilities that you offer?

The IGTR is a Govt of India unit set up under technical collaboration with Germany. It has two divisions: Tool Room and Training. IGTR Ahmedabad, as it is popularly known, is a renowned tool room for design and manufacturing of plastic moulds, die casting dies, press tools jigs fixtures and gauges. It also provides services like design, consultancy precision machining, tool trouble shooting, rapid prototyping, inspection including CMM reports, injection moulding and nitriding using plasma nitriding. IGTR also provides long, medium and short term training in areas of tool engineering CAD/CAM and CAE

What are the implications?

Production using mass production technology; consistent quality; and improved productivity of products manufactured. In the area of training, provide trained manpower to handle latest technology.

What are the benefits?

Backed by German engineering excellence, commitment to quality management system, state-of-the-art manufacturing set up, and trained from day one productive manpower. The facilities set up in assistance from German government are most modern and state-of-the-art. Industries can avail all such facilities at minimal cost, which otherwise are available only with large corporates and MNCs. The company's using these facilities cannot have a better deal!

How strong/effective is the commitment?

IGTR is committed to support the customer till its all requirements are fulfilled. How do the services of IGTR compare with other similar initiatives? Our quality is at par with tools imported from developed nations and the cost is competitive as compared to the best of indigenous tool rooms.

What are the new initiatives at IGTR?

Rapid prototyping is a new development. It is quite common that a new product launched in the market may lead entire business in trouble due to its failure to function properly. Many times the aesthetics of the product are not liked and results in poor market response. It is very important that a product designed for the first time is always seen and function tested physically so that investments are not wasted. This is also true for products, which are copied.

However, major limitation is that the product can not be created unless you have set up the manufacturing facilities. Rapid prototyping is an answer to such needs. IGTR is installing such a facility at Vatva for the industries of Gujarat where one can get three-dimensional model of the product prepared and can convert it into a polymer article. The article produced by RPT needs no mould or dies and can be produced in very thin wall or hollow shape. One can get a small batch of article without making a tool. Size of the article is not a limitation in many cases. One can also produce colours in many varieties. The cost of such prototypes is comparative and can be produced in very short time.

As a part of its endeavour to provide access to modern technology, IGTR has established set up at its Design Centre to provide mould flow services to its customers. It is always a dilemma for mould user to know before hand that the mould will deliver article that meets requirement. On the other hand it is very difficult to arrive at correct reason for a defective article from the mould as mould, machine, material and operator experience are amongst many variables affecting result.

Analysis can also cut cost by avoiding costly retrials and can correct mould design before costly mould material is machined. It can also settle disputes between mould maker and processor and it can also inform you correct process parameters to get defect free article.

(Indo German Tool Room Ahmedabad. Tel: 079-25841960, 25840961, 25840964. Fax: 91-79-25841962. Email: marketing@igtrahd.com)