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Procedia CIRP 40 (2016) 562 – 567

13th Global Conference on Sustainable Manufacturing - Decoupling Growth from Resource Use

Enhancement of productivity of traditional brass manufacturing industry

using sustainable manufacturing concept
H.M.M.M Jayawickramaa, M. Dharmawardanaa, A.K Kulatungaa*, K.G.S.P Karunarathnaa,
S.A.U. Osaditha
a
Dept of Production Engineering, Faculty of Engineering, University of Peradeniya, Sri Lanka

* Corresponding author. Tel.: +94-812393658; +94-718222535; E-mail address: [email protected]

Abstract

The Sri Lankan Brass manufacturing industry has evolved through centuries. Since then, this industry has been operated as family business, there
are many gaps compared to modern manufacturing industries. Hence it faces sever threats from different aspects including escalation of raw
material prices, proper reverse logistic mechanism to collect scarp brass material, lack of competencies to adapt new technology. This research
is carried out to investigate the adaptation of appropriate technology to replace traditional sand casting process and manual sheet metal carving
process. As a secondary measure, a methodology is developed to introduce appropriate technology to marginalized community as University -
Industry partnership. This is paramount important since they do not have required level of technical competencies to use CAD, CAM. Outcomes
reveal that there are number of productivity enhancements in terms of product quality, material efficiency and process standardization.

©©2016
2016The
TheAuthors.
Authors.Published
Published by
by Elsevier
Elsevier B.V.
B.V.This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the International Scientific Committee of the 13th Global Conference on Sustainable Manufacturing.
Peer-review under responsibility of the International Scientific Committee of the 13th Global Conference on Sustainable Manufacturing
Keywords: Traditional Brass industry; CAD/CAM; prototyping; casting; sheet metal forming; appropriate technology

1. Introduction that can be seen in local museums. These are evidences to prove
how prosperous was this nation in industries like: gold industry.
Many of the rapidly developing countries in the world have It has developed as a dominant industry in the country with
taken steps to make their manufacturing sectors competitive in numerous varieties of products and art works which show the
global market to earn more foreign revenues for the quality of their own industry. It reveals that the Buddhist culture
infrastructure development within their countries. Even though has initiated the golden era with the impacts of brass products
Sri Lanka is trying to establish as an industrialized country as a which are eminent witnesses of their culture. There are many
nation since early 90s it has not been a success. The present products used for domestic and as well as in religious purposes,
government too focuses on developing regional economy especially in Buddhist temples. Among those products, oil
greatly. In that perspective, manufacturing sector especially the lamps, goblets, vases, bowls and trays are few of the
SMEs (Small and Medium scale Enterprises) have a bigger role distinguished examples of embedded carvings.
to play by converting their processes towards green while But after the Western invasions in the 15th century there had
minimizing importation of foreign raw material and launching been many drawbacks to the Sri Lankan traditional industries
new businesses to increase value for local raw materials while including brass manufacturing industries. According to
focusing on foreign trade markets. Cumaraswamy’s famous findings [1] of traditional art and craft
It is believed that the Sri Lankan traditional brass industry is on Singhalese (native people) during the late 1800s, Sri Lankan
started by the time of Aryans, who brought several traditional traditional industries operated with many difficulties due to the
industries from India in 200BC. There are number of brass economical, socio-cultural changes taken place during late
products belonging to Anuradhapura era (200BC to 900AD) 1800s and early 1900 when British’s were ruling the Sri Lanka.

2212-8271 © 2016 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the International Scientific Committee of the 13th Global Conference on Sustainable Manufacturing
doi:10.1016/j.procir.2016.01.134
 H.M.M.M Jayawickrama et al. / Procedia CIRP 40 (2016) 562 – 567 563

After introducing the open economy policy to the country in investigated the sustainable production concepts in these
late 1970s, traditional brass manufacturing industries forced to industries. Kulatunga et.al [4] have used a threefold approach
deteriorate. Rapid urbanization and introduction of similar to investigate and have developed a standard model by going
products with low cost materials as well as with advanced along the triple bottom lines of sustainability: Economical,
technologies from other countries are the main causes for this Social and Environmental. According to them there are many
deterioration. Though their theoretical knowledge has been opportunities available in traditional manufacturing sector to
degenerated significantly with the time, they managed to cater extract sustainable consumption and production practices.
the unstable situation. Economic sustainability of this industry Another study on the technological perspective of
gradually diminishes due to three main reasons like: marketing improving the surface quality and mould design [5] reveals that
related problems due to the policy changes by the successive the local die and mould manufactures try non-conventional
governments, inability to find resources such as quality raw methods on a trial and error basis in order to develop low cost
material and skilled labours and as well as lack of opportunities moulds for small batch production. According to this study
to adapt modern manufacturing technologies. there are several issues faced by the local companies in the
Therefore this research is intended to address above issues design and manufacture phases of moulds.
by considering sustainable manufacturing perspectives with When compared to the consideration of ergonomics aspect
technological aspects to enhance the adaptability. Rest of the of traditional brass industries, there is a study carried out by
paper has been arranged as follows: section 2 presents the Jayawardana et.al [6] on health and safety of the brass workers.
literature survey in this area, section 3 is dedicated for the According to the study these brass workers have significantly
methodology adapted in this research. The case study is higher risks of developing respiratory difficulties and also there
presented in section 4 followed by the conclusion in section 5. is an urgency to concentrate on the preventive measures to be
adopted in order to minimize the health hazards. Chanjief et.al
2. Literature review [2] emphasizes that the traditional craftsmen do not wear any
preferred safety equipment and also do not practice any safety
One of the major limitation of this research is that there are regulations. Brass workers use thermal furnaces like cupola and
very few studies have been carried on this area. Authors believe fuels to melt brass, melting emits considerable amount of
that this is also a major drawback behind the current status of carbon dioxide, carbon monoxide etc., which can affect the
the traditional brass manufacturing sector. Main input for this atmosphere and the ambiances. It is obvious that these aspects
work can be found from a Technical Need Assessment (TNA) should be taken into the frame, where any further development
conducted by Chanjief et.al [2] which is the initial phase of this works are to be carried out.
continuous study. According to the study there is a wide gap in It is blatant that the global scenario in regional area seems
technical improvements with a sustainable perspective in the to be the same as the local scenario. According to the findings
local brass manufacturing sector. This study highlights the of Bureau of Energy Efficiency’s SME program for
issues related to policy aspects, level of education and Bhubaneshwar and Jamnagar Brass Cluster in India [7], [8],
awareness, financial aspects and technical aspects. Most of they face the same situation in their brass industry even they
aforementioned issues come under technical aspects and level have a huge market. Their most concern is the energy factor
of education such as: which seems to be a major problem with their production
1. Accessibility to quality raw material and other quantities. Their solutions are not much applicable to Sri
resources Lankan industries, since they use different type of furnaces and
2. Unawareness of the exact technological process of fuels. But it is evident that the local brass industries also in need
modern era. of an efficient furnace and it has been also addressed within this
3. Unavailability of trainings and awareness programs research by considering emission factor and safety hazards as
4. Insufficient technical knowledge in mould preparation well. Though there are certain number of researches, and
to locate the required number of risers and runners, studies available related to the Sri Lankan, and regional
5. Unawareness of the importance of reinforcements in traditional brass manufacturing sector it is blatant that there are
mold building and the cooling rate significant areas to be evaluated and studied. Incorporation of
6. Unawareness of the heat affected zone during welding technologies, optimization methods, modern manufacturing
and manual grinding process processes, and environmentally friendly materials are few of
the possible studies which can be carried out in related to
Most of the issues are not easy to be addressed within a short traditional brass manufacturing industries.
period and some solutions are well beyond our reach due to the
current government and social behavior. Some of the above 3. Methodology
mentioned issues have been considered during the development
phase of the methodology of this work. Another major problem The methodology has been developed based on the previous
is the tendency of traditional manufactures to adapt sustainable work of the TNA [2]. Even though the basement is built with
concepts. According to Kulatunga et.al [3], it can be revealed the TNA, authors have carried out further ground works with
that there are lot of barriers as well as drivers regarding the the goal of achieving the best outcome to enhance the
implementation of sustainable manufacturing concepts in Sri sustainability of local brass industry, which has been
Lankan manufacturing sector. When local traditional considered in the initial phase of the methodology. It is labeled
manufacturing industries are concerned, majority have
564 H.M.M.M Jayawickrama et al. / Procedia CIRP 40 (2016) 562 – 567

as the evaluation phase and it is followed by design and 4. Case study

development, and validation phases.
Evaluation phase focuses on how to achieve resource 4.1 Permanent mould casting
efficiency, process efficiency and product efficiency. Resource
efficiency is subdivided into fuel efficiency, utilization of man Hollow products and solid products can be found in the
hours and raw material efficiency. traditional brass industry. Though the most of the solid
Design and Development works are carried out with products are not necessarily to be solid and they could be
commonly used technologies such as computer aided design manufactured as hollow. But, they have adapted to such
and computer aided manufacturing (CAD/CAM), and rapid malpractices due to the limitations of sand casting techniques
tooling which are currently not used in this sector. As shown in and their previous experiences. It is obvious that manufacturing
Fig. 1, product efficiency, process efficiency, raw material a solid product without a need is a waste of resources like:
efficiency and utilization of man hours are expected achieve material, money, man power, time etc. Since the manufacturing
through the product design and development phase. Though, process should enhance the material efficiency, the mould
Traditional Brass Industry has two major types of product design should be dedicated to reduce the material consumption
categories such as casting products and sheet carving products, by minimizing the thickness of the product, which indeed
this study has focused on both product types. cannot be achieved in sandcasting. In the initial stage a small
Under the casting category, modern casting techniques have product [Fig. 2], which is manufactured by sand casting has
been planned to introduce for the selected brass products which been selected to design a permanent mould. Table 1, represents
are currently manufactured by sand casting. Design and the comparison between the existing product and the expected
development of permanent moulds for the selected products is outcome
expected to be one of the major outcomes. Under the sheet
carving category, studies have been carried out about manual
carvings on brass sheet or plate type products. Experiments
have been conducted in 3 steps to identify the capability of
using a die pressing mechanism for carving products. Also in
terms of fuel efficiency and process efficiency, fabricating an
efficient portable furnace is focused in this study. The issues
of safety hazards with current furnace is also addressed in this
phase.
Fig. 2: selected product for permanent mould design
Finally the third phase: the validation, which tests the
appropriateness of the designed model and the proposed
furnace to the industry. The above proposed furnace, Table 1: Existing product vs expected product
permanent mould designing and die pressing techniques cater
the technological requirements of traditional brass industry in Product feature Existing Expected Percentage
product product change
the following aspects like: cost, resource consumption, process
efficiency, environmental and safety aspects. Avg. thickness in mm 3 1.7 43%
Avg. material volume in mm3 9000 5240 42%
Avg. additional material in mm3 10000 4100 59%

In the designing phase following theoretical factors have

been taken in to account,
1. Bernoulli’s theorem, continuity of low and fluidity to
calculate the mould fill time (MFT)
2. Chvorinov’s empirical relationship to calculate the
solidification time (TST)
3. Theory of thermodynamics to calculate the maximum
volume of the mould along with the product volume
Considering the above factors, it is designed and
manufactured in CNC machining center. SOLIDWORKS and
SolidCAM software are used for 3D modeling and for the
generation of the machine tool path. After preparing the mould,
experiments in several stages have been carried out within the
foundry to accomplish the optimum outcome. Since the
expected thickness level cannot be achieved at once, a strategy
is used to change the thickness of the product without affecting
the mould, and it is achieved by inserting steel sheets between
Fig. 1: Methodology the core and cavity with different thicknesses (0.75mm, 1mm,
and 1.5 mm) to increase the product thickness from 1.7mm to
 H.M.M.M Jayawickrama et al. / Procedia CIRP 40 (2016) 562 – 567 565

3.2 mm for different experimental setups. Initially, gravity die with some old hand tools. There are several famous products
casting method is used to pour molten brass to the riser directly available in the local market such as: sun and moon, tokens,
without exerting any external pressure. Further experiments badges, sacred foot print, flowers and handicrafts. But the
have been carried out to decide the appropriate thickness quality of the works turning into a major issue in the market.
without effecting the product quality and consuming excess This fall in quality is an outcome of lack of technological inputs
material. from the manufactures in this industry.
As mentioned before, the cost of investment is one of the From the beginning of this study the utmost eagerness of the
major reasons for the local brass workers to shift to permanent authors are focused to replace these old ancient techniques with
mould casting. Therefore, a cost estimation of the mould design the use of modern sheet metal forming techniques to improve
and manufacturing is conducted. Table 2 presents an
approximate cost estimation for the entire process.

Table 2: Approximate cost estimation for permanent mould

Cost factor Cost (Rs.)

Design cost 6000
Raw material cost 1350
Part program generation cost 2500
Operator 2250
Fig. 3: Traditional sheet carving work
Cutting tools 3500
Overheads and depreciation 4500
Finishing cost 2000 the product quality and productivity of the operations to reduce
Service charge (25%) 5525 manufacturing cost. It is a process where a brass sheet place
Total 27625 between the core (punch) and cavity (die) which are machined
with embedded carvings. Fig. 4 shows the reference product for
Though the cost seems considerably higher when this work, which is comprise about 100 different types of
comparing with the income of the workers, the mould has carvings. Apparently all these carvings would not be generated
sufficient life span, which can use approximately for 100000 via forming, since some of those fine tune works are not easy
times [9]. Die casting process assure better surface quality and to machine when the die and punch are machined. However the
uniformity, material efficiency. Further, the cycle time is also ultimate objective come together to achieve maximum possible
reduced in permanent mould casting. level.
Since it is hard to find studies carried out regarding the cost
analysis of these local brass products, it is difficult come up
with a proper cost estimation for this product with sand casting
or with permanent mould casting. Since it is perceptible that
the finishing cost is not applicable for permanent mould
casting, assuming all other cost are the same for both types of
castings, and neglecting the amount of material saving of
permanent mould casting the breakeven point in product
quantity is approximately 1850, which can be achieved within
6 months based on the current demand pattern.

Table 3: Breakeven point of the investment for permanent mould Fig. 4: Sacred foot print with more than 100 different types of carvings
which all are embedded by using ancient hand tools
Investment cost Rs. 27625
Per product finishing cost Rs. 15
Breakeven product quantity 1841
Per month average products 350 During the designing phase it is realized that each feature
Per month finishing cost Rs. 5250 cannot be represented in the model due to the existing
Breakeven period in months 5.3 complexity of the pattern. Initially, it is decided to use image
processing facilities to extract these carvings of the product.
4.2 Die pressing However, it is noticed that the study area is very complicated
technologically. Therefore, all the modeling including the
Sheet metal carving products also play a paramount role in carvings are carried out on SOLIDWORKS interface. Table 4
the traditional brass works. In order to manufacture these presents the methodological development of this study. There
products, craftsman must have high level of skills, patience, are positive consequences, which emphasize the requirements
and artistic perceptions. Though these products show similar for further improvements and studies.
artworks, there are some variations due to craftsmen who
establish themselves with their identities. It is really exciting to
admire their art works, which are crafted by their own hand
566 H.M.M.M Jayawickrama et al. / Procedia CIRP 40 (2016) 562 – 567

Table 4: Framework of sheet carving product improvements The next step is to machine the die and punch. Firstly
zoomed section shown in Table 4 (Lotus Flower) is machined
Designed sacred footprint and pressed to identify the level of accuracy and the issues
x Expected product features related to the pattern. Since results of the studies are
modelled with the assistance satisfactory, new die and punch are manufactured, which
of SOLIDWORKS include the complete pattern of the final product (Table 4).
x Does not contain all the With this approach it is expected to minimize the time
carvings of the original consumption of the finishing process, which accounts for 1/3
product due to the of the time required to complete the process by the craftsmen.
x limitations in the tool path Due to the difficulties and complexities of modeling and
generating machining of each pattern of carving, it is essential to perform
a finishing process. However, it seems to be advantageous as
First step
well, since it provides a space for the traditional craftsman to
x Selected from the designed
enhance their identities rather than limiting themselves to a
sacred footprint
specific set of carvings. In addition, product quality will be
x Modeled to fabricate by 3D
enhanced greatly with dimensional accuracy and symmetrical
printer
and identical products can be produced.

Rapid tooling 4.3 Furnace

x Fabricated by using 3D printer
x PLA ( Poly Lactic Acid) used Surprisingly these traditional craftsmen do not consider
as the fabricating material energy as one of the predominant cost components since they
x two steel heads are attached to have been using comparatively cheap energy source of heavy
increase the strength before furnace oil (HFO) for burners and it is very cheap when
usage compared to the raw material they consume. Therefore, they do
not pay much attention towards combustion efficiency of the
burners. This indirectly escalates the cost of manufacturing. In
Experimental work
addition, this leads to the increase of health issues, since many
x Selected gauge 36 Brass sheet
of them do not use proper stacks for the burners while getting
for the experiment
exposed to the exhaust fumes. In addition, excessive emissions
x hydraulic press is used for the
contribute to the environmental pollution as well. One major
process
concern is the effective time they use the furnace and the space
x able to achieve details of the
they have permanently allocated within the sheds. This has
design
made the layout of the working ambiences much complicated
affecting the handling operations and as well as the health and
safety issues. Even though proper insulation exists in the design
Second step
it has become inefficient due to the way they practice it.
x Designed the sacred footprint
Considering all the above negative practices it is decided to
fabricated by 3D printer
design a portable furnace which does not require much space.
x Some fine details could not be
Usually currently using furnaces have the capacity of between
represented due to the
40 to 60kg brasses. Therefore the maximum capacity of the
limitations of the tooling
designed furnace is also specified for 60kg.
x Attached to two steel heads
after fabricating to increase
4.4 Quality enhancement
the strength

Experimental work When considering the product quality, two of the major
x Carried out with a gauge 36 issues of casting products are surface finish and thickness
brass sheet variation of the product. Even though there are some finishing
x Used a hydraulic press for the processes in current practices, it is not efficient because of the
process complexity of product shapes. When the cylindrical shapes are
x Most details are appeared but available, a good surface can be obtained with the use of a lathe
not consistent machine. But even for that, additional machining and operator
x Defects can be seen due to the cost are required. Further it increases the product cycle time.
less uniformity of the load Evidently in permanent mould casting good surface finish is
applied. directly achievable and further finishing operations are not
needed. It is a big advantage in terms of quality perspective,
because same surface level can be achieved throughout the
whole surface of the product. Further the thickness level of
sand casting products is varying due to the finishing operations,
 H.M.M.M Jayawickrama et al. / Procedia CIRP 40 (2016) 562 – 567 567

which removes the additional material from the surface. Since [4] A.K. Kulatunaga, P.R. Jayatilaka, M. Jayawickrama. “Investigation of
with the permanent mould there are no any finishing Sustainable Production Concepts Available in Traditional Manufacturing
Industries in Sri Lanka”, 16th ERSCP Istanbul, Turkey, 2013.
operations, the thickness can keep in the same level as [5] U.P.Kahangamage, K.H.Janaka Mangala, “Investgation of problematic
designed. issues of mould design and manufacture for plastic based industry in Sri
Even there are products (like statues) which are not always Lanka”, Annual transactions of IESL, 2005, pp.1-6.
with a smoothed surface. There can be seen very fine complex [6] P.L.Jayawardana, W.R.de Alwis, M.A.Fernando, “Ventilatory function in
details are required on the surface which are doing manually by brass workers of Gadaladeniya, SriLanka”, Rapid Science Publishers for
SOM, 0962-7480/97, vol.47, No.7, 1997, pp.411-416.
using hand tools within current practices. Since some of those [7] SEE-Tech Solutions Pvt. Ltd. , “Manual on energy conservation measures
details are not achievable through gravity die casting, this work in brass cluster, Bhubaneshwar”
is focused to enhance that by using the minimum level of [8] Winrock international India, “Manual on energy conservation measures in
pressure to inject molten brass in to the mould (pressure die brass cluster, Jamnagar”
casting) where the pressure can be applied manually. [9] ASM internationals, “ASM Handbook volume 15: Casting”
ISBN 978-0-87170-711-6

5. Conclusion

It is revealed that the sustainability of the Sri Lankan

traditional brass manufacturing sector has become a rapidly
growing problem in the last few decades due to the lack of
competencies to adapt to new technologies. Therefore, this
research is carried out to fulfill the gap between the modern
manufacturing methods and the traditional brass manufacturing
sector by introducing appropriate technologies. This paper
represents the design and development phase of a series of
activities on traditional brass manufacturing. This paper
presented the appropriate technologies which can be used to
enhance overall productivity of the industry to enhance the
productivity. Implementation of permanent mould casting and
die pressing mechanism and design and develop a portable
furnace are the major component of this phase. Preparation of
permanent moulds, dies are finished and experimental works
and validation are currently being done before handing over to
craftsmen. Designing and fabricating of furnace is currently
being done.

Acknowledgements

Authors’ sincere gratitude goes to University Research

Grant (RG/2014/24/E) of Faculty of Engineering, University of
Peradeniya, which funds this research. Also, authors would like
to acknowledge Mr. Nuwan and his employees (traditional
brass workers) in Pilimatalawa, Central province, Sri Lanka for
their dedicated supports by being facilitators to carry out some
of the experiments. The staff of the Department of Production
Engineering, University of Peradeinya, Sri Lanka are thanked
for their committed assistance in carrying out this study.

References

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M. Dharmawardhana, R.E. Ekanayake. “Technologycal Needs Assessment
of Traditional Brass Industry to Enhance the Productivity”, 5th Internaional
Conference on Industrial Engineering and Operation Management. Dubai,
UAE, 2015.
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