Technical Studies

Submitteb by: Niyati Mendapara Rajvi Shah Ranjeet Kumar Submitted to: Mr.Anupam Rana

Index
Introduction Design departmet Manual Dept. CAD Dept. Master pattern Room Manual Dept. CAM Dept. Rubber mould Dept. Vulcanizer Wax tree making Dept. Investment Dept. Casting Dept. Polishint Dept. Plating Dept. Stone setting Dept. Quality control Packaging Dept. Floor plans Ergonomics & Hazards 4 6 12 14 16 18 20 22 26 28 30 32 34 36 38 40-47

1. Jewelry Manufacturing Process 2. Jewelry manufacturing process Jewelry manufacturing process includes most advance technologies and dedicated research. Jewelry making is a very composite process undergoing a long and slow procedure making it tough from the initial point to the concluding point. Each product undergoes a series of procedures before we get the net product as a beautiful jewelry product. The natural components of jewelry (stones, metals, and accessories) will undergo multiple processes. These jewelries are unique and involve a lot of time and skill. Except for personalized jewelry which are handcrafted, most of the jewelries are executed by casting machines. Following is a brief description of all the processes involve in the manufacturing chain. 3. In order to produce a unique piece, theDesign Making very initial step is to create a design, this is the point from where the magic begins! An idea of the end product by very talented designers who then makes a sketch of the design. This process of Blueprint Designing is carried out by proficient craftsmen using techniques and methods handed down over decades. Each piece of jewelry starts off with a concept. A concept is basically a rough design in the mind of the designer. The final design is the result of close cooperation between designer and craftsman giving the art object a real hand crafted origin. The designers concept and drawings are used by the Model maker to create the original

piece of Jewelry. 4. Once the master piece of jewelry is complete, it is used to make a high technology mold, which in turn is usedMolding to make wax reproductions of the Jewelry. After the sketch is complete with all the fine details, it is passed on to the molding section. In the molding department the very experienced professional molders then turn the sketch into a master mold which sets the base for the total process there from. The master mold is a very complex level of crafting as the final outcome rests on the master mold. 5. Casting again is a very complex process and requires utmostCasting skilled and experienced casters for the desired final product. The wax replicas are placed in steel containers which are then occupied with investment powder and the containers are heated in a chamber to 550C which solidifies the powder and melts the wax leaving behind a perfect effect. Liquefied metal is then poured into the flasks, allowed to cool, then demolished to reveal the jewelry in casting form. 6. Filing is an essential technique in jewelry making,Filing and although simple in concept following proven practices combined with the right equipment and tools, ensures the job becomes a breeze. Filing Precious Metals Filing is used in jewelry making to remove excess metal, even out surfaces, smooth or to shape, form and texture pieces.

7. Every part must be polished while the mount is being made. The entire mount is carefully madePolishing clean and polished to a the highest degree of smoothness so that each and every part is attractively polished off. After stage setting, the polisher is credit worthy for giving the jewelry a concluding polish. All tinctures of the polishing compounds and rouge must be meticulously got rid of either by careful washing by hand, or by use of supersonic cleaning baths. 8. After the product has passed from the polishing and finishing departments, it has Embellishments/ to undergo for embellishment process.Decorative processes When the products gets casted and foiled, the required decorative stones of the correct sizes and weight are cut and made with extreme preciseness and are then assorted for the final setting which is done once the products leave the foiling and finishing department. It requires immense patience and skill to make the master-model and to produce a exquisitely casting free from defects and which needs the minimum of chasing to make it perfect. Applied wire, which may be drawn or stamped out, can also be, classified as inherent decoration. 9. Once the casting process isFinishing over and the caster delivered the products to the following department, they are then foiled extreme attention for a smooth and soft finish. These castings are then hand finished in order meet to high standards - adding adjustments and settings

Flow chart
before being delivered to all corners across the world. 10. Considerable technical improvements have been made in plating, especially as used in thePlating jewelry trade. Most plating is done by electro- deposition, rhodium, copper, chro mium or other metals being practiced by passing an electric current through a solution and then channelizing the plating metal from the piece of pure metal to the object set aside in the solution. Deliberate attention must be paid to fabricating and polishing procedures because it is vitally significant that consumes to be plated should be perfectly finished in advance. 11. After the plating process is over, the product isQuality Checking brought to the checking department where each and every piece is checked with excessive attention and thoroughly checked for any defects. This process of quality checking is done by very experienced workers and all the defected pieces are send back to the respective departments. 12. Last but not the least, once allTransporting and the products pass through all the Packaging inspections and checking, it is then forwarded for final packaging and labeling. Each product is extensively packed into respective boxes in order to avoid any sort of damages. Thus, each piece of jewelry, regardless of its size and weight, passes through a long and complex manufacturing process forming each piece as valuable, worthful and unique as the process it tolerates.

Design Department
Window Book Shelf Sliding projection board

Brainstorming table Designers Workplace Copier Head Designers office

Manual Design Room

Workstations 5 tables each with desktop and lamp, inbuilt two drawers to store stationery and other imp things. Revolving chair -The height adjustment is activated by a gas strut inside the steel column. A small storage space on side Soft board

Book shelf 5ft high shelf with a slant magazine rack on top and 3 racks for books.

Head Designers office Head designers room has two inlets one from the design room and other from the lobby. Its a glass cabin, and the door from design room is a slider. The office is has L shaped table with a desktop and printer. The office also has an extra two seater couch and a wall mounted book rack.

Conference table A small round sitting area for brainstorming and group discussions, placed opposite to window which has pull down projector screen.

CAD Department
Workstations 3 tables each with a desktop, a printer, a copier/scanner A commercial copier is placed in one corner. Window

Commercial Copier

Workstations

Traditionally, CAD denotes programs that replace the pencil and assist the designer in the representation of his ideas. These programs aid in the achievement of a quick development of the design and allow an immediate control. Moreover, they enable the transmission of the designed geometric patterns to other programs for machining. I have said traditionally, because unceasing evolution has somewhat changed the original characteristics of these systems. Initially, this software was mainly used for mechanical design. Later they underwent a true transformation and gave birth to two distinct branches: the first one led to the development of programs named CAE (Computer Aided Engineering), and the second one led to CAID (Computer Aided Industrial Design), both software for model development and study of style. The programs of the first kind are of a more technical nature. CAID programs dont require operations like dimensioning and patterning and give more emphasis to the creative phase. They enable a perfect simulation of the reality and give immediate concreteness to ideas. Consequently, different kinds of CAD systems have been developed that are devoted to different design and modelling types, such as: Polygonal modelling Surface modelling Solid-parametric modelling Hybrid modelling.

Polygonal modelling: This is the most common CAD modelling software: all models are created as a combination of small squares and triangles, Surface modelling: This CAD software shapes the surface, ie. the skin of the designed object, and enables the achievement of very complex shapes, Solid parametric modelling: This software is based on the geometric parameters defining the object. The ability to modify the design whilst keeping some parameters constant is typical of this kind of modelling. For example, if we change the scale of the star on the left side of Figure 3 with a nonparametric modelling system, all dimensions of the star will be changed. If we perform the same operation with a parametric CAD, one parameter of the drawing an be kept constant whilst others are changed. Hybrid modelling: CAD systems that combine surface and solid modelling, Figure 4, and enable the creation of complex patterns, starting from simple models. These classifications do not have a commercial purpose, like classifying the products from different software houses; each type denotes a specialization, with a completely different approach to design, and has advantages and drawbacks. A design that is quite easy using one type of software can become very complex if another one is used. For example, to design a model with recurrent geometric patterns, like a bangle adorned with fretwork, Figure 5, then a true CAD, that is a solid modelling system, is preferable.

In contrast, if I want to design an artistically very elaborate object, Figure 6, a CAID system, that is a surface modelling system, is preferable. Consequently, software selection should be carefully considered and should be based on production characteristics and potential of the company. It must be remembered that CAD design is definitely not automatic and always man is the thinking subject. A wrong choice can cause big problems in the use of the system and, in some cases, can make it completely useless. There is a wide range of modelling systems offered on the market and an inexperienced company can have great difficulties in making the correct choice.

Workstations 3 tables each with a desktop and a printer One inspection table RPT machine A window

CAM Department

Workstations

Copier

Head Incharge workstation

Window

The RPD Machine A fact that cannot be denied, however, is the influence that rapid product development (RPD) processes have had on the jewellery sector and how jewellery is made. The way that jewellery can be designed to the way that it can be produced, whether in single, low or high volumes, has changed dramatically in recent decades. Longestablished methods of jewellery design and manufacture are still embraced today by traditional jewellers who utilise age-old skills to create and produce bespoke pieces of art. However, the 3D digital revolution and the emergence of advanced manufacturing technologies now means that jewellers across the board have a much wider range of tools at their disposal for creating new and innovative jewellery designs. The manufacture of jewellery has typically involved a number of key steps, namely: creating the design creating a primary model of the design (traditionally by hand crafting or CNC) creating a pattern producing a silver master creating a silicon/rubber mould for wax injection of mass produced pieces casting / production of final pieces & finishing. 3D CAD software has had a significant affect on jewellery design with the ability to create complex geometries that previously were not possible. Furthermore, the advent and subsequent

developments and refinements of additive fabrication (AF) processes, that can build the 3D designs directly from the CAD models have driven opportunities much further than could have been envisaged even twenty years ago. The ability of some of the advanced AF platforms to build in metals has seen the emergence of some jewellery collections that are directly manufactured in this way. There are still some limitations in this area for mass uptake, specifically the range of materials available, but early adopters are inspiring continued growth and development. More commonly, AF is being used in rapid prototyping and rapid tooling applications to produce jewellery models as the precursor to investment casting or die casting creating the primary model or a direct wax pattern from which to achieve a rubber or silicon mould. These applications have seen massive developments in many areas of the jewellery sector, eliminating some of the time-consuming steps of the traditional process. For jewellery applications the additive processes that produce parts with the tightest tolerances and highest resolutions have driven deepest into this sector. The processes that have had notable success within the jewellery market are the DMLS (direct metal laser sintering) process from EOS, specifically for direct applications; the Perfactory process from Envisiontec; the SLA process from 3D Systems; and Solidscapes range of additive machines utilising wax materials.

Master pattern Room

Master Pattern room 8 benched oval table with individual partition is placed in one half of room with attached leather for metal recovery, and other necessary equipments. The table has 6 paneled light over it. A soldering machine Storage cabinet QC chart

Storage cabinets

Work stations

Soldering Machine

Copier

Measurements 36 X 22 X 37

Rubber Mould Making Dept.

4 tables with chair and inbuilt cabinet for storing tools. A Vulcanizer Small furnace Oven A lerger baniet for storing raw materials and rubber molds.

Machine

Workstations

Vulcaniser

Oven

Storage

Head of Dept.

Ruber Mould Making Dept.

Wax tree making

Storage

Work stations

Investment Dept.

Storage

Workstations

Head of the dept.

Vaccum casting machine

Dewaxing machine

Investment casting is by far the most widely used technique for the production of gold jewellery. Each year, large quantities of carat gold alloys are processed by this method. It is therefore of importance thatvmachines used for jewellery investment casting should meet the efficiency and quality standards expected in large scale manufacturing equipment. Casting Machines Jewellery-type investment moulds cannot be filled by simple gravity pouring. The combination of unvented moulds with low permeability refractory, the need to reproduce fine detail and delicate sections together with the relatively small size of melts and the consequent low hydrostatic head and low thermal content of the metal preclude this possibility. Casting of the metal into the mould is therefore almost invariably carried out in some form of casting machine. A basic function of the casting machine is to apply pressure to the molten metal so that it penetrates and fills the mould completely. This same pressure may also be used to effect transfer of the molten metal to the mould Erom the crucible when this is part of the machine. Centrifugal force, pressure or vacuum, or a combination of them, are used to perform these two functions. The machine may also have built into it a means of melting the metal or a crucible or hearth in which the metal can be melted by external torch heating. Ancillary functions provided on the more sophisticated machines are melt temperature indication and regulation, atmosphere control and

casting pressure regulation.

Casting Dept.

Storage

Workstations

Water jets

Water jets

Polishing Dept.

Water jets

Tumbling Machine

Buffing

Work stations

Storage

Plating Dept.

Magnetic polishing

Ultrasonic

Steam machine

Sink

Electroplating Storage

Head of Dept.

Stone setting Dept.

Head of Dept.

Workstations

Storage

Stone setting Stone sorting

Quality Control Dept.

Work stations

Head of Dept.

Storage

Packaging & Dispatch

Workstatios

Storage

The system includes tray storage facilities using Gratnells plastic trays and moulded slide channels. Generally provided in base units but this facility can be added to tall cupboards also.

Floor plans

ERGONOMICS IN THE WORK ENVIRONMENT

Protect Your Muscles and Joints: Adjust the position of your work table so its comfortable for you Have things positioned so you dont need to reach for them Stretch before you begin working Find the most comfortable position o Sit on a stool whenever possible o Your body should be well supported Find a stable, comfortable position if you must stand Whether you are at work or at home it is important to assess your activities to make sure they are correct for you ergonomically. For example, assess your body position as you work to make sure you are in the most comfortable position. Jewellery makers do detailed work that requires them to stay in one position for long periods of time. This puts them at risk of muscle strain (arms, neck and back) and eye strain. Over the years this could lead to an injury. As you work, pay close attention to how you feel physically after you have completed a jewellery making task. If you identify something as a potential problem, you can make changes before it leads to an injury. This means you will be able to continue working on jewellery making projects long into the future. It is also important to note that if you are comfortable in your work, you will also be more productive. o If possible, lift one foot onto a stand, keep your back straight, keep your feet apart, with one foot in front of the other Keep your elbows close to your body and support your arms Place items you are working on at waist or elbow level o Just below elbow level if you are sitting Hold tools properly Take breaks and stretch Try to work somewhere that is quiet or free of distractions Ensure the temperature of your work area is comfortable Ensure that you have good lighting Protecting Others Keep a safe distance between yourself and others when you are using equipment Keep things off the floor, including cords so others dont trip Let people know when metal and tools are hot o Never walk away from hot metal in case someone tries to move it Clean up whenever you have finished working Safe Use of Equipment Handle Tools and Equipment Safely: Talk to your instructor before using any tools or equipment Read manuals and safety guidelines before you begin Follow all manufacturers safety guidelines Wear all recommended safety equipment and clothing for the job Tie your hair back and remove jewellery (e.g. rings and necklaces) Check that the equipment is in good repair and properly installed Ensure that your work area is tidy before you begin Ensure that there is space between your work and any gas cylinders Confirm that the gas cylinder is connected properly (your instructor will connect the gas for you) Safely store or hang up tools when you are finished Power Cord Safety Tips: Check power cords for burns and report any damage to your instructor Inform the instructor if you burn a cord Never leave cords near heat Never twist, tie or tangle power cords

 Keep power cords clear of other tools Do not drape cords across any part of your body Carry tools by the handle only Switch off all tools before connecting them to a power supply Plug into the nearest power supply and check that the cord does not lay across the floor where other people will be walking Pull cords by the plug rather than the cord when unplugging equipment from an outlet Unplug tools before working on them, adjusting them or setting them up Turn off power and unplug any equipment you are not using Soldering Safety Set up a separate area for soldering Have a ceramic block or charcoal block available to work on Select solders that do not contain cadmium or lead Avoid breathing solder fumes Make sure your work area is well ventilated or wear a respirator Clean your work area, removing anything flammable before you light the torch Wear goggles Never touch any area that has been recently soldered Never touch any solder that drips off your work

Pickle Pickle is a mixture of water and a commercial acid. It will remove contaminants, flux and oxides from the surface of your metal. You can use sulfuric acid (strong water soluble mineral acid), nitric acid (a highly corrosive and toxic strong acid) or sodium bisulphate (dry acid). Tips for using Pickle: Add water to the container first, then add the acid o If you add the acid first, adding water will cause an explosion o You can remember the order by thinking water is the largest quantity so add it first Wear goggles, gloves and an apron to protect yourself from acid burns to your skin and clothing Keep the pickle warm o Most jewellery makers use a crock-pot o At home, label your crock-pot so it is never accidentally used for food Avoid breathing the fumes from the pickle, it can irritate your lungs Keep a lid on the heated pickle Place items into the pickle gently o If you drop your piece into the pickle it can cause the acid to splash Rinse your skin immediately with soap and water if you touch or splash the pickle solution o If acid splashes on your eyes rinse them for 15 minutes, and have them checked by a doctor Store the pickle away from any other chemicals

such as flux Clearly label all storage containers o In your home workshop, it is important that you label any container you use for jewellery making Polishing Compounds Some polishing compounds contain free silica so work in a well ventilated area Wear a dust mask Wet sand whenever possible o Wet sanding will help to keep the dust down Note: If you are using a polishing machine: Tie your hair back Avoid wearing anything that could get caught in the machine (jewellery) Keep your hands away from the spinning disks

II. CONDITIONS OF OPERATION AND MAINTENANCE Prohibition of the Following Operational Practices: Incineration, refining and use of blow furnaces. Melting and alloying of metals except for use of small hand ladle not exceeding 0.5 liter in volume and heated by torch, and use of electric furnace and induction melters not exceeding 4 liter capacity. Usage and storage of propane and acetylene. Usage and storage of dry cyanide chemical powder. Discharge of untreated hazardous waste into the Citys sewer system or trash bins. Use of pure oxygen in wax injection (only compressed air may be used). Usage, Storage and Processing of Chemicals (alcohol, methanol, acetone, ammonia, cyanide solution, sulfuric acid, hydrochloric acid, nitric acid, and boric acid) is allowed under the following conditions: For metal finishing, usage of Magnetic Tumblers, listed by an LADBS approved Testing and Listing Agency, is preferred over the use of cyanide. However, when cyanide is the only alternative, only premixed solution is allowed. Types and amount of chemicals stored shall be per the LAFD F-315 special permit. Chemicals shall be properly stored in labeled containers and containers shall be stored in cabinets. Cabinets shall be Factory Mutual or UL listed and meet Cal-OSHA and NFPA Code 30 requirements.

- Cabinets shall have automatic closure and cabinet doors shall be closed at all time. - Cabinets shall have proper signage identifying the types of chemicals stored therein. - Incompatible chemicals must be kept in separate cabinets. - Only small quantities of chemicals sufficient for one-days work may be outside of the cabinet. All chemical wastes including liquid (chemical stripping solutions) or solids (polishing and dust collections) shall be collected, stored and manifested through a Registered Hazardous Waste Hauler or treated before discharge to the public sewer under City of LA Industrial Waste Management Division permit. Empty chemical containers shall be removed for proper disposal or relocation off site. Usage of Hydrogen, Oxygen , Methane And Anhydrous Ammonia is allowed under the following conditions: Only odorized (hydrogen and methane) gases are permitted to be used. Storage of hydrogen shall be limited to 240 cubic feet (one cylinder) per tenant and 6000 cubic feet per building. Storage of oxygen shall be limited to 480 (two cylinders) for the first 1500 square feet; with an additional cylinder per 750 square feet of additional space per tenant. Oxygen generators may be used in lieu of limited tank quantity under LAFD Division 5 permit. Methane cylinders may be permitted under LAFD F-315 permit if piped natural gas is unavailable.

Anhydrous ammonia may be permitted under LAFD Division 5 permit. All compressed gas cylinders, unless stored in locations or container where they cannot be knocked over or damaged, shall be secured by chain (min. grade 30 w/ 3/16 inch thick links) as approved by LAFD, cable or other noncombustible devices. Compressed gases shall be limited to those quantities listed on LAFD F-315 Permit. Usage of Open-flame Devices (torches, ovens, kilns, etc.) is allowed under the following conditions: Devices shall maintain the required 18 inches clearances from combustible materials at all times. Torches, hoses and holding device shall be listed by an LADBS approved Testing and Listing Agency: - Torches shall be used over non-combustible work surfaces. - Unlisted holding device shall be constructed such that it supports the weight of the torch and hoses without visible distortion. Miscellaneous Work and storage areas shall be kept clean of debris and accumulating dust. Change dust filters on buffing and polishing equipment. All exit pathways from area(s) of manufacturing or storage of hazardous materials shall be kept clear. Smoking is prohibited in manufacturing or hazardous storage areas. Signage for No Smoking shall be posted.

III. REQUIREMENTS FOR BUILDING UPGRADES FIRE-LIFE SAFETY For High-rise buildings permitted on or after July 1, 1974, no fire-life safety upgrades are required. However, all existing fire-life safety components and systems must be in good working condition. For High-rise buildings permitted prior to July 1, 1974, that have complied with the High-rise Retrofit Ordinance, no additional firelife safety upgrades are required. However, all existing fire-life safety components and systems must be in good working condition. For High-rise buildings permitted prior to July 1, 1974, that have not complied with the High-rise Retrofit Ordinance, fire-life safety upgrades shall be done per LAMC Section 91.8604 (Fire Safety Standards). For Low-rise buildings, fire-life safety upgrades shall be required under this guideline as follows: Fire Sprinkler System shall be required: For tenant space 1. When the floor area of the story exceeds 1,500 square feet and, for at least one side of the building at that story, lacks the minimum 20 square feet of opening for each 50 lineal feet or fraction thereof of the exterior wall (see LAMC Section 91.904.2.2 for detail requirements); or 2. When tenant space of non-Type I or non-Type II buildings that exceeds 3000 square feet and is not subdivided with walls of two-hour fire-resistive construction (see LAMC Section 91.7203.5.2 for detail requirements). For entire building when jewelry manufacturing is

on or above the third floor. Fire Alarm System (pull stations) with backup battery shall be required for the entire building when jewelry manufacturing is on or above the third floor. Other Fire-life Safety requirements (means of egress, shaft enclosures, etc.) shall comply with F-1 Occupancy MECHANICAL VENTILATION AND MAKE-UP AIR SYSTEM Hooded mechanical exhaust and dedicated mechanical make-up air system, if required, shall be operating during the usage of chemicals and open-flame devices. Windows are not allowed to be opened for exhaust ventilation. Hooded Mechanical Exhaust to the Roof and Dedicated Mechanical Make-up Air System shall be required for all heat producing equipment or open-flame devices (without fire sprinkler component). Minor repair and assembly area less than 500 square feet and in conjunction with jewelry retail are exempted. General Ventilation with Dedicated Mechanical Make-up Air System at a minimum rate of 6 air changes per hour shall be required for all manufacturing areas. Minor repair and assembly area less than 500 square feet and in conjunction with jewelry retail are exempted. Alternate Ventilation Systems may be considered where supported by accompanying reports from a Certified Industrial Hygienist or licensed Mechanical Engineer. LADBS will develop and have available a set of approved

alternative standards. Window Louvers In Lieu of Make-up Air System may be considered on an individual case-by-case basis provided no short circuiting occurs.