Inside a pattern making workshop
Embarking on an apprenticeship at Sri Guruvayurappa Engineering Works was a transformative experience for me. During these 2 weeks, I had the unique opportunity to immerse myself in the intricate world of pattern making (casting). This blog reflects my journey and the valuable lessons I learned along the way.
The Workshop Environment
Sri Guruvayurappa Engineering Works is a bustling hub of activity where patterns for machines are crafted with precision and skill. The owner, Raghu V., manages this workshop along with two other branches. The main client, Bharat Fritz Werner Limited (BFW), relies on the expertise of Raghu and his team to create high-quality patterns.
The workshop itself is a dimly lit room filled with piles of wood logs, wood powder, and an array of tools and machines. Each day begins with Bala Subramanyam, one of the four dedicated employees, opening the workshop, saying a prayer, and starting his work at 9 AM. His colleagues, R. Ashok, Thangaraj, and Satish Kumar, soon join him, and together they sign in and begin their day.
Daily Routine
The daily routine is structured yet flexible, allowing for a harmonious blend of hard work and camaraderie. The employees start their day at 9 AM and work continuously until 6 PM, with two tea breaks and a lunch break.
Morning Routine: Bala Subramanyam opens the workshop, and the other employees join in. Satish Kumar turns on the radio, filling the workshop with music as they work.
Breaks: At around 10:30 AM, the team takes their first break. If the owner is present, one person stays back while the others go out. The lunch break at 1 PM sees one employee going home while the rest share their meals at the workshop.
Afternoon Routine: Work resumes at 2 PM and continues until 6 PM, with a tea break at 4 PM. Overtime work is common when necessary.
The Work
Pattern making is a meticulous process that requires both skill and precision. Patterns, typically made of teak or deal wood, are replicas of the objects to be cast. These patterns are essential for preparing the cavity into which molten material will be poured during the casting process. An engineer provides the pattern designs, which are then executed in the workshop.
Tools and Materials
The workshop utilizes a variety of self-made tools, crucial for the accuracy and efficiency of the work. Tools are sharpened using two methods:
Small Chisels: Sharpened on an oil stone with water.
Large Chisels: Sharpened on hardwood with sand to avoid losing temper.
The wood used for patterns is usually old and repurposed, such as from old doors or packing materials, as fresh wood tends to bend easily. The wood is cleaned, nails removed, and then planed to be ready for use.
My Contributions
During the initial days, I spent most of my time observing and learning from the employees. Gradually, I was assigned small tasks, starting with sanding wood inside grooves and later moving on to more hands-on tasks such as:
Painting Patterns: Each color on the pattern indicates different machining areas.
Yellow: Areas where machining is done.
Red: Areas where no machining is done.
Black: Areas that will be left open.
Cutting Wood: Using a saw to cut wood for various purposes.
Handling Screws: Tightening and removing screws to join wood planks.
Drilling Holes: Using both machine drills and hand drills for screw placements.
My apprenticeship at Sri Guruvayurappa Engineering Works was more than just a learning experience; it was an opportunity to witness the dedication and teamwork that goes into pattern making. The employees welcomed me with open arms, and their willingness to share their knowledge made my time there invaluable. This experience has given me a deep appreciation for the craftsmanship involved in this field and the hard work of those who keep it alive.
