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PROJECTS

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Thuja

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Industrial Design Portfolio

Projects

Redesigning Labour

Redesigning Labour

Thuja

Awarded first place and a grant at the

Wisser and Family Innovation Challenge 2.0

Awarded first place and a grant at the

Wisser and Family Innovation Challenge 2.0

8 Weeks - Individual

8 Weeks - Individual

An ergonomic bamboo headgear designed for tea women workers, made with

cloth and natural foam, featuring a strap system that shifts weight from the head

to the shoulders for better comfort and safety, while preserving the traditional

essence of the jaapi.

An ergonomic bamboo headgear designed for tea women workers, made with cloth and natural foam, featuring a strap system that shifts weight from the head to the shoulders for better comfort and safety, while preserving the traditional essence of the jaapi.

Imagine carrying twelve one-litre steel flasks,

hanging from your head for 50 hours a week;

a burden that grinds deeper into your bones day by day.

"We lead stressful lives with no rest, and
the fear of losing daily our wage is always there."

"Due to discomfort associated with repetitive hand movement in bending posture while carrying the

load of the basket with plucked tea leaves on the back, the workers perceived maximum discomfort at

the neck, wrists, back and upper arms. The work stress on the women workers may be reduced by

implementing ergonomic interventions like, reduction of load of plucked tea leaves being carried in the

basket and sufficient rest during the daily rigorous work hours."

-Indian Journal of Hill Farming

Product

Relief without disruption:

Relief without disruption:

Even the most ergonomic head support loses comfort

over time. Thuja’s strap system lets workers shift the

load from the head to the shoulders, offering relief

without removing or altering their setup

Even the most ergonomic head support loses comfort

over time. Thuja’s strap system lets workers shift the

load from the head to the shoulders, offering relief

without removing or altering their setup

Recognition:


Thuja was awarded the first place at Wisser and Family Innovation Challenge 2.0, hosted at Don Bosco Institute, Jorhat. We also received a grant of 2.3 lakh for further development of the project.


Thuja was awarded the first place at Wisser and Family Innovation Challenge 2.0, hosted at Don Bosco Institute, Jorhat. We also received a grant of 2.3 lakh for further development of the project.


"We lead stressful lives with no rest, and
the fear of losing daily our wage is always there."

Research

Initial research was carried out at Cinnamara Tea Estate over a continuous period of 2 weeks.

Initial research was carried out at Cinnamara Tea Estate over a continuous period of 2 weeks.

Observations

Observations

(These observations were a result of extensive field research, conversations,
role play and secondary research conducted with tea workers of Assam.)
(These observations were a result of extensive field research, conversations,
role play and secondary research conducted with tea workers of Assam.)
Women balance household work with
long, exhausting hours in tea gardens.
Women balance household work with
long, exhausting hours in tea gardens.
Breaks lack dignity, unsafe water,
harsh conditions, inadequate rest.
Breaks lack dignity, unsafe water,
harsh conditions, inadequate rest.
Aspirations for alternative income
(like cattle rearing) remain unfulfilled
due to lack of resources.
Aspirations for alternative income
(like cattle rearing) remain unfulfilled
due to lack of resources.
Daily tasks involve carrying 20–25 kg baskets with makeshift supports that cause pain and injury.
Daily tasks involve carrying 20–25 kg baskets with makeshift supports that cause pain and injury.
Tools cause cuts, stress, and mobility restrictions; plastic often replaces traditional materials.
Tools cause cuts, stress, and mobility restrictions; plastic often replaces traditional materials.
Education and healthcare exist but don’t translate to real opportunities.
Education and healthcare exist but don’t translate to real opportunities.
Wages depend on strict quotas; workers feel underpaid and insecure.
Wages depend on strict quotas; workers feel underpaid and insecure.

Analysis

Analysis

Pain Points

Insights

Opportunities

Problem Statement

Tea plantation workers, especially women, carry 20–25 kg of tea leaves daily using plastic ropes and towels that

place excessive pressure on the head and neck. This leads to chronic pain, musculoskeletal disorders, and long-

term postural damage. Existing equipment lacks ergonomic support, disrupts movement, and often replaces

traditional bamboo craft with unsustainable plastic alternatives.


Approach

Approach

community-centric

community-centric

culturally relevant

culturally relevant

ergonomic

ergonomic

This approach not only alleviates daily physical challenges but also fosters a sense of pride and ownership

within the community, creating a tangible connection between heritage and practical innovation.

Empathy Mapping

Based off field research and

qualitative interviews.

SAYS

“My shoulder hurts from plucking leaves all day.”

“We only earn ₹1000 a week, men don’t pluck leaves because pay is too low.”

“I wish I could have gone to school; almost all of us

are illiterate.”

“It’s too hot to work here all day.”

“After 5, we don’t feel safe because of drunk men roaming.”

DOES

Wakes 3–6 AM to finish chores before 8 AM fieldwork.

Plucks tea leaves, carries 25 kg baskets twice daily.

Eats lunch in harsh sun, drinks unsafe water.

Works as a bungalow maid after 5 PM to earn extra.

THINKS

Pain and injuries are just “part of the job.”

Work demands skill, speed, and resilience.

Wants alternative income but lacks means.

Sees healthcare access as crucial.

FEELS

Underpaid and financially strained.

Slight reassurance under govt. oversight, yet insecure.

Proud to support her family; women’s role feels central.

Monika Tanti

Access the entire research document here.

"We lead stressful lives with no rest, and
the fear of losing daily our wage is always there."

Design

Is there a way to

harness the

shoulder option

when feeling tired

of wearing in

head?

A product to collect tea leaves at the same

time something to protect from wind and

rain possible collection methods:

Why everyone

still uses

bamboo

basket and

ties

it to their

head?

Mockups

A product to collect tea leaves at

the same time something to protect

from wind and rain possible

collection methods:

User Testing

Comfort:


Although there were sizing and functionality issues in the first

round of user testing, the one area which aced it was comfort.

Development

Development

3 New Mockups:

3 New Mockups:

New iterations with different materials, form and fitting have been developed and are currently awaiting user

testing which has been scheduled for the end of October 2025.

New iterations with different materials, form and fitting have been developed and are currently awaiting user

testing which has been scheduled for the end of October 2025.

Thuja