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Quarry Management System QMS of TAMIN

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Quarry Management System (QMS) of TAMIN (Tamil Nadu Minerals Ltd)
Presentation before the Jury Committee for The National Award on e-Governance
http://shrimagzagenda.blogspot.in/2015/03/tamin.html

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Quarry Management System QMS of TAMIN

  1. 1. QUARRY MANAGEMENT SYSYEM (QMS) Presentation before the Jury Committee for The National Award on e-Governance 22-Dec-2014 M. Vallalar, I.A.S. Managing Director Tamil Nadu Minerals Limited (A Government of Tamil Nadu Undertaking) 31, Kamrajar Salai, Chepauk Chennai 600 005
  2. 2. Agenda • About TAMIN • Key Issues and Challenges Faced • E-Governance Interventions Implemented • Benefits Realized • Future Directions • Conclusion and Summary Quarry Colombo Zubrana
  3. 3. About TAMIN • Established in April 1978, wholly owned by the Government of Tamil Nadu. • Workforce of 1311 personnel including Administrative, Technical and Workers (Skilled, Semi-skilled, etc.) • Exploits, processes and markets raw granite blocks and granite value added products • Processes and markets major minerals such as Graphite, Silica Sand, Vermiculite, Limestone and Quartz & Feldspar • Mines, quarries, divisional offices and factories are spread over in various parts of the State (600 Kms) • Exporting to countries as USA, Spain, Italy, China, Japan, Dubai, Poland, Slovenia, Croatia etc. Corporate Office (Chennai) Divisions (10) Quarries (33) Mines (9) Mini Tile Plants (2) Industrial Units (6) Show Room Central Workshop at Salem
  4. 4. Key Issues and Challenges Faced Issues of Transparency, Efficiency and Accountability (Manual System) Local Management of individual Quarries, Divisional Offices and Factories caused lack of effective controls / monitoring Reports were sent to the TAMIN Head Office from mines & quarries on weekly basis and subsequently compiled Low Focus / Visibility on ground operations due to non availability of data on daily basis Day-to-day monitoring not possible Manipulation / mis-interpretation of data Manual system caused low visibility, inaccuracy and unreliable reports from the field
  5. 5.  TAMIN has introduced a new web based software “Quarry Management System” called QMS during Nov.2012.  It is a centrally managed software that collects data of production / sales / despatches etc. in the quarry / mine / factory on a daily basis  It converts the data into reports for efficient and transparent management with high accuracy.  It is a unique software, designed and developed based on TAMIN’s requirement  QMS is not mere computerization of office. It was designed to integrate various kinds of mining activities like production, recovery percentage, mine wastage, sales, mine safety and optimum utilization of men & machinery E-Governance Initiative QMS – An innovative effort
  6. 6. E-Governance Initiative Implemented  Low cost in-house equipment provided for implementation.  Alignment of software system developed and the processes followed  Provided Adequate Training and Capacity Enhancements by providing equipment's and support  Removed manual processes after implementation of e-governance solution  Constituted a Mine Auditing Committee to physically validate data entered in QMS TAMIN Granites, Chennai
  7. 7. E-Governance Initiative Implemented Platform Details  Project cost: Rs. 6 Lakhs  Used Open Source Technology  Developed Platform (Front end): PHP  Database (Back end): MySQL  Hosted at: TAMIN Server at Head Office  Utilized BSNL for connectivity  Security System:  Hardware firewall: SonicWall 2040  Software: Symantec Endpoint Protection Home Page of QMS
  8. 8. E-Governance Initiative Implemented Software Features  Entries made in Divisional Offices – Single Entry on daily basis and Multiple View, Locking of entries after certain time  Multiple MIS reports are generated daily • Production Performance, Sales Performance, Stock Availability • Shift-wise Men & Machinery Performance, Under-utilized Machinery List • Non-working Machinery with its Service Status • Fuel Consumption Details • Important Materials / Machinery Requirements for Continuous Quarry Operation • Follow up of Court Cases, Tender Status • Statutory Requirements of Mines  Consolidation of Data at Head Office Level  Daily Dashboard Report for MD Generated by System and interaction enabled with field by online chatting  Daily Review and consequent Decisions made at Head Office.  Portal Provided for Sales Function.  Analysis -> Discuss -> Directs online
  9. 9. E-Governance Initiative Implemented Training and Capacity Building  Provided equipment – Laptop, Cameras, Data Card and Connectivity to all required officers / quarries / mines / factories.  Provided Training in Computer Systems and Applications to all officers and staff.  Provided Training in Photography to staff.  Designated one day in a month for training activities Quarry Site Training Programme, Yellikaradu Quarry, Mettur Dam
  10. 10. E-Governance Initiative Implemented Process Alignment  System determined process for Immediate conversion of unfinished blocks to finished blocks chronologically.  Recording of waste generated in each stage of quarry & mine operation.  Selection of blocks in chronological order by Buyer  Payment within stipulated time  Verification of Granite Block Measurement with help of digital photographs Verification of Block Measurement using Digital Photograph
  11. 11. E-Governance Initiative Implemented Process Alignment  This e-Governance initiative especially measurement checking of granite blocks by digital photographs helps to avoid revenue loss.  Ex. If 10 Centimeter of measurement is omitted intentionally or by error in each side of one cubic meter granite block, there will be loss of about 20% in volume of the block.  The revenue loss may be in crores. Verification of Block Measurement using Digital Photograph
  12. 12. E-Governance Initiative Implemented Mine Auditing Committee  Composition: Geologists , Mine Engineers, Mines Surveyors and external experts (retired Director from GSI)  Audits each mine physically once in two months  Cross checks the data in the QMS entered with reference to the actual volume mined.  Each Mine / Quarry has a 3 Member Core Committee (consisting of Officer, Supervisor and Worker) – Daily activities are monitored and data validated by them. Maintain Core Committee Register.
  13. 13. Benefits Realized Key Process Benefits  Faster Decision Making Capability Provided to TAMIN  Automatically analysis various data and generate daily performance report of each quarry, mines and factories.  These reports are sent by way of emails followed by SMS alerts to Field / Divisional Office staff (about 80% of the workforce are getting SMS alerts on daily basis). These reports assist the Divisional Managers to fine tune daily operations of the quarries / mines / factories resulted in increase in revenue and performance.
  14. 14. Benefits Realized System Benefits  All data including photographs are documented on daily basis and that can be retrieved at any point of time  Optimum use of natural mineral wealth is ensured  Optimum utilization of men & machinery is ensured  Improved Quality of service provided to the buyers  Verification of the measurements of the granite blocks lying in a remote quarry from the Head Office is made possible.  A sense of alertness, vigil, vigour, competitiveness, achievement and self reverence was instilled in the minds of the working force and management.  Increase in revenue due to accuracy of measurements and close monitoring of operations
  15. 15. Benefits Realized Key Quantitative Benefits (2013-14) PROFIT ₹ 24.69 Crores [603% Increase over previous year] SALES ₹ 188.87 Crores [55% Increase over previous year] EXPORT SALES ₹ 45.81 Crores [182% Increase over previous year]
  16. 16. Sales, Export Sales and Profit (Before Tax) Growth Data Sales Turnover Export Sales Profit before tax Before QMS After QMS
  17. 17. Benefits Realized Key Qualitative Improvements In Previous System (manual system) In Present System (QMS) There was no mechanism to monitor the size of the Granite blocks produced from primary cutting stage which resulted in low level production of higher size blocks which cause revenue loss. Now, every granite block is monitored from the stage of primary cutting to finished product which enables production of large size blocks and reduction in cost of production and high cost realization Blocks are selected by the buyers as they wish rejecting most of the granite blocks which resulted in revenue loss The blocks are sold in chronological order only. Hence we are able to sell all the blocks without omission. The Head Office cannot see the measurement of the granite blocks and had to fully depend upon the statements of the field. There was chance for malpractices, inaccuracy in measurement and other complaints. Every block is digitally photographed with measurement tape and uploaded which can be seen in HO with measurement. Men & machinery were not effectively monitored due to poor MIS as the quarries are remotely situated. QMS sets standard for effective utilization of men & machinery and any shortfall in utilization is indicated in the next day report which helps management take appropriate timely action. Delayed Mine Auditing Almost daily Mine Auditing and Management intervention in case of exception. CCTV Cameras installed in mines / quarries. SMS alerts are given
  18. 18. Benefits Realized Additional Benefits  All time high production in black granite, graphite ore, limestone, silica sand, Indian standard sand, raw vermiculite and exfoliated vermiculite  All time high sales turnover in black granite, graphite, limestone, Indian standard sand, exfoliated vermiculite  Idle men & machinery were identified and reduced considerably.  Efficiency of men & machinery has increased  Fuel consumption in each machinery in the quarry is closely monitored  Quarry-wise recovery percentage of granite has been closely monitored  Accuracy of measurement of granite block has been ensured  Upload of photograph of each granite block with measurement  Undressed block & finished block stock has been reduced considerably  Turnover & profit has increased  Work flow in the processing of sales has been simplified  Close monitoring of each stone and every machineries in the quarry / mines are made possible from Head Office  Day-to-day activities of all quarries / mines / factories like production, sales, dispatch, waste generation has been monitored from Head Office  All reports like selection list, invoice, dispatch challan, tax report etc. are being generated through this software. Hence, duplication of work is avoided and accuracy & transparency are ensured.
  19. 19. Future Directions In-House • Mobile & Tablet Computing External • Extension to other government organizations who are dealing with mines and minerals • Extension to Private Players – to increase transparency
  20. 20. Conclusion and Summary  This Quarry Management System is a prelude to effective monitoring of mineral wealth.  TAMIN has demonstrated the effective use of ICT and e-Governance in achieving organizational efficiency and effectiveness.  This software with some modification can be utilized in other organizations, who are dealing with mining and quarrying activities.  The Principal Secretary to Government, Industries Department, Government of Tamil Nadu, appreciated the efforts taken by TAMIN in bringing transparent management system through this QMS Software and suggested to introduce this system in other departments as TANMAG / TANCEM.  This has been achieved through in-house efforts  With additional assistance and resources, more improvements can be made in the working of TAMIN. “Transparency is the key to good governance. E-Governance is the only effective way of transparent governance.” - Shri Narendra Modi, Prime Minister of India
  21. 21. Annexure E-Governance Software Reports – Screen Prints Quartz FeldsparRaw Vermiculite Exfoliated Vermiculite Limestone Silica Sand Graphite Major Minerals quarried and processed by TAMIN
  22. 22. SALES TURNOVER (Rs. in Lakhs) 1 24 69 98 168242407592830 1175 1072 1422 1873 2606 3578 4020 4008 3436 3132 4070 5317 6651 6670 6705 8002 9021 10015 10991 10147 9389 10505 11041 10222 10091 12223 18887 0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000
  23. 23. EXPORT SALES (Rs. in Lakhs) 0 21 59 85 147 221 328 453 695 999942 1326 1781 2507 3404 3822 3765 3081 2319 2474 2745 2492 2870 2205 2152 1233 1762 1866 672 217 355 281 124108 1623 4581 0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
  24. 24. PROFIT BEFORE TAX (Rs. in Lakhs) -8 6 11 14 28 28 45 135154 215229 593 929 1622 1954 2151 1529 267 101 725 985 753 1127 623 370397 521 381 427 258 101 67 69 78 351 2469 -500 0 500 1000 1500 2000 2500 3000 24
  25. 25. SALES – BLACK GRANITE (Rs. in Lakhs) 0 20 44 65 101167222325 522 685 541 900 1074 908 1579 1624 1634 837 13 2273 2188 2950 2811 2437 2814 2894 3131 3642 3474 4538 3873 3862 4462 4513 5240 9107 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 2
  26. 26. SALES – LIMESTONE (Rs. in Lakhs) 0 2 3 5 2 8 49 99 86 119 60 38 30 17 29 35 38 22 0 129 182 155 173 191 125 62 76 152 151 157 291 260 746 429 2240 2862 0 500 1000 1500 2000 2500 3000 3500 26
  27. 27. SALES – EXFOLIATED VERMICULITE (Rs. in Thousands) 9 0 1 1 10 27 52 16 22 230 293 631 1157 1197 1119 1823 2306 1851 2261 3923 3972 4578 5238 6391 8308 9348 9593 12413 11047 12543 18220 0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 27
  28. 28. SALES – GRAPHITE FLAKES (Rs. in Lakhs) 1 0 2 0 0 0 0 0 4 3 121 231 250 352 444 375 518 618 776 745 1028 1020 1045 1400 1251 1403 2547 2590 2835 0 500 1000 1500 2000 2500 3000 28
  29. 29. SALES – INDIAN STANDARD SAND (Rs. in Lakhs) 0 0 0 0 0 0 16 20 24 28 31 29 31 29 50 42 50 56 61 61 67 67 83 83 83 85 97 94 121 136 192 203 244 346 457 613 0 100 200 300 400 500 600 700 29
  30. 30. PRODUCTION – BLACK GRANITE (Quantity in Cubic Metre) 17 931 2044 1787 1356 2630 3579 4487 74307203 4798 4474 5272 4076 3679 4161 4225 2054 2763 6835 6834 9597 8434 7808 8647 10990 12405 15106 13619 17629 22217 18408 17998 15915 16062 23817 0 5000 10000 15000 20000 25000 30000 30
  31. 31. PRODUCTION – LIMESTONE (Quantity in Metric tonne) 5536 11438 12014 8240 6991 7772 74154 144563 122262 152242 74512 45136 27041 19492 23201 22301 22551 15900 0 73830 100740 110562 127692 158793 94147 49385 55750 76550 76730 115275 221500 155600 353470 180400 674682 701413 0 100000 200000 300000 400000 500000 600000 700000 800000 31
  32. 32. PRODUCTION – RAW VERMICULITE (Quantity in Metric tonne) 233 550 702 1202 1167 1860 1131 1065 954 900 918 1106 865 761 877 761 481450 0 1102 1230 1331 1596 1951 1765 1458 1855 1417 1491 1687 1921 1603 2154 1697 1373 2201 0 500 1000 1500 2000 2500 32
  33. 33. PRODUCTION – SILICA SAND (Quantity in Metric tonne) 45 75 1584 3709 7231 11795 3238 113 568 352 480 609 359 312 824 946 710 1254 1908 1234 2722 1583 3755 2180 2507 2520 2419 2961 2707 3094 3129 3329 3901 3206 4212 7500 0 2000 4000 6000 8000 10000 12000 14000 33
  34. 34. PRODUCTION – GRAPHITE ORE (Quantity in Metric tonne) 101 1091 959 1136 1926 2029 3484 3274 265 3550 0 0 0 21330 15609 4642 39391 32656 17867 32464 50320 41320 42627 42840 57200 58961 49308 59227 50764 49329 57205 67959 87995 0 10000 20000 30000 40000 50000 60000 70000 80000 90000 100000 34
  35. 35. PRODUCTION – EXFOLIATED VERMICULITE (Quantity in Metric tonne) 6 3 2 35 19 10 10 91 111 255 400408 299 545 671 436 464 758 703 880 961 1054 1234 1335 1355 1680 1334 1218 1752 0 200 400 600 800 1000 1200 1400 1600 1800 35
  36. 36. PRODUCTION – INDIAN STANDARD SAND (Quantity in Metric tonne) 658 782 1037 1127 1236 1201 1231 1173 1352 1380 1720 1739 1766 1735 1858 1298 1852 2006 2162 1728 2217 2118 2231 2535 2381 2859 3486 3078 3300 3714 0 500 1000 1500 2000 2500 3000 3500 4000 36
  37. 37. Daily Reports for review Division / Unit wise production target, achieved production & sales, stock details etc. Highlights of the above statement: •By clicking the each figure, we can see the detailed reports •Division-wise production achievement against target •Monitoring undressed blocks which are not dressed more than 15 days •Monitoring selected blocks which are not paid more than 15 days •Invoiced blocks which are not delivered from the quarry within 20 days from the permit date •Stock of dummy blocks, finished blocks, sold but not dispatched blocks in the quarry site
  38. 38. Daily Reports for review Top 10 un-utilized machineries The above statement will be helpful to the management for the following aspects: •Identify the idle machineries and divert to the needy places •Pre-planning tendency has improved, resulted in increase in production
  39. 39. Daily Reports for review Non-working machineries The above statement will be helpful to the management to follow the repair work which resulted in drastic reduction of break-down days / hours.
  40. 40. Daily Reports for review Quarry daily requirements The above statement is helpful to take immediate action for procurement of materials.
  41. 41. Daily Reports for review Mine-wise Performance (Major Minerals) The above statement is helpful to know the stock details, production & sales performance, pending supply details etc.
  42. 42. MACHINERY PERFORMANCE Report Daily machine / Vehicle wise performance, utilized man power, utilized consumables
  43. 43. RECOVERY Report Quarry-wise recovery percentage report
  44. 44. PERFORMANCE Analysis Report (AUTO GENERATED)
  45. 45. Task Manager - Discussion Board
  46. 46. Proposals – Discussion Board
  47. 47. Pending Proposals
  48. 48. Thank You! Granite Processing Unit at Melur, Tamil Nadu

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