Sumul Dairy was established in 1951 by milk producers in Surat, India to gain fair prices and combat exploitation by private milk traders. It has since grown to include multiple processing plants, chilling centers, and a cattle feed factory. Sumul Dairy was awarded a Certificate of Merit in 2003 for quality. The summary focuses on the cooperative's origins, growth over time, and recent recognition for quality.

1. SUMUL DAIRY
AT A GLANCE
VENUE : IMC, Mumbai
DATE : 21-March -2003
PRESENTED
BY
AMIT M. VYAS
MANAGER (TECHNICAL)

2. MESSAGE FROM OUR MANAGING DIRECTOR
We are honored that we have been selected for award of Certificate of Merit
by IMC - RBNQ.
It is our privilege to receive this award on behalf of "SUMUL PARIVAR" which
is made of "Milk Producers, Employees, Distributors, Contractors,
Suppliers and Consumers".
We are engaged in a business created by milk producers of Surat District on
principles of Co-operation, Mutual Benefit, Self help & create an
Infrastructure to meet our own requirements. Our endeavour is to work for
our betterment and to improve our quality of life through a Co-operative
Institution.
We mean - to improve quality at all levels and not only to satisfy or to delight
our consumers but to make them feel that they are the part of us. We intend to
provide our consumers not only the Milk and Milk products but also to provide
"Good Health & Nutrition" to them.
This recognition will not only encourage us to do much more than what we can
normally do, but will also "Boost our Efforts" in achieving more for under
privileged members of society specially in Rural Areas.

3. Genesis of Sumul
 Milk Producers’ of Surat District were being exploited by
Private Milk traders known as “Bhatias”. The Milk
producers used to bring milk from villages in the Surat City
and the entire trade was taking place at the bank of Tapti
River. As Supply and Demand was never considered, the
Milk Producers were at the Mercy of Milk Traders and they
never received remunerative and reasonable price for Milk.
 The then, the Co-operative Leaders set together to find out
ways and means to come out of the shackles of Milk
Traders. After several meetings they agreed to organize the
Surat District Co-operative Milk Producers’ Union Ltd so
that unitedly under co-operative umbrella they can have
their voice to get & receive a reasonable return of the Milk
they produced.

4.  The Surat District Co-operative Milk Producers’ Union
Limited, abbreviated as SUMUL- its trade name and
literally meaning Sound Price, came into existence on
August 22, 1951 and registered under the Bombay Co-
operative Societies Act, 1925, with the joint untiring and
dedicated efforts of Veteran Leaders of Co-operative
Movement. Shri Ashabhai S. Patel became the first
Chairman.
 From 1951 to 1968 the Raw Milk trade was carried out as
there was no plant and the Milk was supplied directly to
consumers & sold to traders in bulk.
 In 1968, the Dairy Plant at Surat was established with the
aid of Sweedish Credit Loan and it was commissioned on
March 17, 1968 with milk handling capacity of 40,000 ltrs
per day .

5. OBJECTIVES OF SUMUL
The Sumul Dairy was established with the following
objectives :
 To provide guaranteed remunerative milk market
round the year for surplus milk
 To provide maximum return to producers
 To Provide good quality Milk and Milk Product to
consumers
 To increase milk productivity at most economic rate
by providing technical input services to the producers.

6. SUMUL PERFORMANCE
Particulars 1951-52 1970 1980 1990 2000
No of
Society
8 62 605 780 968
No of
Producers
175 8700 83800 145520 207258
Total milk
procurement
(Ltr/day)
200 29693 111533 257315 563946
Price Paid
(Rs/Kg fat)
6 19 38 96 202
Milk sale
(Ltr/day)
1751 29099 89226 246017 390433

7. Transformation at Sumul
 Govt. of India announced Economic Reforms &
Globalization activity as per WTO & GATT agreement in
1990, which included Dairy Industry too.
 Our reactions were-
– Government can not do this to Co-operative Dairy sector
– This will affect poor farmers development
– This sector should continue getting Government support &
develop this industry only in Co-operative sector
– Protection should continue.
– To launch agitation against Government decision to continue
privileges in Dairy sector - as continued in Sugar Industry.
– MNC’s will seek advantage of our efforts put so far.

8. Transformation at Sumul
 But everything was turned down by Government- In fact no
patient hearing was given to us. A blunt answer - “We can not
go back on decisions we have taken. You please learn to live
with this”.
 Maximum we could get was promulgation of MMPO-1993 to
give protection of milk sheds & other. But this remained only
a paper tiger. This was for all Co-operative dairy sector. But
Government have decided to scrap the MMPO in year 2003.
 In 1995-we started thinking about Threats & Weakness of our
system.
 We found that we are vulnerable from all directions-Internally
and Externally. As External environment was beyond our
control, we thought to concentrate on improving internally. We
then started studying our business and found ways to improve
our people, systems, skills and knowledge.

9. Transformation at Sumul
What we did was………work on
 1. Employee Development
(Attitude, Skill & Knowledge)
 2. Started “Self Development” - Training in 1995
(Self Management Leadership, Meditation)
 3. Total Quality Management in 1996
 4. Total Productive Maintenance in 1999.
For System Development
 1. Database Management in 1999
 2. ISO 9002 & HACCP System in 2000
 3. ISO 14001 in 2001

10. DIFFERENT UNITS OF SUMUL UNION ARE
 SUMUL DAIRY, SURAT (591)
– 5 LAKH LTPD - 0 KM
 Navi Pardi Chilling Centre (N.P.C.C.) (66)
– 2 LAKH LTPD - 25 KM
 Uchchhal Chilling Centre (U.C.C.) (49)
– 1 LAKH LTPD - 105 KM
 Bajipura Chilling Centre (B.C.C.) (113)
– 3 LAKH LTPD - 50 KM
 Sumuldan Factory-Chalthan (S.D.F.) (96)
– 200 MT PD - 18 KM
• TOTAL Employee (915)
UNITS OF SUMUL

11. 11
O
O
O
O
O
O
O O
O
O
O O
O
O
Cream
Homogenizer
CREAM
SEPARATOR
CREAM
40% FAT
WHOLE
MILK
(6.5 / 9.0)
TEMP.
+ 50 C
M I L K C O L D S T O R E
P A S T E U R I Z E R
[ Heating to 800C & Cooling to 40C ]
C H I L L E R
TRIBAL VILLAGE
COOPERATIVE SOCIETY
O O
O
O
O
O
O
O
O O
O
O
O O
O
O
M I L K
CHILLING PLANT
O
O
O
O O
O
O
O O
O
O
POUCH FILLING
MACHINES
M I L K
P.S.M.
MILK
(4.5 /8.5)
M I L K
8OC 4OC
8OC
C I T Y
MILK
MILK

12. 12
B U T T E R
MELTING VAT
>600c
STRAINER
C R E A M
T A N K
40%Fat
Cream
CREAM
PASTEURIZER
120 C
BUTTER
CHURN
.
.
.
BUTTER
GHEE
KETTLE
105 - 1100 C
TEMP.
- 150 C
B U T T E R C O L D S T O R E
DRYING
CHAMBER
EVAPORATING PLANT
GHEE
FILLING M/C
BUTTER MAKING M/C
M I L K
M I L K
P O W D E R
P L A N T
WHITE
BUTTER
SMP SMP

13. MAIN
DAIRY PLANT
CATTLE FEED
FACTORY-CHALTHAN
MANGROL
B H A R U C H
S E R V I C E S :
1. CATTLE FEED PRODUCTION
2. VETERINARY SERVICES
3. ARTIFICIAL INSEMINATION
4. CO-OPERATIVE DEVELOPMENT
5. EXTENSION ACTIVITIES
6. MILK PROCESSING
& MILK PRODUCTS MANUFACTURE
7. MILK DISTRIBUTION
CHILLING CENTRE
km distance from Surat
CATTLE FEED FACTORY
TALUQA / TEHSIL NAME
UMARPADA
UCHCHHAL
VYARA
MANDVI
VALOD
MAHUVA
PALSANA
BARDOLI
KAMREJ
CHORYASI
OLPAD
NIZAR
DEDIAPADA
135 km
CHASWAD
100 k m
UCHCHHAL
CHILLING
CENTRE
100 km
BAJIPURA
CHILLING CENTRE
[Diagnostic Lab]
50 km
NAVIPARDI
CHILLING
CENTRE
28 km
 NIZAR COMPLEX
165 km
 MAIN DAIRY PLANT
U K A I
D A M
SONGADH
WORK AREA OF SUMUL

14. 14
^ ^ ^
^
1951
Registration of
Surat District Co-operative Milk Producers’ Union Ltd.
1968
Hon.Divine Pujya Yogiji Maharaj of ‘Akshar Purushottam’
inaugurated Dairy Plant and named “SUMUL DAIRY”.
1979
Inauguration of extension wing of Dairy Plant
with polyethylene pouch packing by Dr. V. Kurien.
1975 Inauguration of 30,000 LPD Chilling Centre at Bajipura.
1970
Inauguration of Cattle Feed Plant at Chalthan
having 200 MT capacity per day.
1985 Expansion of 200,000 LPD Dairy Plant.
1988 Decentralization of mobile Veterinary services
1992
Commissioning of Oil Packaging Station at Chalthan
for packing edible oil with brand name ‘DHARA’
1999
Launching of
Total Productive Maintenance program.
1982
Inauguration of milk Chilling Plant
having 30,000 LPD capacity at Uchchhal
1996 Inauguration of 200,000 LPD Chilling Plant at Navipardi.
1996
Launching of
Total Quality Management program.
2000 ISO 9002 & HACCP 9000 CERTIFICATION
1995
Inauguration of
12.5 MTD POWDER PLANT
2001 ISO 9002 CERTIFICATION FOR CATTLE FEED PLANT
RAW CHILLED
MILK

15. SUMUL’S VISION STATEMENT
“WE ARE SOCIALLY RESPONSIBLE
ORGANISATION WITH COMMITMENT TO
CONSUMER DELIGHT AND RESPECT FOR
ALL. WE BELIEVE IN GROWTH AND
CONTINUOUS IMPROVEMENT THROUGH
TEAMWORK, TRUST & EXCELLENCE,
WITHOUT COMPROMISING OUR HONESTY
AND INTEGRITY”

16. SUMUL VISION - 2005
Milk Procurement
Milk Sale
Quality
Production cost
Distribution System
5,61,977 Liters
International Std.
RS. 290 Crores RS. 551 Crores
7,51,000 Liters
5,51,000 Liters
INTERNATIONAL STD.
ISO 9000
HACCP
Minimum Production
Cost
Consumers oriented,
Quick and effective
4,32,811 Liters
VISION - 2005
Turnover

17. MILESTONES
 Date of Registration 22-08-1951
 First board Meeting 30-10-1951
 Shilanyas of Sumul 30-04-1968
 Sumul name given on 03-02-1968
 Inauguration By PM 17-03-1968
 Milk distribution in Bottle 03-05-1968
 Cattle Feed Factory 10-04-1970
 Sumul Magazine 01-07-1970
 Establishing Member of GCMMF 09-07-1970
 Bajipura Chilling Centre 26-01-1975
 Mobile Veterinary Route 20-06-1977

18. MILESTONES
 Milk Distribution in Polybag 07-12-1978
 Uchchal Chilling Centre 01-04-1982
 Buttermilk Distribution In Polybag 01-06-1987
 Powder Plant 04-12-1985
 Navi Pardi chilling Centre 27-10-1996
 Launching TQM 06-05-1996
 Launching TPM 19-10-1999
 ISO 9002 & HACCP Certification of Dairy 2000
 ISO 9002 Certification of Cattle Feed Factory 2001
 ISO 14001 Certification of Dairy 2002

19. PRODUCT MILESTONES
The overview of path of success in the local liquid Market
 Milk distribution in bottle : 1968
 Milk distribution in polybag: 1978
 Buttermilk distribution in polybag : 1987
 Whole milk (Sumulya) in bulk : 1988
 Whole milk (Sumulya) in 500ml : 1991
 Homogenised toned milk in500ml: 1994
 Homogenised Toned milk in200ml : 1995
 Flavoured milk : 1993
 Paneer : 1994
 Sweets : 1994
 Shrikhand : 1995
 Lassi : 1995
 Past. Milk in 5 Liters in Pack : 1998
 Masala Chhas, Meethi Chhas & Jome in Pouch :2000
 Pizza & Ice-Cream 2001
 Rasgulla, Gulab jamun, Sugar & Cow Milk 2002
 Tea 2003

20. PRODUCTS OF SUMUL
•MILK VARITIES
• PSM (STANDARDISED MILK) * SUMULYA (WHOLE MILK) *
• DELITE ( HOMOGENISED TONED MILK) *CHHAS * JEERA CHHAS
• MEETHI CHHAS *FLAVOURED MILK – JOME, COW MILK
•PASTURIZED WHITE BUTTER & TABLE BUTTER * GHEE
•PANEER -PLAIN, MASALA * SWEETS * SHRIKHAND
•SKIMMED MILK POWDER
• PIZZA * SOFTY * SUGAR * TEA
•BALANCED CATTLE FEED FOR MILCH ANIMALS
RS. 353 CRORES FOR YEAR 2001-2002
TURNOVER OF SUMUL

21. PRODUCTS OF SUMUL

22. QUALITY POLICY
WE AT SUMUL DAIRY, ARE DEVOTED, DEDICATED
AND MOTIVATED WORKFORCE TRAINED TO
ENSURE CONSISTENT SUPPLY OF GOOD QUALITY
AND SAFE MILK AND MILK PRODUCTS TO
ACHIEVE HIGHEST LEVEL OF CUSTOMER
SATISFACTION.
WE WILL ACHIEVE THIS BY MONITORING AND
UPGRADATION OF PROCEDURES AND PROCESS
APPLYING SCIENTIFIC INNOVATIONS AND STATE
OF THE ART TECHNOLOGY AND REMAIN
ECOFRIENDLY.
17th August, 1998 MANAGING DIRECTOR

23. OUR STRATEGIC FOCUS
 Cooperative Focus
– Village level development, Clean Milk Production &
Veterinary Services
 Customer & Market Focus
– Relationship, Awareness & Product availability as per
their need and time
– Competitors Watch, Own agents relationship, Market
research
 Quality Focus
– Continuous Improvement in Quality defined according
to Customers
 Organizational focus
– Think globally and act locally

24. CO-OPERATIVE DEVELOPMENT

25. PICTURE GALLERY OF CD ACTIVITIES
Urea Treatment to encrease
Paddy Straw nutritive value
Rural Sanitation
Program
Celebrating Milk Society Cleanliness Day on
2nd October at Societies under ICD Programs
Sankar Cow giving 25 ltrs of Milk per day
of Shri Rameshbhai Patel of Haldharu
Dudh Mandli under “Sankar Gav dwara
Ghar-Angane Samruddhi” programme
Achievement of Veterinary activities of
Sumul, Desi-Surti Buffallo of Shri.
Dhirubhai Bhanabhai Patel, Member,
Umra Dudh Mandali got 18th pregnency
Auditor - Supervisor Sankalan
Meeting organised by Sumul
Meeting of Womens under “Anemia Control
Programme” in colloboration with UNICEF
Objective Determination
Programme at Velda , Tal-Nizar
Meetings under Cooperative
Development Programme
Meetings under Cooperative
Development Programme
Meetings under
Cooperative
Development
Programme
Planning Village rural drinking
water supply scheme under
Sector Reform Programme
Ghaschara Biyaran
Programme on
“Plantation” & Free
Eye Checkup
Camp” organised
by Sumul Dairy &
Rotary Surat
Midtown
Awarding certificates under Artificial Insemination
Training programme

26. PICTURE GALLERY OF CD ACTIVITIES
Opening Ceremony of ‘Inter-net’
facility at Anaval, Tal-Mahuva by
M.P. Shri. Mansinhbhai Patel
Inauguration of “Animal Health
Camp” by Shri.Sudambhai R.
Patel, Vice Chairman, Sumul
Inaugural ceremony of “Animal Care Camp”
by Shri Sudambhai Patel, Vice-Chairman &
Shri. P. R. Patel, MD, Sumul
Dipa Program to raise high yielding milch animals
Calf-Buffalo Identification &
Insurance Programme by Sumul
“Veterinay Care & Infertility Camp”
organised by Sumul at Villeges
Office of Kosadi Dudh Mandali under
“Dudh Ghar” aid programme
Calf Ralley under “Dipa” Program
Milking Machine under “Quality
Improvement” program
Artificial Insemination Activity
Clean Milk Production
Programme
Animal Cooling System under CD programs Bulk Chilling Unit at Society level to
improve Milk Quality
Automatic Milk Collection Station of
Sumul at Society level
Plantation by
Directors, MD &
sumul
employees
Sector Reform
Program

27. Cooperative Focus
 Maximum Return to our Producers
 Developmental Programs
– Organization of new DCS (Village milk co-op soc)
– Milk procurement and milk route transportation
– Milk competition at taluka level and district level.
– Cattle feed competition
– Artificial insemination
– Breed improvement program(DIPA)
– 24 hours mobile veterinary services at door step of producer members (route
and special visit)
– Disease diagnostic laboratory
– Vaccination program for disease prevention at subsidies rate.
– Distribution of balance cattle feed (sumul dan) at no profit no loss basis
– Hybrid fodder seed distribution at subsidies rate.
– Electric chaff cuttersuda at subsidies rateWomen Dairy Co-operative
Leadership Development Programe
– Women seminar
– School Education program
– Film show for Profitable Dairy business at village level
– Monthly bulletin for Milk business [ SUMUL SETU ]

28.  Developmental Programs
– Management committee Member/ Secretary program at DCS
– Educational tour (Chilling centre, SDF ,SUMUL, DAIRYFARM)
– Cattle insurance activity
– Group insurance under Janta personal accident policy
– Automatic milk collection station at subsidise rate
– Bulk milk chilling unit at village level
– Internal consultant development program at village level
– Clean milk production program
– Planning and budgeting program
– Women self help group
– Anemia control program
– Rural sanitation program
– Cow buffalo identification program
– Sector reform program for drinking water at village level
– Dairy Herd Improvement Program Actions (DIPA)
– Disease Preventive Measure Program
– Mineral Mixture & Deficiency Program
– Animal Cooling System for Milk Shed
Cooperative Focus

29.  Technology Upgradation
– Milko Testers, Automatic Milk Collection Units, Connecting with Internet
– Bulk Milk Coolers
 Community Development
– City Development
 Road Deviders Maintenance
 Fountain Development
 Garden Development
– Dairy Visit
 Villages, Institutions, Organisations
– Healthy Baby Contest
– Recipe Contest
– Drawing Contest
– School Education Program
Cooperative Focus

30.  Anemia Control Program
– Mrs Shantiben Rameshbhai Gamit
 Due to this program our work efficiency has been improved, Health is improved,
Hemoglobin increased, Good health of new born children
 Sanitation Program
– Urmilaben Dipakbhai Chaudhari
 Due to this program our Health is improved, now we have Facility
our time is saved, there is saving of money due to good health,
there is safety in comparision to going outside in night
 Education & Literacy Program
– Shilaben Bhangiyaben Gamit
 Due to education knowledge, skill & attitude is improved. Can do
signature and educate childrens, can keep accounting of house &
dairy business, agriculture, Self Confidence developed, broad
vision
Views
PHOTO
PHOTO
PHOTO

31. Customer & Market Focus
 Launching Dairy & Non-Dairy Products from time to time
 Supply Chain Management
– Milk Distribution Agents & Parlors to make products
available at vicinity of houses
– Delivery - 5 Times a Day, Satisfying Customers during
Crisis Situations - Riots & Natural Calamities
– Milk Distribution Transport Network
– Training to Supply Chain people to handle both Product &
Customer
 Customer Relationship Programs
– Partners of Change, Customer Meet & Dairy Visits
– Sumul Healthy Baby Contest & Drawing Contest
– Women in Health Program : Recipe Show, Slogan
Contest, Advertising Contest
– Customer Complaint Management System
– School children program

32. Customer & Market Focus
 Customer Communication
– Field Staff & All Employees
– Agents / Milk Booth Operators & Agents Meeting
 Customer Surveys
– Improving Quality, Services, Know Expectations,
Demand Estimation, Know Brand Image
 Implementing Customer concept of TQM at each level of
Organisation.
 Loans for Agents
 Packaging Redesigning
 Launching Dairy & Non-Dairy Products from time to time
 Milk Price stability since last 2 year
 Website “www.sumuldairy.com” for online product
information & taking order

33. MARKETING ACTIVITY
It is well understood concept that “A product cannot get success untill consumers
involved as partners to it’
Shri. P. R. Patel, MD, Sumul organising “Partners of Change Programme”
Housewives are involved to provide feedback on the different product & its quality
and are made aware with production activity on regular basis
Advertising through Hoarding during Festival Seasons
“Paneer Show” organised for Sumul
Products Promotion at Varachha, Surat
“”Sumul Dairy Cooking Competition” organised
by Sumul at Hotel Holiday Inn, Surat
“”Rasoi Show” organised by Sumul
at Hotel Holiday Inn, Surat
“Sumul Dairy Parlour” & “Snowcap Pizza” appreciated by
customers for its uniqueness
Transport Services for Milk Distribution & Sales
Activity of Sumul always active in all times &
situations

34. MARKETING ACTIVITY
Prize Distribution Ceremony of “Sumul Healthy Baby Competition” and “Sumul Painting Competition”
School students visiting Sumul as a part of their education to know about production activity
School student busy in “Sumul Painting Competition 2001-02” organised by Sumul & Saint Xaviers School
Inauguration Ceremony of
“Sumul Healthy Baby Competition - 2001-02”
Mrs. Mira Ramnivas Addnl. Police Commissioner of
Surat giving prize to winner baby under
“Sumul Healthy Baby Competition - 2001-02”

35. PRODUCTION ACTIVITY

36. Quality & Organisational Focus
 Sumul is doing value addition at each stage in terms of :
 Improving raw milk quality, Controlling microbiological
growth & Improving Product shelf life
– Coordination between CD Development Dept, Chilling Centres,
Marketing, Production & QC
– Undertaking activities like - Clarification, Pasturization,
Standardization, Bacteriological Testing etc
 Process Reengineering undertaken
– for optimizing process & storage temperature
– reduction in Material Handling during manufacturing process &
usage of SS Pipelines & Equipments.
– Technological upgrading of equipment's by incorporating state of
art technology & Automation in certain areas
– CIP through Centralized CIP unit supported by Manual Scrubbing
of Pipelines & Tanks etc.
– Improving MBRT at all levels

37. Quality & Organisational Focus
 Adherence to Standards
– PFA, W&M & NDDB
– ISO 9002 / HACCP & 14001
 Improving Good Manufacturing Practices
 Implemented TQM, KAZIEN, SQC & TPM concept at
all stages.
– Increased Overall Equipment Efficiency (OEE)
 Reduction in Machine Down Time
 Increase in Preventive Maintenance
 Reduction in Leakage, Quality Rejection &
Reprocessing
– Availability of Maintenance Personnel at Floor
– Multi skill development
– Reduction in Utility Consumption

38. Quality & Organisational Focus
 Computerization at each level, Centralized Oracle based
Data Management System for all activities for sharing
information & analyzing it whenever required.
 Employees Development
– Training on Personality Development
– Training on Self Management Leadership (SML)
– Training on Quality Concepts
 Total Quality Management (TQM), Quality Circle,
Small Group Activities, Kaizen, Statistical Quality
Control (SQC)
 Total Productive Maintenance (TPM)
 ISO 9000 / HACCP & ISO 14001
 Vision 2005 Program
 Sponsoring For Higher Education

39. Quality & Organisational Focus
 Promoting Participation in Competition
 Sharing Experiences with other Organizations
 Recognizing & Rewarding Achievements in Programs
 Conducting Regular Meeting & Committees.
 Sharing Information through In-house Magazine
“Sumul Setu”
Awards
 As a result of all these efforts Sumul has been able to
receive many awards in the past years and shall be able to
achieve many more.

40. INTERNATIONAL MILK PRICE
(Producer Price)
6.9
8.35
9.7
10.1
7.7
7.7
8.2
11.98
11.61
10.65
10.3
6.74
0
2
4
6
8
10
12
14
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
YEAR
Rate :
Rs /
Ltr
Inernational
Rate
Gujarat

41. COMPARATIVE : INTERNATIONAL
MILK PRICE WITH SUMUL
9.9
7.7
13.2
22.1
36.5
7.7
11.92
12.62
14.00
8
13.1
12.46
10.44
10.30
14.12
12.68
14.68
10.66
0
5
10
15
20
25
30
35
40
Japan
Switzerland
USA
EU
New
Zealand
Australia
World
India
Gujarat
SUMUL-01-COW
SUMUL-01
BUF
SUMUL-01Avg
SUMUL-02-COW
SUMUL-02
BUF
SUMUL-02Avg
SUMUL-03-COW
SUMUL-03
BUF
SUMUL-03Avg
Rate : Rs / Ltr

42. STATE WISE MILK RATE
11.9
10.710.410.2
9.9
9.8 9.4 9
8.3
9.9
0
2
4
6
8
10
12
Gujarat
AP
Haryana
Punjab
MP
Rajasthan
UP
Maharashtra
Karnataka
India
YEAR

43. TURNOVER
0.41 18.83
78.11
183
353
0
50
100
150
200
250
300
350
400
1970 1980 1990 1995 2001
Turnover(in crores)

44. MILK PROCUREMENT
65,843,837
63,115,586
79,991,951
73,920,017
97,082,536
98,882,959
112,280,311
108,429,871
118,407,060
160,929,736
187,796,293
177,535,980
185,681,310
205,840,280
198,162,669
53,808,434
0
50000000
100000000
150000000
200000000
250000000
300000000
86-
87
87-
88
88-
89
89-
90
90-
91
91-
92
92-
93
93-
94
94-
95
-5-
96
96-
97
97-
98
98-
99
99-
00
00-
01
01-
02
In
Kgs

45. PRICES PAID PER KG FAT
75.75
90.50 91.67 95.67
115.73
128.45 132.46
151.13
176.75179.68
184.67
195.00 199.00202.00 205.00
0
20
40
60
80
100
120
140
160
180
200
87-88 88-89 89-90 90-91 91-92 92-93 93-94 94-95 95-96 96-97 97-98 98-99 99-00 00-01 01-02
Prices Paid per Kg Fat

46. 207.87 220.93
251.91 249.23
0
50
100
150
200
250
300
1998-99 1999-00 2000-01 2001-02
Return in Crores
NET RETURN TO PRODUCERS

47. 204205.00
205546.00
207258
209208
201000
202000
203000
204000
205000
206000
207000
208000
209000
210000
1998-99 1999-00 2000-01 2001-02
No of Members
TOTAL MEMBERS

48. 170000.00
175000.00
180000
185000
160000
165000
170000
175000
180000
185000
1998-99 1999-00 2000-01 2001-02
No of Members
POURER MEMBERS

49. MILK PROCUREMENT VS SALE
-30,000,000.00
20,000,000.00
70,000,000.00
120,000,000.00
170,000,000.00
220,000,000.00
1
9
8
6
-
8
7
1
9
8
7
-
8
8
1
9
8
8
-
8
9
1
9
8
9
-
9
0
1
9
9
0
-
9
1
1
9
9
1
-
9
2
1
9
9
2
-
9
3
1
9
9
3
-
9
4
1
9
9
4
-
9
5
1
9
9
5
-
9
6
1
9
9
6
-
9
7
1
9
9
7
-
9
8
1
9
9
8
-
9
9
1
9
9
9
-
0
0
2
0
0
0
-
0
1
2
0
0
1
-
0
2
Milk procuremet Milk sale

50. PRODUCTION
&
ENGINEERING
ACTIVITIES

51. POUCH FILLING IN IST SHIFT VS IIIRD SHIFT
395000
612920
699341
50000 14516 21071
0
100000
200000
300000
400000
500000
600000
700000
BEFORE
TPM (99-
00) (IST
SHIFT)
AFTER
TPM (01-
02) (IST
SHIFT)
(02-03) (IST
SHIFT)
BEFORE
TPM (IIIRD
SHIFT)
AFTER
TPM (01-
02) (IIIRD
SHIFT)
(02-03)
(IIIRD
SHIFT)
BEFORE
TPM (99-00)
(IST SHIFT)
AFTER TPM
(01-02) (IST
SHIFT)
(02-03) (IST
SHIFT)
BEFORE
TPM (IIIRD
SHIFT)
AFTER TPM
(01-02) (IIIRD
SHIFT)
(02-03) (IIIRD
SHIFT)
Ist Shift :
01-02 => 55.16 % Increase
02-03 => 77.05 % Increase
IIIrd Shift :
01-02 => 70.96 % Reduction
02-03 => 57.86 % Reduction

52. HIGHEST FILLING IN 1ST SHIFT
737489
717636
730199
724370
718123
749189
770498
767790
754239
779716
745718
762849
695000
700000
705000
710000
715000
720000
725000
730000
735000
740000
745000
750000
755000
760000
765000
770000
775000
780000
Highest Filling in Ist Shift
31-Aug-01 1-Sep-01 2-Sep-01 3-Sep-01 4-Sep-01 6-Sep-01 13-Sep-01 14-Sep-01
27-Sep-01 28-Sep-01 1-Oct-01 3-Oct-01 12-Oct-01 13-Oct-01 14-Oct-01 15-Oct-01
1-Nov-01 2-Nov-01 28-Dec-01 16-Jan-02 13-Mar-02 21-Jun-02 24-Jun-02 16-Jul-02
21-Jul-02 4-Aug-02 5-Aug-02 6-Aug-02 10-Aug-02 11-Aug-02 12-Aug-02 13-Aug-02
14-Aug-02 16-Aug-02 17-Aug-02 18-Aug-02 19-Aug-02 20-Aug-02 21-Aug-02 22-Aug-02
23-Aug-02 24-Aug-02 26-Aug-02 28-Aug-02 30-Aug-02 1-Sep-02 4-Sep-02 5-Sep-02
6-Sep-02 11-Sep-02 14-Sep-02 15-Sep-02 17-Sep-02 18-Sep-02 24-Sep-02 25-Sep-02
26-Sep-02 27-Sep-02 28-Sep-02 29-Sep-02
Aug-02
Jul-02
Jun-02
Nov-01
Oct-01
Sep-01
2001-02 2002-03
Sep-02

53. HIGHEST FILLING IN 1ST SHIFT
761144
775949
800062
806796
836426
850556
740000
745000
750000
755000
760000
765000
770000
775000
780000
785000
790000
795000
800000
805000
810000
815000
820000
825000
830000
835000
840000
845000
850000
855000
860000
Highest Filling in Ist Shift
14-Oct-02 20-Oct-02 21-Oct-02 2-Nov-02 8-Nov-02 10-Nov-02 14-Nov-02 22-Nov-02
23-Nov-02 24-Nov-02 25-Nov-02 26-Nov-02 3-Dec-02 4-Dec-02 8-Dec-02 10-Dec-02
12-Dec-02 13-Dec-02 16-Dec-02 17-Dec-02 18-Dec-02 19-Dec-02 20-Dec-02 21-Dec-02
22-Dec-02 23-Dec-02 24-Dec-02 25-Dec-02 26-Dec-02 27-Dec-02 28-Dec-02 29-Dec-02
30-Dec-02 31-Dec-02 1-Jan-03 2-Jan-03 3-Jan-03 4-Jan-03 5-Jan-03 6-Jan-03
7-Jan-03 8-Jan-03 9-Jan-03 10-Jan-03 11-Jan-03 12-Jan-03 13-Jan-03 16-Jan-03
17-Jan-03 18-Jan-03 19-Jan-03 20-Jan-03 21-Jan-03 22-Jan-03 23-Jan-03 24-Jan-03
25-Jan-03 27-Jan-03 28-Jan-03 29-Jan-03 30-Jan-03 31-Jan-03
Oct-02
2002-03
Nov-02 Dec-02
Jan-03
18-Dec-02
28-Jan-03

54. OVERALL EQUIPMENT EFFICIENCY
(OEE) OF POUCH SECTION
48.0
80.0
86.01
45
55
65
75
85
BEFORE TPM (99-00) AFTER TPM (01-02) AFTER TPM (02-03)
O.E.E.
(%)
01-02 => 66.66 % Increase
02-03 => 79.18 % Increase

55. OEE % OF POUCH MACHINES
81.5 81.5 81.3
80.4 81.1
85.26 85.76 85.5
87.86
90.51
93.74 93.24
85.63
70
75
80
85
90
95
Mar-02 Apr-02 May-02 Jun-02 Jul-02 Aug-02 Sep-02 Oct-02 Nov-02 Dec-01 Jan-03 Feb-03 Avg
(12
mth)

56. OEE % TREND OF POUCH MACHINES
57.92 58.59
63.17
59.88
62.79
65.39
67.3
66.09
72.09
69.83 69.63
72.04
79.53
78.15 78.66
80.18 80.26 80.73
81.5
81.57 81.33
80.4 80.89
85.26 85.76 85.5
87.86
90.51
93.74 93.24
62.15
75.72
86.01
55
60
65
70
75
80
85
90
95
100
Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Avg
OEE
(%)
OEE
2000-01
OEE
2001-02
OEE
2002-03

57. MILK POUCH EVENING LEAKAGE % AT DOCK
0.68
0.7 0.71
0.76
0.82
0.67
0.36
0.31
0.22
0.23
0.26
0.22
0.26
0.33
0.29
0.25
0.36
0.26 0.26 0.25
0.23
0.22 0.21
0.23
0.32
0.21
0.29
0.249
0.342
0.272 0.28
0.31
0.58
0.27
0.27
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Avg
2000-
2001
2001-
2002
2002-
2003

58. MILK POUCH MORNING LEAKAGE % AT DOCK
0.71 0.70 0.71
0.79
0.72
0.65
0.26
0.19
0.15
0.18 0.17 0.177
0.20
0.23 0.22
0.30
0.19
0.22 0.21 0.20
0.23 0.22
0.20 0.21 0.2
0.27
0.225
0.1990.211
0.54
0.25
0.21
0.243
0.31
0.231
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Avg
2000-
2001
2001-
2002
2002-
2003

59. AVG LEAKAGE % AT DOCK
0.24 0.25
0.80
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
1.1
BEFORE TPM (99-00) AFTER TPM (01-02) AFTER TPM (02-03)
AVG
LEAKAGE
%
01-02 => 70 % Reduction
02-03 => 69 % Reduction

60. WASTAGE % AT POUCH
MACHINE
1.1
0.25 0.25
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
1.1
1.2
BEFORE TPM (99-00) AFTER TPM (01-02) AFTER TPM (02-03)
WASTAGE
%
01-02 => 77.75 % Reduction
02-03 => 77.75 % Reduction

61. WEIGHT VARIATION IN MILK
POUCH
35
6 6
0
10
20
30
40
BEFORE TPM (99-00) AFTER TPM (01-02) AFTER TPM (02-03)
VARIATION
(IN
GMS)
01-02 => 82.85 % Reduction
02-03 => 82.85 % Reduction

62. MANPOWER ENGAGED IN POUCH SECTION
VS MILK SALE
200 196 186
419.832
450.236
500.038
2.095
2.296
2.687
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
2000-01 2001-02 2002-03
0
100
200
300
400
500
600
Avg No of
Workers
(Per Day)
Avg Milk
Sale
(X1000 ltrs
Per Day)
Ratio : Milk
Sale
(X1000 Ltr)
Per Worker

63. WATER CONSUMPTION VS
MILK HANDLING
33318 22603 18030
666367
452050
360600
16608
16501
18521
0
100000
200000
300000
400000
500000
600000
700000
2000-2001 2001-2002 2002-2003( upto Feb
2003)
15800
16300
16800
17300
17800
18300
18800
Water
Consumption
per month (in
1000 ltrs)
Actual Cost of
water per
month (in Rs.)
Milk Handling
per month (in
1000 ltrs)
Ratio : Water
consumption
vs Milk
Handled (ltr)
2.01
1.37
0.97

64. FUEL CONSUMPTION (NG+FO) VS
MILK HANDLING
136627 144300 119229
1187047
1233699
1166344
16608
16501
18521
0
200000
400000
600000
800000
1000000
1200000
1400000
2000-2001 2001-2002 2002-2003( upto Feb
2003)
15800
16300
16800
17300
17800
18300
18800
Fuel
Consumption
per month
Actual Cost of
fuel per month
(in Rs.)
Milk Handling
per month (in
1000 ltrs)
Ratio : Fuel
Consumption
vs Milk
Handled (in
1000 ltrs)
8.23 8.75
6.44

65. ELECTRICITY CONSUMPTION VS
MILK HANDLING
613886 633436 643277
3257960
3395337
3201598
16608
16501
18521
0
500000
1000000
1500000
2000000
2500000
3000000
3500000
4000000
2000-2001 2001-2002 2002-2003( upto Feb
2003)
15800
16300
16800
17300
17800
18300
18800
Electrical
Consumption
per month
(Units)
Cost of
Electricity
Consumption
per month (in
Rs.)
Milk Handling
per month (in
1000 ltrs)
Ratio :
Electricity
Consumption
vs Milk
Handled (in
1000 ltrs)
36.96
38.39
35.52

66. MILK HANDLING
VS MAINTENANCE COST
1036684 765551 585537
12440202
9186613
6440904
16608
16501
18521
0
2000000
4000000
6000000
8000000
10000000
12000000
14000000
2000-2001 2001-2002 2002-2003( upto Feb
2003)
15800
16300
16800
17300
17800
18300
18800
Maintenance
Expenditure
per month (Rs)
Total
Maintenance
Expenditure
(Rs)
Milk Handling
per month (in
1000 ltrs)
Ratio : Milk
Handled (ltrs)
per Rupee
Maintenance
Expenditure
1.34
1.80
2.88

67. ELECTRIC MOTOR BURNT
HP & EXPENSES
257
1729
290
123
1215.5
140.872
58
192.5
40.856 96 189.8
43.588
0
200
400
600
800
1000
1200
1400
1600
1800
1999-00 2000-01 2001-02 2002-03 - Conv by
monthly avg
Motors
burnt
Total HP
Expendit
ure
(X1000
Rs)
Reduction % (Exp)
From base yr 99-00
51.42 % in 2000-01
85.91 % in 2001-02
84.97 % in 2002-03

68. BEARING CONSUMPTION
31.58
20.20 18.00
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
Jan-Dec 2000 Apr-Mar 2002 Apr-Feb 2003
Avg
Consumption
Per Month (for
expensive
bearings)
Reduction (No’s-%)
From base yr 2000
36.0 % in 2000-2001
67.25 % in 2002-2003

69. SEAL CONSUMPTION
Reduction (No’s-%) From base yr 2000 in 2001-02 & 02-03
FM =63.3, 68.2 % ; EM=56.7, 51.5. % & SS=20.6, 82.9 %
19.42
7.50
4.25
7.13
3.25
3.38
6.18
3.64
0.73
0.00
2.00
4.00
6.00
8.00
10.00
12.00
14.00
16.00
18.00
20.00
AVG 2000 AVG 2001-02 AVG 2002-03
FM
TYPE
EM
TYPE
SS SLIP
RING

70. OEE % OF PROCESS SECTION
71.8
74.1
75.3
78.6
85.8
87.0
86.0 86.0
85 85
81.5
85.0
60.0
65.0
70.0
75.0
80.0
85.0
90.0
Apr-02 May-02 Jun-02 Jul-02 Aug-02 Sep-02 Oct-02 Nov-02 Dec-02 Jan-03 Feb-03 Avg

71. FEED WATER HARDNESS
5
4 4
10
0
2
4
6
8
10
12
2000 2001 2002 2003
FEED
WATER
HARDNESS
(PPM)
60.00 %
Reduction

72. REFRIGERATION SECTION POWER
CONSUMPTION & EFFICIENCY
66.35
68.27
82.16
60
65
70
75
80
85
2000-2001 2001-2002 2002-2003
LTR
/
Unit
Milk
Processed
(Ltr) / per
unit
consumpti
on
01-02 => 2.89 % Increase
02-03 => 23.83 % Increase

73. 250
500
750
1900
500
250
1750
0 0
2500
0 0 0 0 0 0 0 0 0 0 0 0
3000
2500
0
500
1000
1500
2000
2500
3000
JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
2001
2002
2003
AMMONIA CONSUMPTION IN
REFRIGERATION SECTION

74. YIELD COMPARISION FOR
DIFFERENT VARIETY OF MILK
429 439
383
434
380
408
605
661
427
432
0
100
200
300
400
500
600
700
YIELD
(in
number
of
pouches
per
kg
of
film)
PSM 500
ML
SUMULYA
500 ML
DELITE
500 ML
DELITE
200 ML
BUTTER
MILK
2001
2002

75. QUALITY
IMPROVEMENT

76. MILK RETURN VS MILK DISPATCHED
0.14590
0.09929
0.09557
0.00000
0.02000
0.04000
0.06000
0.08000
0.10000
0.12000
0.14000
0.16000
2000-01 2001-02 2002-03
Avg Milk
Return vs
Milk
Dispatche
d (%) per
Month
% Return
01-02 => 31.94 % Reduction
02-03 => 33.54 % Reduction

77. REDUCTION IN MILK RETURN
DUE TO LEAKAGE
0.019954
0.000031
0.00000
0
0.0005
0.001
0.0015
0.002
0.0025
0.003
0.0035
0.004
0.0045
0.005
2000-2001 2001-2002 2002-2003
Avg Milk
Return
due to
leakage
vs Milk
Dispatch
ed (%)
% Return
01-02 => 99.82 % Reduction
02-03 => 100.00% Reduction

78. 0.132
0.130
0.127 0.127
0.1260.126
0.1250.125
0.1270.1270.127
0.1260.1260.1260.1260.1260.126
0.125
0.126
0.127
0.125 0.125
0.126
0.125
0.125
0.120
0.122
0.124
0.126
0.128
0.130
0.132
0.134
J
A
N
F
E
B
M
A
R
A
P
R
M
A
Y
J
U
N
J
U
L
A
U
G
S
E
P
O
C
T
N
O
V
D
E
C
A
v
g
2001
2002
2003
Acidity
(LA)
RAW MILK ACIDITY

79. 7.6
7.18
6.9 6.86
7.06 7.08
7
7.1 7.1
6.7
6.8
6.4 6.4 6.4 6.44
6.3
6.4
6.3
6.4 6.4
7.03
6.67
6.92
6.61
6.40
6.2
6.4
6.6
6.8
7
7.2
7.4
7.6
7.8
J
A
N
F
E
B
M
A
R
A
P
R
M
A
Y
J
U
N
J
U
L
A
U
G
S
E
P
O
C
T
N
O
V
D
E
C
A
v
g
2001
2002
2003
Temperature
*C
RAW MILK TEMPERATURE

80. 0.5
1.02
0.59
1.04 1.03
1.11
1.18 1.18
1.22
1.26
1.13
1.14
0.911
1.01
1.12
1.05
0.54
1.26
1.14
1.104
1.08
1.16
1.26
1.19
0.4
0.5
0.6
0.7
0.8
0.9
1
1.1
1.2
1.3
1.4
J
A
N
F
E
B
M
A
R
A
P
R
M
A
Y
J
U
N
J
U
L
A
U
G
S
E
P
O
C
T
N
O
V
D
E
C
A
v
g
2001
2002
2003
Temperature
*C
RAW MILK MBRT

81. PASTEURIZER MBRT
6.0
7.0 7.0
5.8
6.0
6.2
6.4
6.6
6.8
7.0
7.2
BEFORE TPM (99-00) AFTER TPM (01-02) AFTER TPM (02-03)
MBR
HRS
01-02 => 16.66 % Increase
02-03 => 16.66 % Increase

82. POUCH MBRT
5.5
6.0 6.0
5.0
5.2
5.4
5.6
5.8
6.0
6.2
6.4
BEFORE TPM (99-00) AFTER TPM (01-02) AFTER TPM (02-03)
MBR
HRS
01-02 => 9.0 % Increase
02-03 => 9.0 % Increase

83. MILK REPROCESSING DUE
TO QUALITY REASONS
0.46
2.06
1.89
0.0
0.5
1.0
1.5
2.0
2.5
2000 (Jan-Dec) 2001 (Jan-Dec) 2002 (Jan-Dec)
REPROCESSING
%
2001- 8.32 % Increase
2002- 73.39 % Reduction
Standard upgraded

84. 7.23
7.05
6.82
7.28
6.89
6.39 6.36
6.22
5.97
6.1
6.2
6.56 6.5
6.65
6.17
6.4
6.3 6.24 6.22
5.98
6.04
6.86
6.29
6.01
5.5
5.7
5.9
6.1
6.3
6.5
6.7
6.9
7.1
7.3
7.5
J
A
N
F
E
B
M
A
R
A
P
R
M
A
Y
J
U
N
J
U
L
A
U
G
S
E
P
O
C
T
N
O
V
D
E
C
A
v
g
2001
2002
2003
Temperature
*C PASTURIZED MILK STORAGE
TEMPERATURE

85. 13
8
5
7
6 6
0
6 6
5
3
0
4
2
5
4
6
5
4
5
4
2
4
6
6
5
4
6
0
2
4
6
8
10
12
14
J
A
N
F
E
B
M
A
R
A
P
R
M
A
Y
J
U
N
J
U
L
A
U
G
S
E
P
O
C
T
N
O
V
D
E
C
A
v
g
2001
2002
2003
Frequency
of
Occurance CUSTOMER COMPLAINT FOR WEIGHT
VARIATION

86. CUSTOMER COMPLAINT FOR
GHEE
0.09
0.05
0.006
0.0170.015
0.006
0.0062
0.0056
0.07
0.01
0.027
0.11
0.12
0.13
0.01
0.03
0.1
0.09
0.049
0.03
0.007
0.1
0.04 0.028 0.032
0.021 0.021
0.009 0.006
0
0.02
0.04
0.06
0.08
0.1
0.12
0.14
J
A
N
F
E
B
M
A
R
A
P
R
M
A
Y
J
U
N
J
U
L
A
U
G
S
E
P
O
C
T
N
O
V
D
E
C
A
v
g
2001
2002
2003
%
Complaint

87. CUSTOMER COMPLAINT FOR
PANEER
0.12
0.02
0
0 0 0 0 0
0 0
0.04
0.003
0.015 0.006 0.004 0.01
0
0.13
0.07
0.11
0
0 0 0 0 0 0 0
0
0
0.02
0.04
0.06
0.08
0.1
0.12
0.14
J
A
N
F
E
B
M
A
R
A
P
R
M
A
Y
J
U
N
J
U
L
A
U
G
S
E
P
O
C
T
N
O
V
D
E
C
A
v
g
2001
2002
2003
%
Complaint

88. PERFORMANCE OF
BUTTER MILK BATCHES
0 0 0
0.1
0.61
0 0
0.85
0
0.36
0
1.84
0.08
0.86
0.74
0
0 0
0.76
0.07
0.09
0 0 0 0 0 0 0
0.85
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
2
J
A
N
F
E
B
M
A
R
A
P
R
M
A
Y
J
U
N
J
U
L
A
U
G
S
E
P
O
C
T
N
O
V
D
E
C
A
v
g
2001
2002
2003
%
Rejection

89. PERFORMANCE OF
JEERA / SWEET CHHAS BATCHES
0 0
2.5
0 0.007 0
2.5
0.52
3.68
0
0 0
0
0
0
0
0
0
0
0
1.3
0
0
0 0
0.32
0
0.5
1
1.5
2
2.5
3
3.5
4
J
A
N
F
E
B
M
A
R
A
P
R
M
A
Y
J
U
N
J
U
L
A
U
G
S
E
P
O
C
T
N
O
V
D
E
C
A
v
g
2001
2002
2003
%
Rejection

90. CUSTOMER COMPLAINT FOR FLAVOURED
MILK (JOME)
0.07
0 0 0
0
0.11
0 0 0
0.02
0
0.01
0.009
0.005
0.012
0.097
0.005
0
0.01
0 0 0 0
0 0
0
0
0.02
0.04
0.06
0.08
0.1
0.12
J
A
N
F
E
B
M
A
R
A
P
R
M
A
Y
J
U
N
J
U
L
A
U
G
S
E
P
O
C
T
N
O
V
D
E
C
A
v
g
2001
2002
2003
%
Complaint

91. CUSTOMER COMPLAINT FOR
SWEET (PEDA)
0 0 0 0
0 0 0 0 0
0.02
0.19
0
0
0 0 0
0
0 0 0 0 0 0 0
0
0.02
0.04
0.06
0.08
0.1
0.12
0.14
0.16
0.18
0.2
J
A
N
F
E
B
M
A
R
A
P
R
M
A
Y
J
U
N
J
U
L
A
U
G
S
E
P
O
C
T
N
O
V
D
E
C
A
v
g
2001
2002
2003
%
Complaint

92. CUSTOMER COMPLAINT FOR SHRIKHAND
0.24
0.75
0.92
0.32
0.23
0.35
0.314
0.12 0.11
0
0.32
0.22
0.14
0
0
0.14
0.12
0.27
0.18
0.0045
0.16
0.187
0.11 0.11
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
J
A
N
F
E
B
M
A
R
A
P
R
M
A
Y
J
U
N
J
U
L
A
U
G
S
E
P
O
C
T
N
O
V
D
E
C
A
v
g
2001
2002
2003
%
Complaint

93. BCU MILK TEMPERATURE
8.3
8.5
8.8
6.9
5.8
5.6 5.7
5.5
5.3
5.6 5.5 5.4 5.5
5.4
5.56
6.5
5.3
5.6
6.1
5.5
5.7
5.4
5.6
5.6
5.7
5.3
5.2 5.3
5.48
4.5
5
5.5
6
6.5
7
7.5
8
8.5
J
A
N
F
E
B
M
A
R
A
P
R
M
A
Y
J
U
N
J
U
L
A
U
G
S
E
P
O
C
T
N
O
V
D
E
C
A
V
G
2001
2002
2003
*
Centigrade

94. BCU MILK ACIDITY
0.131
0.133
0.131
0.126
0.122
0.124
0.125
0.123
0.125
0.124 0.124
0.123
0.13
0.123
0.133
0.127
0.128
0.125
0.125
0.123
0.124
0.126 0.126 0.126
0.125
0.124
0.123
0.123
0.123
0.12
0.125
0.13
0.135
0.14
JA
N
FEB
M
A
R
A
PR
M
A
Y
JU
N
JU
L
A
U
G
SEP
O
C
T
N
O
V
D
EC
A
VG
2001
2002
2003
Acidity
(%)
LA

95. BCU MILK MBRT
2.08
1.22
2.04
2.4
2.48
2.57
3.16 3.13
2.24
2.35
3.09 3.1
3.13
2.45
2.42
2.26
2.48
2.36
2.37
2.29
2.22
2.32
2.35
2.57
3.23
2.31
2.44
2.54
3.04
1
1.5
2
2.5
3
3.5
J
A
N
F
E
B
M
A
R
A
P
R
M
A
Y
J
U
N
J
U
L
A
U
G
S
E
P
O
C
T
N
O
V
D
E
C
A
V
G
2001 2002 2003
HRS

96. CUSTOMER
FOCUS

97. DEMAND VS SALE
400
282
425
294
450
326
475
341
500
356
520
353
545
380
571
390
590
397
200
300
400
500
600
(in
1000
ltrs)
1993-
94
1994-
95
1995-
96
1996-
97
1997-
98
1998-
99
1999-
00
2000-
01
2001-
02
Demand Sale

98. NUMBER OF AGENTS
548
603 636
716
764
875
955
1111
1263
1370
1420
1470
1520
1700
400
600
800
1000
1200
1400
1600
1800
1989-90
1990-91
1991-92
1992-93
1993-94
1994-95
1995-96
1996-97
1997-98
1998-99
1999-00
2000-01
2001-02
2002-03

99. SALE (LITERS)
184071
203391
212225
222616
246378
253334
252052
269350
295710
327360
341690
356000
353318
379382
390433
397318
431181
100000
150000
200000
250000
300000
350000
400000
450000
86-87
88-89
90-91
92-93
94-95
96-97
98-99
00-01
02-03
Sale
Per
Day

100. STANDARDIZED MILK SALE
269 270
288
285
282
261
266 265
254
261
240
250
260
270
280
290
300
93-
94
94-
95
95-
96
96-
97
97-
98
98-
99
99-
00
00-
01
01-
02
02-
03
Sale
Per
Day
(‘000
ltr)

101. SKIMMED MILK SALE
5
8
5 5
7 7
6
5
8
10.9
0
2
4
6
8
10
93-
94
94-
95
95-
96
96-
97
97-
98
98-
99
99-
00
00-
01
01-
02
02-
03
Sale
Per
Day
(‘000
ltr)

102. SUMULYA MILK SALE
6
10
14
21
32
52
68 65 66
73
0
10
20
30
40
50
60
70
80
93-
94
94-
95
95-
96
96-
97
97-
98
98-
99
99-
00
00-
01
01-
02
02-
03
Sale
Per
Day
(‘000
ltr)

103. DELITE (TONED) MILK SALE
3 6
19
30
35 33
39
56
69
85
0
10
20
30
40
50
60
70
80
93-
94
94-
95
95-
96
96-
97
97-
98
98-
99
99-
00
00-
01
01-
02
02-
03
Sale
Per
Day
(‘000
ltr)

104. FLAVOURED MILK SALE
113.45
110.32
107.61
117.13
90
95
100
105
110
115
120
98-99 99-00 00-01 01-02
Total
Sale
(‘000
ltr)

105. JOME
(FLAVOURED MILK) SALE
(PER MONTH)
10420
9345
8386 8189
9762
14500
0
2000
4000
6000
8000
10000
12000
14000
16000
97-98 98-99 99-00 00-01 '01-02 '02-03
Avg
Sale
Per
Month
(‘LTR)

106. GHEE SALE
308.46 347.54
506.43
1396
0
200
400
600
800
1000
1200
1400
98-99 99-00 00-01 01-02
Total
Sale
(‘000
KG)

107. GHEE SALE
(PER MONTH)
29952 25288 28963
45682
116169
173099
0
20000
40000
60000
80000
100000
120000
140000
160000
180000
97-98 98-99 99-00 00-01 '01-02 '02-03
Avg
Sale
Per
Month
(‘KG)

108. PANEER SALE
40.09
46.10
58.08
72.30
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
98-99 99-00 00-01 01-02
Total
Sale
(‘000
KG)

109. PANEER SALE
(PER MONTH)
2607
3327
3843
6106
6463
7627
0
1000
2000
3000
4000
5000
6000
7000
8000
97-98 98-99 99-00 00-01 '01-02 '02-03
Avg
Sale
Per
Month
(‘KG)

110. SWEET SALE
24.38
30.00
42.00
49.42
0.00
10.00
20.00
30.00
40.00
50.00
60.00
98-99 99-00 00-01 01-02
Total
Sale
(‘000
KG)

111. SWEET SALE
(PER MONTH)
2132 1912
2437
3510
3986
7201
0
1000
2000
3000
4000
5000
6000
7000
8000
97-98 98-99 99-00 00-01 '01-02 '02-03
Avg
Sale
Per
Month
(‘KG)

112. SHRIKHAND SALE
28.87
49.14
62.04
70.59
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
98-99 99-00 00-01 01-02
Total
Sale
(‘000
KG)

113. SHRIKHAND SALE
(PER MONTH)
1256
2524
3556
5184
5531
6035
0
1000
2000
3000
4000
5000
6000
7000
97-98 98-99 99-00 00-01 '01-02 '02-03
Avg
Sale
Per
Month
(‘KG)

114. PARTICIPANTS OF
HEALTHY BABY CONTEST
640
720
847
1010
750
1010 1021 1033 1000
1138
0
200
400
600
800
1000
1200
92-9393-9494-9595-9696-9797-9898-9999-00 00-01 '01-
02
No of Participants

115. PERFORMANCE OF
CATTLE FEED PLANT &
CHILLING CENTRES

116. PRODUCTION IMPROVEMENT AT CATTLE
FEED PLANT, CHALTHAN
6308
6621
7035
5800
6000
6200
6400
6600
6800
7000
7200
AVERAGE PRODUCTION (MT) PER
MONTH
1999-2000 2000-2001 2001-2002
 TPM WAS
IMPLEMENTED AT
SDF CHALTHAN IN
NOVEMBER-2000.
11.52 %
Increase 1999->2002

117. PRODUCTION IMPROVEMENT AT CATTLE
FEED PLANT, CHALTHAN
218 227
246
109.0 113.5123.0
0
50
100
150
200
250
PRODUCTION (MT) PER
DAY
CAPACITY UTILIZATION
(%)
1999-2000 2000-2001 2001-2002
INSTALLED CAPACITY OF PLANT IS 200 MT PER DAY

118. 10
7
4.5
12
9
6.5
0
2
4
6
8
10
12
MINIMUM TEMP MAXIMUM TEMP
1999-2000
2000-2001
2001-2002
CHILLED MILK TEMPERATURE OF BCC AT
THE TIME OF RECEIVING AT SUMUL
IN * C

119. 0.59 0.56
0.45
0
0.1
0.2
0.3
0.4
0.5
0.6
%SOUR+CURD
1999-2000
2000-2001
2001-2002
YEAR WISE COMPARISION OF
SOUR+COURD % VS TOTAL MILK RECEIVED
AT BCC
IN %

120. 5302
3075
1535
0
1000
2000
3000
4000
5000
6000
AVG EXPENDITURE (RS) PER MONTH
1999-2000
2000-2001
2001-2002
IN * C
REVINDING & OVERHAULING CHARGES FOR
MOTORS OF BCC
Reduction %
base yr 99-00
42.0% in yr 2000-01
71.0% in yr 2000-02

121. 14.90
13.45
12.50
13.00
13.50
14.00
14.50
15.00
COST (PAISA) PER LITRE OF MILK
2000-2001
2001-2002
IN PAISA
TOTAL UTILITY EXPENDITURE OF
NPCC
9.73 %
Reduction

122. MILK HANDLING VS MAINTENANCE
EXPENDITURE OF NPCC
88.42
119.6
0
20
40
60
80
100
120
MILK HANDLED (LTRS) PER RUPEE
MAINTENANCE EXPENDITURE
2000-2001 2001-2002
35.26 %
Increase

123. EMPLOYEE
DEVELOPMENT

124. EMPLOYEES RECOGNISED FOR
OUTSTANDING PERFORMANCE
53
94
122
0
20
40
60
80
100
120
140
1999-00 2000-01 2001-02
No of Employees
given Awards /
Certificates for
outstanding
performance as
individuals / team

125. TRAINING HOURS UNDER ISO 9002 / HACCP
403
694
1130
300
400
500
600
700
800
900
1000
1100
1200
2000-01 2001-02 2002-03
Avg
Hrs
/
Month
Against Minimum
Standard 400 hrs / pm
under ISO 9002 / HACCP

126. TRAINING HOURS UNDER ISO 14001
677
1198
300
400
500
600
700
800
900
1000
1100
1200
2001-02 2002-03
Avg
Hrs
/
Month

127. ABSENTIEESM
5.48
5.30 5.15
4.38
5.09 4.98
4.13
0.00
1.00
2.00
3.00
4.00
5.00
6.00
1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03
Abseentism (%)

128. INDIRECT BENEFITS TO THE
ORGANISATION & TO THE EMPLOYEES
 EMPLOYEES HAVE SHOULDERED MORE
RESPONSIBILITIES.
 EMPLOYEES HAVE BECOME MORE POSITIVE.
 THEY NOT ONLY POINT THE PROBLEM, BUT TAKE
PART IN SOLVING IT ALSO.
 INTERNAL & EXTERNAL CUSTOMERS SATISFACTION IS
IMPROVED.
 ORGANISATION HAS BECOME MORE FLEXIBLE ONE.
 COST CUTTING HAS BECOME A CONTINUEOUS
PROCESS.
 ABSEENTISM HAS REDUCED.
 DISCIPLINE HAS IMPROVED RESULTING IN NO NEED
TO ISSUE WARNINING LETTERS.
 EMPLOYEES ARE MORE SATISFIED.

129. INDIRECT BENEFITS TO THE
ORGANISATION & TO THE EMPLOYEES
 MORE DELEGATION TO LOWER LEVELS.
 BETTER WORK DISCIPLINE.
 CLEANER WORK PLACE.
 ENTHUSIASM IN EMPLOYEES INCREASED.
 PREPARED TO TAKE UP CHALLENGING JOBS.
 CHANGE IN HABITS AMONG EMPLOYEES.
 SUPERVISORS LEARNING THE ART OF MANAGING.
 PROBLEMS FROM NON-MANUFACTURING
DEPARTMENTS ARE REDUCING.

130. FUTURE OBJECTIVE OF
SUMUL
The Sumul Dairy shall provide
proper Nutrition and Good Health
to its customers in addition to
achieving customer delight

131. Achievements
Particulars Previous
Data
Results
/Current Data
Pouch Filling
Avg.
3,96,000
pouches
6,30,000
pouches(highest
7,37,489)
Avg. Leakage
on Dock
0.7% 0.1%
Avg. Pouch/Kg
film
419 per kg 442 per kg
Avg. OEE 48 79.53
Motor Burnout 14 per
month(165/ye
ar)
4 per
month(41/year)
Reduction in
Maintenance
cost
Rs.1,06,23,93
8
31,06,927(saved
7,51,7010.93) in
cr.

132. Achievements
Electricity
Units/Day
9395 6489(Saved 45%)
Water
Consumption
34,330
ltrs/month
18,730/month till
date
Leakage (Ghee) 0.4% 0.01%
Milk Pouring
Capacity at NPCC
24,446.64/hour 34,200 ltrs/Hour
Reduce Acidity at
NPCC
0.131% 0.123%
AutoGarage(Trave
led KM)
5,33,278 km 5,16,200
km(Reduction by
17,000 km i.e.3.3%)
Cattle Feed Plant
increase in
production
6685 MT
/Month
8098 MT/Month
(Increase by
21.14%)
MBRT(Shelf Life) 6.0 Hrs 7.0 hrs
Previous Data Achievements

133. Achievements
Boiler water
TDS
4142 2150(92.65%
reduced)
Mkt.Return
Complaint
87642ltrs 45356Ltrs.(%improve
ment 92 %)
Plastic Pouch
waste
1.1% 0.25%
Weight
Variation
35 gm/pouch 6 gm/pouch
Customer
Complaint in
Flavored Milk
3.87% 0.09%
Customer
Complaint in
GHEE
0.29% 0.13%
Customer
Comp.in
0.3 0.007

134. Achievements
Milk
Reprocessing
3.5% 1.0%
Furnase Oil
Cons.
Rs.
17,57,666
Rs.12,31,498(41%
saved)
Bearing
Cons./yearly
399 130
Reduce Seal
Cons
233 57
Sweet Section-
Fuel Cons
314/100
ltrs
185/100 ltrs
Milk Returns-
sales SGA
61224
ltrs(0.33
% of
sales)
9629(0.006% of
sales)
Stationary Cons
in Sales
131400
papers
56575(Saved by
57%)

135. THANK YOU