quarry management system qms of tamin
TRANSCRIPT
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
Agenda
• About TAMIN
• Key Issues and Challenges Faced
• E-Governance Interventions Implemented
• Benefits Realized
• Future Directions
• Conclusion and SummaryQuarry Colombo Zubrana
About TAMIN
• Established in April 1978, wholly ownedby the Government of Tamil Nadu.
• Workforce of 1311 personnel includingAdministrative, Technical and Workers(Skilled, Semi-skilled, etc.)
• Exploits, processes and markets rawgranite blocks and granite value addedproducts
• Processes and markets major mineralssuch as Graphite, Silica Sand,Vermiculite, Limestone and Quartz &Feldspar
• Mines, quarries, divisional offices andfactories are spread over in variousparts 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
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
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
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
E-Governance Initiative
ImplementedPlatform 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
E-Governance Initiative
ImplementedSoftware 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
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
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
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
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.
Benefits RealizedKey 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.
Benefits RealizedSystem 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
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]
Sales, Export Sales and
Profit (Before Tax) Growth Data
Sales Turnover Export Sales Profit before tax
Be
fore
QM
S
Afte
r
QM
S
Benefits RealizedKey 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
Benefits RealizedAdditional 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.
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
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
Annexure
E-Governance Software Reports – Screen Prints
Quartz FeldsparRaw Vermiculite Exfoliated Vermiculite
Limestone Silica Sand Graphite
Major Minerals quarried and processed by TAMIN
SALES TURNOVER(Rs. in Lakhs)
1 24 69 98 1682424075928301175
1072
1422
1873
2606
3578
4020
4008
3436
3132
4070
5317
6651
6670
6705
8002
9021
10015
10991
101479389
10505
11041
10222
10091
12223
18887
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
20000
EXPORT SALES(Rs. in Lakhs)
0 21 59 85 147221
328453
695
999942
1326
1781
2507
3404
3822 3765
3081
23192474
2745
2492
2870
22052152
1233
17621866
672
217355
281124108
1623
4581
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
PROFIT BEFORE TAX(Rs. in Lakhs)
-8 6 11 14 28 28 45135154
215229
593
929
1622
1954
2151
1529
267
101
725
985
753
1127
623
370397
521
381427
258
101 67 69 78
351
2469
-500
0
500
1000
1500
2000
2500
3000
24
SALES – BLACK GRANITE(Rs. in Lakhs)
0 20 44 65 101167222325522
685541
9001074
908
1579
1624
1634
837
13
2273
2188
2950
28112437
2814
2894
3131
3642
3474
4538
3873
3862
4462
4513
5240
9107
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
2
5
SALES – LIMESTONE(Rs. in Lakhs)
0 2 3 5 2 849
99 86 11960 38 30 17 29 35 38 22 0
129182 155 173 191
12562 76
152 151 157
291 260
746
429
2240
2862
0
500
1000
1500
2000
2500
3000
3500
26
SALES – EXFOLIATED VERMICULITE(Rs. in Thousands)
9 0 1 1 10 27 52 16 22 230 293631
1157
1197
1119
1823
2306
1851
2261
3923
3972
4578
5238
6391
83089348
9593
12413
11047
12543
18220
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
20000
27
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
SALES – INDIAN STANDARD SAND(Rs. in Lakhs)
0 0 0 0 0 016 20 24 28 31 29 31 29
50 42 50 56 61 61 67 6783 83 83 85
97 94
121136
192203
244
346
457
613
0
100
200
300
400
500
600
700
29
PRODUCTION – BLACK GRANITE(Quantity in Cubic Metre)
17931
2044
1787
1356
26303579
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
PRODUCTION – LIMESTONE(Quantity in Metric tonne)
5536
11438
120148240
69917772
74154
144563
122262
152242
74512
45136
27041
19492
23201
22301
2255115900
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
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
11021230
1331
1596
1951
1765
1458
1855
14171491
1687
1921
1603
2154
1697
1373
2201
0
500
1000
1500
2000
2500
32
PRODUCTION – SILICA SAND(Quantity in Metric tonne)
45 75
1584
3709
7231
11795
3238
113
568352 480 609
359 312
824 946710
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
PRODUCTION – GRAPHITE ORE(Quantity in Metric tonne)
101
1091
959
11361926
2029
3484
3274
2653550
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
PRODUCTION – EXFOLIATED VERMICULITE(Quantity in Metric tonne)
6 3 235 19 10 10
91 111
255
400408
299
545
671
436
464
758703
880
961
1054
1234
13351355
1680
1334
1218
1752
0
200
400
600
800
1000
1200
1400
1600
1800
35
PRODUCTION – INDIAN STANDARD SAND(Quantity in Metric tonne)
658782
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
Daily Reports for reviewDivision / 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
Daily Reports for reviewTop 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
Daily Reports for reviewNon-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.
Daily Reports for reviewQuarry daily requirements
The above statement is helpful to take immediate action for procurement of materials.
Daily Reports for reviewMine-wise Performance (Major Minerals)
The above statement is helpful to know the stock details, production & sales
performance, pending supply details etc.
MACHINERY PERFORMANCE ReportDaily machine / Vehicle wise performance, utilized man power,
utilized consumables