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

RECOVERY ReportQuarry-wise recovery percentage report

PERFORMANCE Analysis Report (AUTO GENERATED)

Task Manager - Discussion Board

Proposals – Discussion Board

Pending Proposals

Thank You!

Granite Processing Unit at Melur, Tamil Nadu