computer applications in aavin - information and library network...
TRANSCRIPT
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CHAPTER 5
COMPUTER APPLICATIONS IN AAVIN
5.1 AAVIN COMPUTERIZATION INITIATIVE
Aavin had a tie up with the Rajasthan Electronics & Instruments Ltd.
(REIL) for its computerization initiative. REIL has a prominent place amongst the
electronics industry of Rajasthan. The company is a joint venture between the
Government of India and the Government of Rajasthan, through their respective
institutions. The area of business extends to manufacturing and marketing of
electronic products/ services in the following areas: a) Agro-Dairy Sector b) Solar
Photovoltaic Sector c) Industrial Electronics Sector and d) Information
Technology. The REIL has successfully integrated the products into a more
versatile system, developed in-house through its own development efforts, called
the Milk Collection Station. The Tamil Nadu Milk Marketing Federation first made
an order to purchase the REIL product in the year 2008-09 and subsequently
purchased 7 Milkoscan Minor during the year 2010-11. REIL has entered into an
agreement with FOSS, Denmark for high end process automation solutions,
which are based on Infra Red, near Infra Red, Flowcytometry and Laser Optics
technologies. The Company shall leverage it country-wide sales-and-support
network to supply and support these solutions, and sustain its leadership in
Indian Dairy business. The offered solution caters to the following
requirements. a) Dairy Herd management b) Dairy Farm management c) Milk
Analysis management d) Management of Hygiene quality of Milk and Milk
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products. The REIL Products and Milk Collection Station are mentioned in the
following table 5.1 and 5.2.
TABLE 5.1 REIL PRODUCTS FOR DAIRY OPERATIONS
Central Milk Testing
Dairy
Milko scan FT+
Milko Scan FT 6000
Milko scan FT1
Milko Scan Minor
Direct Contact Analyser
Fossomatic FC
Combi Foss 5000 kit
Milko scan FT2
XDS Process Analytics
XDS Lab Rapid Content Analyser
Combi Foss 6000 kit
Bacto Scan FC
Food scan Versatile Dairy Analyser
Process Analytics Dairy
BactoScan FC 50 Semi Automatic
Process Scan FT
Routine Dairy Analyser
InfraXact Dairy Ssystems
Source: REIL
TABLE 5.2 REIL’S MILK COLLECTION STATION
S. No Product Applications
1. Electronic Milk Tester For measurement of % Fat content in Milk at Village Milk Cooperative Societies.
2. Milko Scan Total Milk quality parameter analysis for Dairies
3. Automatic Milk Collection Station
For fair & prompt payment to farmers at Village Milk Cooperative Societies
4. DP-EMT Low Cost version of Milk Collection Station for small village Milk Cooperatives Societies
5. PC-MCS Personal Computer based version of Milk Collection Station with accounting facility
6. Smart Card based PC Milk Collection Station
For fair & prompt payment to farmers at Village Milk Cooperative Societies
7. Raw Milk Reception Dock Network Automation
Process Automation of Raw Milk Reception Docks at Dairies
8. Raw Milk Reception Dock Sample Automation
Milk sample collection and movement automation at Raw Milk Reception Dock
Source: REIL
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In the following paragraphs a brief account on the Electronic Milk Tester,
Milko Scan, Automatic Milk Collection Station, DP-EMT, PC-MCS, Smart Card
based PC Milk Collection Station, Raw Milk Reception Dock Network
Automation, Raw Milk Reception Dock Sample Automation of the REIL is given.
5.1.1 Electronic Milk Tester
Electronic Milk Tester has been adopted as an essential instrument for
measurement of milk fat. Percentage of fat content is displayed quickly and
accurately on a digital readout. Several thousand small/large Dairies and Village
Milk Collection Centers are being benefited with its use. Electronic Milk Tester
works on the principle of photometric measurement of light scattered by the fat
globules present in the milk sample. The measuring procedure follows the
conventional system of dilution, mixing, homogenization and photometric
measurement.
5.1.2 Milko Scan
Milko-Scan 133-B is the latest microprocessor controlled instrument for the
determination of Fat, Protein, Lactose, SNF & Total Solids in Milk and Dairy
products like Sweet cream, Ice cream mix, Yoghurt, cottage cheese, Whey, Hard
Cheese, Sweetened condensed milk & Skim milk. A patented 'B' Filter is
specially designed to measure the Fat content in raw milk regardless of cattle
breed, change in feed composition & seasonal variations, all year round. Another
advantage of the 'B' filter is its high accuracy in measuring the constituents if
storage milk products like Ice cream mix, Fat filled milk powders and infant
formula.
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Milko-scan works on the principle of Infrared Spectrophotometer. The infrared
energy produced by a wide range source is filtered through IR filters of specific
wavelengths and focused through the samples under test. This energy passes
through the samples and strikes a detector which converts it into a
corresponding electrical signal. This signal after amplification and certain
corrections is processed by an microprocessor to be displayed on the LCD panel.
5.1.3 Milk Collection Station
The Milk Collection Station is a specially designed, integrated unit, which
combines the several functions of a milk collection centre. It measures the
weight, fat content and gives the price of the milk brought in by each producer.
The equipment is particularly useful for the milk cooperatives / milk collection
centres as it can also maintain a summary of milk supplied. This state of the art
equipment operates both on battery and mains and is able to process and record
120-150 milk collection entries per hour. An Electronic Milk Weighing Unit, the
Electronic Milk Tester and Data Processor Unit is main components of the
system. The membership codes of individual members are entered automatically
by member identity card / manually by an electronic key-board.
5.1.4 Data Processor Electronic Milk Tester (DPEMT)
Data Processor Electronic Milk Tester (DPEMT) comprises of two main units, an
Electronic Milk Tester and a Personal Computer. It measures the fat content of
the milk. The membership codes of individual members are entered manually by
a keyboard. The weight can be entered either manually or captured
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automatically. If a Milk Weighing System is connected to the unit it gives the
printout of the price of the milk brought in by each producer.
5.1.5 PC based Milk Collection Station
PC based Milk Collection Station is a specially designed integrated unit, which is
a combination of several units viz; the AZ Electronic Milk Tester, Milk Weighing
System and Personal Computer with 80 column printer. It measures the weight,
fat content and gives the printout of payment slip to the supplier of milk in each
shift. The system also facilitates storing ten days/monthly/yearly data and printing
of cumulative summary of shift as and when needed. This state of art equipment
is able to perform120-150 operation in an hour. The sequence of operation
requires pouring of milk in a weighing container, collection of milk sample at the
time of pouring, entering the member's code through keyboard, measuring of fat
content, and calculation of payment and printout of slips.
5.1.6 Smart PC Based Milk Collection Station
The Smart PC Based Milk Collection Station is specially designed integrated
system, which is a combination of several units viz; AZ Electronic Milk Tester,
Milk Weighing System, Personal Computer with smart card reader / writer and
80-column Printer. It is integrated with software support for milk collection and
Society Accounts Management. The system is suitable for instant weighing of the
Milk, measurement of Fat content and calculating the amount payable to the
member based on Fat & Weight. The smart card serves the purpose of member
identification and acts as an Electronic Pass Book for the member wherein
his/her milk transaction data is stored. The system can also be used later for
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maintaining the complete records of the collection centre together with details of
all transactions of the village co-operative society. This system can perform 120-
150 operations in an hour. The sequence of operation require, insertion of smart
card, pouring of milk in a weighing container, collection of milk sample at the time
of pouring, measuring of fat content, calculation of payment and printing of
payment slip. The Exhibits represents the pictorial representation of the device in
the following page.
5.1.7 Raw Milk Reception Dock
Raw Milk Reception Dock (RMRD) is the primary point of liquid milk entry in
dairy. It is specifically meant for the reception of milk brought in cans, from
villages located over a wide area. It is different from the bulk milk collection
system, which are also in operation in these dairies. The collection process starts
from the villages, groups of which are assigned to distinct Milk Truck Routes.
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EXHIBIT 1 RMRD
EXHIBIT 2 REIL DEVICE
The milk cans from individual villages of many such routes are unloaded at the
RMRD, after which the milk is weighed (EWU) and tested (EMT or Milko-Scan)
separately to issue a milk receipt statement (Hardcopy) according to the
measured parameters during the daily shift. The picture of the Raw Milk
Reception Dock is given below. Table 5.3 is given the details about the REIL
products implementation by Aavin..
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Table 5.3 REIL PRODUCTS AND AAVIN IMPLEMENTATION
Si. No Product Applications Implemented in AAVIN
1. Electronic Milk Tester Used for testing in most of the societies
2. Milko Scan Used for testing in societies who are providing rates based on testing
3. Automatic Milk Collection Station
Installed but not properly utilized.
4. DP-EMT Not Installed in none of the societies
5. PC-MCS Installed but not fully functional
6. Smart Card based PC Milk Collection Station
Not Implemented
7. Raw Milk Reception Dock Network Automation
Exclusively for testing in Dairies, most of the features are not used.
8. Raw Milk Reception Dock Sample Automation
Functions are partially used. Mainly for testing the milk, most of the features are not used.
5.2 REQUIREMENT AND UTILITY OF COMPUTER APPLICATIONS IN AAVIN In this section the researcher describes the requirement and utility of
computer applications at all levels of the Aavin Dairy Cooperatives and also
compare the Aavin computer application initiatives with Amul Computer
application initiatives.
5.2.1 Requirement and Utility of Computer Application at the Milk Producers Cooperative Society Level: Regarding the Village Milk Co-operative Societies, at village level, a total number
of 9,231 Milk Producers’ Co-operative Societies are functioning in Tamil Nadu,
which includes 1,491 Milk Producers’ Women Co-operative Societies. About 62
Milk consumer Co-operative Societies are also functioning in the State to cater to
the need of the milk consumers. There are 4.19 lakh milk producers now pouring
milk to the societies. The Members of Dairy Co-operative Societies are paid
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dividend for their share capital, bonus and patronage rebate when the society
earns profit and additional price for the quantity of milk poured.
Milk Producers Cooperative Society is the collecting hub of milk from the
producers. The Collection of milk is done from the members of the society and it
checked with the quantity and the quality factors of the milk. The Federation has
started implementing the Automatic Milk Collections Centers, but the MPCS have
not started using them effectively in the region of Aavin, Tiruchy.
The procurement of milk is done from the members of the milk producer’s
cooperative society twice a day in the morning and in the evening. Member is a
registered person of a cooperative society. He/she pays a nominal fee to the
society and agrees to the rules and regulations of the cooperative society. The
Milk Producers cooperative society procures milk only from the members. Being
a member, he gets the benefit of getting the incentives and bonus once in a year.
Procurement of the milk will be done twice a day. Where ever the computer
application has been implemented, a module is available to collect the
information about the members and his socio-economic details.
The factors which decide the quality of the milk are LR, Temperature, FAT and
SNF reading. The process involved in the collection of milk are : when the
members of the society visit a MPCS to sell their milk, the quantity of the milk will
be intimated to the members immediately, where a small sample of the members
milk will be collected for finding out the quality. After the collection is over, the
members sample will be evaluated for the quality factor in the absence of the
member. The AAVIN has defined a rate chart for the milk collected and it will vary
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from time to time based on the economic situation and demand of the members
over a period of time. Annexure 15 shown the rate chart for the cow milk, the rate
offered to the members based on the quality of the milk he sold to the society.
Annexure 16 shown the rate chart for the buffalo milk. After the LR, Temperature,
Fat and SNF defined for the particular sample of the milk collected from the
member. The rate for the sample is multiplied with the quantity of the milk
supplied. In the Milk Producers Cooperative society where there is no computer,
this process is done in a manual calculation which is a time consuming process.
In the societies where there is availability of computers, the details of LR,
Temperature and FAT were fed in to the corresponding member number. Once
the factor has been entered, based on the LR, Temperature and the FAT, the
Quality factor SNF is calculated by computer application.
After the calculation of the quality the data are recorded in a book to calculate the
amount to disperse once in 15 days. The details of the individual like member
number, quantity of milk given, LR, Temperature, Fat, SNF, rate per litre and
amount for the quantity are recorded twice a day. A classification of milk based
on the milch animal, cow/buffalo, is also recorded separately. This record is
called “Kolmuthal Pathivedu” In the computerized milk producers’ cooperative
society, the procurement details are recorded once the information of the
individual details are entered in to the system. After the collection of milk and
recording it to the corresponding books, the quality of the total procurement will
be evaluated and overall quality of the milk procured will be registered.
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The milk procured will be dispatched to the Milk Producers Cooperative Union by
the transportation facility provided by the Milk Producers Cooperative Union. The
payment for the milk sold from the milk producer’s cooperative society to the milk
producers cooperative union will 0.50 paise more for a litre. The Milk Producers
cooperative union holds 0.10 paise for the administrative expense and will give
back 0.40 paise per litre milk sold from milk producer’s cooperative union.
Another model is the milk collected from the milk producer’s cooperative society
will not be delivered to the Milk Producers Cooperative Union Directly; the milk
will be delivered to the nearest bulk cooling units. From the bulk cooling units, the
milk will be delivered to the Milk Producers Cooperative Union.
Here the challenge which is prevailing now a day is the union will give the
payments based on the overall quality of the milk from the bulk milk collection
centers. Since the recordings of information of milk from the Milk Producers
Cooperative Society to the Bulk Cooling Stations are done manually, they were
not able to exactly find the Milk Producers Cooperative Society which is
supplying less quality milk. Thus all the Milk Producers Cooperative Society is
getting affected because of this bulk purchase.
The Quality of the milk and the quantity of milk sent from the Milk Producers
Cooperative society to the Milk Producers Cooperative Union is intimated to the
society by the vehicle which transports the milk between them. The information is
recorded in a separate register which is called Union Register. The union register
holds the information like the date, the quantity of cow milk supplied, the LR,
Temperature, Fat and SNF for the cow milk, the rate for the cow milk and the
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amount for the cow milk, the quantity of buffalo milk supplied, the LR,
Temperature, Fat and SNF for the buffalo milk, the rate for the buffalo milk and
the amount for the buffalo milk. Some of the Milk Producers Cooperative Society
are recording these details in computers.
Other records which are managed by the societies are the loan details for the
milch animals. The Societies facilitate the members by means of supporting them
by recording the details of the loan repayment. Some of the milch animals were
been purchased by the Government Schemes where there will be subsidies for
the repayment. None of societies are utilizing the computers applications for this
record maintenance.
Based on the Government policies according to the community the member
belongs, there will be a subsidy in the purchase of milch animal. The recording of
the details of members will help the society to identify the correct beneficiary. The
Insurance for the milch animals is recommended by the Milk Producers
Cooperative Union for the milch animals of Milk Producers Cooperative
Societies. A record is maintained by the Milk Producers Cooperative Society for
the member’s animals.
The AAVIN is supporting the members by the supply of feed and fodder to the
members of milk producers cooperative societies. A separate register is
maintained by the Milk Producers Cooperative Society. From the funds of the
Milk Producers’ Cooperative Society, the payments of the staffs are managed.
Based on the volume of the society the number of staffs ranges from 2 to 20. The
salary and the other benefits for the employees are maintained in a separate
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book. Once in 15 days the payment are made to the members of the society, and
a record will be maintained for the payment information with the deduction of any
loan availed by the members. The infrastructure facilities available in Milk
Producers Co-operative Societies are given in Table 5.4.
TABLE 5.4 INFRASTRUCTURE IN MILK PRODUCERS COOPERATIVE SOCIETY
Details Availability and present scenario
Computers Available and are installed with Linux OS
Printers Dot Matrix Printers are available
Software Licensing Societies are not aware of Licensing
Weighing Units Available and not integrated with computers
Testing Units Available and not integrated with computers
Software Development No Standardised software application is available.
Networking Not Available
Internet Connectivity Not used because of delay in approval from union
Backup Power Backup is available in some of the societies and data backup is not in existence.
With the absence of internet connectivity, Compact Disc backup can be
taken and can be shared to the respective union. When the society are not in a
position to afford the computers, two are more societies are integrated to share
the usage of computers. Most of the societies are not aware of the software
licensing practices, if they are budget is not sufficient for the software licensing;
they have to plan for the open source software development. Once the union and
milk producers’ cooperative societies plan to migrate their operation from the
licensed software to the open source software, they have to plan for training. Milk
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Producers Cooperative Union and Milk Producers Cooperative Society have to
invest funds for the training. The status of the computer utility in the Producers
Cooperative Societies are given in the following Table 5.5
TABLE 5.5 STATUS OF COMPUTERIZATION IN MPCS
Area MPCS Chilling Centers
Milk Procurement System
Partially Computerised
Not Computerised
Accounts Not Computerised Not Computerised
Stores Not Computerised Not Computerised
Purchase Not Computerised Not Computerised
HR Not Computerised Not Computerised
The Computerization initiatives of Aavin are compared with that of Amul in the Table 5.6. TABLE 5.6 COMPARITION BETWEEN MPCS OF AMUL AND AAVIN
Area AAVIN AMUL
Milk Procurement System
Partially Computerised Fully Computerised that includes integration with quality testing, weighing and milk accounting systems.
Accounts Not Computerised Fully computerised using customized software. But some manual systems are being followed for purposes of audit
Stores Not Computerised Fully computerised, but not integrated with accounts. Interface between stores and accounts is through manual systems.
Purchase Not Computerised Integrated with the stores information system and most of the process are computerised.
HR Not Computerised Payroll which is a part of accounts is computerised, other activities do not use computers
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5.2.2 Requirement and Utility of Computer Application at the Union Level:
The Milk Producers Cooperative Union collects the milk from the milk producer’s
cooperative societies. 17 District Co-operative Milk Producers Union are
functioning in Tamil Nadu. Primary Milk Co-operatives functioning in the area of
operation are affiliated to the concerned District Unions. The District Collectors of
the Districts where the Union is located are the Special Officers of the Unions in
the place of elected boards. The Main activities of the unions are to procure milk
from Primary Societies, promote clean milk production, quality based milk cost
payment, supply of input services, animal health coverage, supply of feed and
fodder, implementation of Stare and Central Government schemes at District
level, conversion of surplus milk into skim milk powder and milk products,
marketing of liquid and milk products locally and through Metro Dairies.
At present AAVIN, Trichy is collecting milk from Pudukkottai also. The
chilling centre at Pudukkottai was established on 20.04.1986 under Operation
Flood and operated till 16.10.1993. The chilling centre was closed as it could not
be operated with full capacity. So, the Union collects milk from the Milk Societies
and send to Tiruchirappalli Union, and gets processed and packed for marketing.
The AAVIN, Trichy – Milk Producers Cooperative Union receives milk from the
Milk Producers Cooperative Society by means of different routes framed by the
union. The milk is procured from the bulk coolers in tank vehicles and from the
other MPCS by means of milk cans. After receiving the data, a sample of milk is
collected from the tank vehicle or the milkcan and is registered in the book. Here
the testing is done manually and the details are entered in to the computer. After
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the recording the details of the milk collected from the various societies, the milk
units were sent for processing and manufacturing of milk and milk products. Milk
not confirming to the standards laid down is rejected straightaway. The Steps in
the process of milk is described in Chart 5.1.
CHART 5.1 PROCESS OF MILK
Reception
Reception
Chilling Process
ocess
Reception
Storage tank
Reception
Pasteurization Stage
Reception
Cream Separator
Reception
Homogenizer
Reception
Storage Tank
Reception
Cream Storage Tank
Reception
Storage Section
Reception
Butter Packing Section
Reception
Ghee Melting Tank
Reception
Refrigerator and
Water Tank
Reception Packaging Section
Reception
Storage Section
Reception
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This reduces the tendency of fat to separate at and float the surface as a cream
layer. This process also makes the milk more easily digestible. The milk is
pasteurized to 80 degree Celsius to destroy pathogenic bacteria. Finally, the milk
is chilled to 4 degree Celsius and stored. The milk is now ready for travel to
thousands of waiting consumers. Just prior to dispatch, the milk is glycol chilled
to about 2 degree Celsius and either automatically packed in polyethylene
pouches or loaded in AAVIN fleet of Insulated road milk tankers to be delivered
at the various distribution points. Here, the AAVIN, Trichy is recording the
information at various stages in manual records. Regarding the marketing,
pasteurized milk in sachets is the main product of this union being marketed in
and around Trichy District and also sent to Metro Grid to feed Chennai people.
As per the status of 2010- 2011 an average of 83,000 litres of milk is sold
through 275 Commission Agents in Trichy and Karur District. The milk in bulk
quantity is supplied to more than 50 Government and 20 Private institutions.
Here, the AAVIN, Trichy is using the computer applications partially for recording
the information. The total automation is not available at this stage.
Ghee is manufactured from this Union certified by the ‘Agmark’ and sold in 200
gm., ½ kg and 1 kg pet bottles. The demand of Ghee in local market and up
countries is increasing day by day. The manufactured information and marketed
details are recorded in a manual book. AAVIN, Trichy is also manufacturing Milk
Khova. An average of 25 kgs of Milk Khova per day is manufactured and sold in
Trichy Town and programs are on the anvil to launch it as a milk sweet through
retail outlets. Here the manufactured details and the marketing details are
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recorded in a manual system. The marketable surplus milk is being diverted to
other product dairies for conversion and the converted products such as butter
and milk powder are marketed through Federation all over the country. The
marketable surplus details are maintained in manual system. The Deputy
Registrar of the AAVIN, Trichy is responsible for coordinating the policy and
management of milch animal’s advisory with the members of the cooperative
society. Veterinary Services are provided by the AAVIN, Trichy to the members
of the Milk Producers Cooperative Society. Table 5.7 shows the comparison.
TABLE 5.7 THE COMPARISON OF MPCS UNION TRICHY AND AMUL
AREA AAVIN AMUL
Milk Procurement System
Partially Computerised and not integrated with any testing measures.
Fully Computerised that includes integration with quality testing, weighing and milk accounting systems.
Accounts Partially Computerised and not integrated with any module
Fully computerised using customized software. But some manual systems are being followed for purposes of audit
Stores Partially Computerised and not integrated with any module
Fully computerised, but not integrated with accounts. Interface between stores and accounts is through manual systems.
Purchase Not Computerised Integrated with the stores information system and most of the process are computerised.
HR Payroll is handled by the computer application
Payroll which is a part of accounts is computerised, other activities do not use computers
Veterinary Visit Booking
Computers are not used for this service
Computers are used extensively in capturing data, allocating doctors for the visit and for generating billing
Cattle Feed Plant
Data is not integrated with the union.
Fully Computerised – computing facilities used in production planning, purchase and other activities. Input supply module is also computerised in the chilling centres.
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5.2.3 Requirement and Utility of Computer Application at the Tamilnadu
Cooperative Milk Producers’ Federation (TCMPF) Level:
The institutional frame has a three-tier structure with the Primary Milk Producers’
Cooperative Societies at the grass root (Village) level, Milk Producers’ Co-
operative Union at the middle (District) level and Federation of District Co-
operative Milk Producers’ Union at the apex (State) level.
The brand name of Dairy Cooperative is ‘aavin’. The Federation has 4 Dairy
Units in Chennai which collect milk from District Unions, process and pack in
sachets and send for sale to consumers in and around Chennai City. Sale of
liquid milk in Chennai and Districts has increased steadily.
The Tamilnadu Cooperative Milk Producers’ Federation (TCMPF) is a
successor body to the Tamilnadu Dairy Development Corporation, which was a
company, registered under the Companies Act. The TCMPF has implemented
Operation Flood I, II & III in Tamilnadu and at present there is a three-tier system,
namely, Village Dairy Co-operatives at the village level, District Co-operative Milk
Producers Unions, there a 43 Chilling Centres, 12 Dairies, 4 Feeder Balancing
Dairies, with spray drying powder plants having a conversion capacity of 70
M.Ts. a day. There are three Cattle Feed Plants supplying about 11,491 M.Ts. of
cattle feed per year. In addition, there are three modern Dairies at Chennai Metro
including a Product Dairy, manufacturing a wide variety of milk products including
Yoghurt, Ice-cream, as well as milk and ghee sweets. The Federation also has a
Nucleus Jersy and Stud Farm at Ooty and a Buffalo Frozen Semen Station at
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Erode. The Federation is also implementing Progeny Testing Scheme for
buffaloes and white cattle.62
A considerable quantity of milk procured from the Milk Producers
Cooperative Unions is send to the Milk Producers Federation every day for
Marketing and for production of dairy products.
Aavin produces 4 varieties of milk. They are 1. Toned milk (3% Fat), 2. Doubled
toned milk (1.5%) 3. Standardized Milk (4.5%), 4. Full Cream Milk (6%)
Milk products of 'Aavin' and Dairy Cooperatives are popular among the
consumers in Tamil Nadu. Madhavaram, Ambattur and Sholinganallur Dairies
activities is Milk Processing and Ambattur Product Dairy is manufacturing milk
products. Table 5.8 below shows the Milk processing capacity of the Aavin
Federation.
TABLE 5.8 SHOWING THE CAPACITY OF MILK PROCESSING IN THE FEDERATION
Name of the Dairy Activity Capacity (in Litre Per Day)
Madhavaram Milk Processing 2,00,000
Ambattur Milk Processing 4,00,000
Sholinganallur Milk Processing 4,00,000
Product Dairy, Ambattur Milk Products 10,000
Metro Supply Unions are Vellore, Kanchipuram, Villupuram, Trichy, Thanjavur,
Dharmapuri, Salem, Erode and Coimbatore. The functions of TCMPF are
Production Management, Inventory Management, Production Planning, Quality
Control, Personnel Management, Engineering, Marketing and Customer Care
and Support Cell.
62
STEP Project Proposal: page 5
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5.3 PRODUCTION MANAGEMENT
Production is executed by the Federation in Central Dairy, Sholinganallur
Dairy and Ambattur Dairy. Production of Milk and Milk Products is one of the
important activities of the Production unit. Here the process starts from the
receiving of milk from various Milk Producers Cooperative Unions and the Milk
Producers Cooperative Society which are part of the Federation. Here the
process involves from the collection of milk and ensuring the quality received
from the various union and societies.
After receiving the milk, the milk is made as part of various processes for
classifying the milk and making it suitable for dairy products. Here the
information received from the unions and societies are recorded in manual
registers. The Automation is done in the process of classifying the milk, whereas
the data is not stored in any form of computer application.
In the production management lot of labour are used for performing the
operation and monitoring the process of production. The details about the
employees are managed by the HR Department. Around 70 % of the employees
who are part of the Federation are manual labour.
Regarding the Administrative Head, Individual Deputy General Manager
(Production) will manage and supervise the total plant. He is in charge of the
entire dairy activities. He is responsible for the prepacking process and loading
the milk.
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In this department, only the information of procurement is managed by a
computer application and no integration with other departments like planning,
maintenance, HR and accounts.
5.3.1 Production and Maintenance
The Production process of the Federation involves various machineries.
5.3.2 Madhavaram (Central) Dairy
Central Dairy was erected to handle 1.0 Lakh Litres per day in bottles and later
converted to production of sachets with effect from 1997. Present handling
capacity is 3.0 Lakh Litres per day, despatches 2.7 Lakh Litres per day in
sachets, 0.2 Lakh Litres per day to Bulk Vending Units and 0.10 Lakh Litres
Pasteurized Chilled water to Products Dairy.
Dairy is equipped with latest Processing Plant, Homogenizer, CIP System
and Packing Machines. Dairy is having Solar panels to heat and the feed water
to the Boilers. The Dairy is equipped with latest Effluent Treatment Plant to
handle 3.0 Lakhs Litres per day. The Effluent Treatment Plat functions as per the
norms of the Tamilnadu Pollution Control Board and Treated Effluent Water is
utilized for Agriculture and Garden purpose within the Dairy and also to the
Fodder Farm of the Dairy Development Department.
5.3.3 Ambattur Dairy
Ambattur Dairy was constructed by the National Dairy Development Board
on Turn-key basis with a capacity of 2.0 Lakh Litres per day for Bulk Vending
despatches. The Sachet production was added during 1980. Ambattur Dairy
handles 3.4 Lakh Litres per day in sachets, 0.3 Lakh Litres for Bulk Vending
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despatches and 0.1 Lakh Litres per day processed chilled water to Products
Dairy.
The sterilized flavoured milk in bottles production at the rate of 2000 bottles is
carried out in four different flavours, Pista, Badam, Elachi and Pineapple in 200
ML. bottles. The marketing demands are met as per the needs. The distribution
of Milk is spread from George Town, North Chennai to Chrompet in the South
and up to Thiruvallur on the West. The Dairy is equipped with adequate
processing facilities. The latest Pasteurizer, Homogenizer and Packing machines
were added as per the needs. The Dairy is equipped with an Effluent Treatment
Plant with a capacity of 4.0 Lakh Litres per day. Effluent Treatment Plant
functions as per the norms of the Tamilnadu Pollution Control Board and the
treated trade Effluent is utilized for Agriculture purpose within the Dairy premises.
5.3.4 Sholinganallur Dairy
Sholinganallur Dairy was established during May 1995 with a handling capacity
of 4.0 Lakh Litres per day, 3.0 Lakh Litres for Bulk Vending despatches and 1.0
Lakh Litres per day in sachets. The present handling is 3.4 Lakh Litres per day in
sachets and 0.3 Lakh Litres per day for Bulk Vending dispatches. This is the first
automatic Dairy having Reception, Quality check and Processing with
Programmed Logistics Control System. The dairy is equipped with Processing,
Quality assurance, CIP, Packing and Cold Storage facilities. Dairy is equipped
with latest Effluent Treatment Plant to handle 5.0 Lakh Litres per day. Effluent
Treatment Plant is operated as per the Tamilnadu Pollution Control Board norms
and the treated trade effluent water is used for agriculture purpose within the
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Dairy premises. Deputy General Manager (Production and Maintenance) at
Central Dairy, Sholinganallur and Ambattur Dairy is managing the maintenance
activities of the Dairies. He is the administrative head of the employees working
in the dairy. The computers are used in the department for the document typing
only.
5.3.5 Production Planning
Regarding the Planning department, the information from the unions plays
an important role in deciding the forecast of requirements and the needs of
processed milk and milk products. The recording of information periodically will
help this department to decide or to draft a plan immediately. But this department
is dependent on the unions for gathering information and for planning. Planning
department has proposed the Government in the increase of milk production
through milk producers co-operative societies, increase in milk and milk product
sale and improve the milk marketing. All the details in this department are
managed manually; the computers are used for preparing reports as an
enhanced version of typewriter.
5.4 TRANSPORTATION OF MILK
Transportation is one of major activity of the Dairy Cooperatives. As milk is
a perishable product, it is important to procure the milk and have to make the
arrangement for reaching it to the appropriate destination within a stipulated
period. Regarding the management of Transportation it involves identifying the
availability of tankers for the collection of raw milk and sending the processed
milk to the milk vending machines. Other responsibilities involved are the
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maintenance and repair of vehicles periodically. On time to time basis, it may be
required to purchase new vehicles for the Federation based on the demand for
planning a new route.
Deputy General Manager (Transport) is responsible for the management
and the supervision of the transport unit of Madhavaram, Ambattur and
Sholinganallur Dairy. The Responsibility of the department involves managing
the repairs and maintenance of heavy and light vehicles, purchasing of
consumable items and spares for the transport vehicle, purchase of light and
heavy vehicles and monitoring the registration, insurance and road tax details
etc., He is the administrative head for the staff working under his control. All the
records are managed in this department manually. There is a wider scope for
computer applications in this department for administrative tasks.
5.5 INVENTORY MANAGEMENT (ENGINEERING)
The Federation involves Engineering Activities in Milk Processing and the
Milk Product Production Units. For the smooth running of the production,
periodically federation is involved in the purchase of capital equipments’, packing
materials, consumable spares in respect of Metro Dairies and Product Dairy.
Engineering department provides technical support to production and marketing
units. The department is responsible for the ISO, MMPO and HACCP related
activities. Tender related matters are managed by this department for the
procurement of items.
Deputy General Manager (Engg) / Material and Purchase is responsible
for administrating the activities of Engineering department and identifying the
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materials required on time to time basis and purchase of materials. The inventory
of the items is managed by recording the data in registers. The Computer
Applications is not available for the inventory management.
5.6 ACCOUNTS / FINANCE
The Accounts department manages the accounting functionality of the
Federation. It is accountable to the financial handling of the Federation only. It is
not related with functionalities of the unions. The Accounts department of the
Federation is computerized but it is not integrated with purchase or the marketing
department. The data are fed in to the computers manually.
Federation has developed an application named as FAP. The application takes
care of all the internal operation of 9 units. The Madhavaram Unit will operate the
accounting functionality individually and at the end of the year they will
consolidate with the Ambattur and Sholinganallur unit of account. The Application
has the facility of preparing the day book, General Ledger and total accounting
information. The Application uses the grouping method. The Application supports
the feature of Inter Unit transfer facility. The federation manages the accounts in
two forms. One is by means of operational accounts and another is non-
operational accounts. The information shared to the researcher is Head office will
make the expenditure and credit it to the marketing department. Milk Bill will be
debited by the head office and credited for the respective book of accounts. Apart
from the FAP Package, pay bill application is used for preparing the payroll.
Through this application all the financial statement with respect to the
federation are taken. Some of the reports are Day Book, Balance Sheet, Trading,
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Profit and Loss, Head Grouping of A/C. Accounts department is also involved in
the activity of employee house building advance. The accounts department
handles the employee house building advance of all the 9 units. Tally Software is
used to maintain the employee house advance accounts.
Provident Fund facility is available to the employees of the Federation. A
Separate Application was developed by the federation for the calculation of the
payment details. An employee can check his status by accessing the website
http://www.aavinnet.com/epf/ and providing the details like Year, EPF Account
Number and Date of Birth of the Employee. Deputy General Manager (Finance)
is the overall control of finance and accounts in respect of all units under the
control of Joint Managing Director and Joint Managing Director’s Office. He is
responsible for budgeting, capital and revenue, preparation and getting approval
of board. He will monitor the audit of accounts periodically and settlement of
objections.
5.7 MARKETING
Marketing is performed in 16 zonal offices. The processes that are performed by
marketing department are Card Sales, Route Schedule and Distribution. Dairy
Management involves managing the received milk, number of sachet, quantity of
milk procured, quantity of free milk procured,. The consolidation of received milk,
number of sachet, quantity of milk procured and quantity of milk procured are
performed by the federation.
5.7.1 Milk Card Sales System
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In the marketing department, one of the major challenging tasks is Milk Card
Sales in the milk parlor. Computerization plays a major role in managing the milk
card issued. A detailed study was performed to manage the renewal process of
the milk cards. With the detailed discussion of NIC, Federation is working on the
development on an online application. By means of this application it is possible
for the consumer to renew the milk cards with the help of the internet.
5.7.2 Computer Reports of the Marketing Department
The Major reports which are generated by marketing department using the
computers are Sales Receipts, Bank Statement, Demand and Collection
Statement, FIR Reports and Quality Control Reports. General Manager
(Marketing) is the overall administrative head of marketing unit I.e. Milk Division
and Product Divisions. He is responsible for monitoring sale of milk cards and
distribution of milk. He is responsible for monitoring sale of products in metro and
upcountry. He is responsible for sales account reconciliation and dues collection.
He will be monitoring the sales promotion. The other responsibilities that
includes are handling customer complaints and market supervision.
5.8 QUALITY CONTROL
Based on the petition by the consumers action will be taken. The information are
recorded in a manual register.
5.8.1 Customer Complaint Cell
The consumer can file by means of telephone or by means of an email.
The complaints are registered and taken necessary action within the earliest
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time. Deputy General Manager (Quality Control) is in charge of the activities in
regard to qualify control of milk and milk products. He will be monitoring the milk
arrivals from the District Unions to Metro Dairies. He will field milk and product
analysis. He will address customer complaints on milk and products quality.
Surprise visit to all the unions. To check the milk adulteration, engage quality
control staff. Here all the records are registered manually. No computer
applications are used for gathering and storing the data.
5.9 ADMINISTRATION
Joint Managing Director is the overall administrative head of the entire
JMD Unit consisting of four Metro Dairies, Marketing and transport unit. His
responsibilities includes controlling and co-ordination activities among
production, marketing – milk and milk products, quality control and transportation.
The other responsibilities are identifying marketing area for each Dairy. By
means of gathering the data he gives guidance if required by the units. As most
of the departments are not computerized, he is dependent on his subordinates
for collecting information and decision making. The status of Computer
application initiatives in the Aavin federation are given in the table 5.9.
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TABLE 5.9 PRESENT SCENARIOS IN AAVIN, TRICHY
Details Availability
Server Not Available
Printer Available
Software Licensing Not Available
Desktop Machine (1 unit) Old Machines are available and not up graded for some years
Testing Units Available and not integrated with any computer applications
Software Development Trial was executed for standarisation and are not successfully implemented
Networking No Networking is and not practiced
Backup Facility Power Backup is available and data backup is not available.
The comparison of the Tamil Nadu Cooperative Milk Producers Federation with
the Gujarat Cooperative Milk Producers Federation regarding the
computerization and the result is made in the table 5.10.
TABLE 5.10 SHOWING THE COMPARISON OF THE TAMIL NADU AND GUJARAT FEDERATIONS
TCMPF GCMPF
Production Planning and Management
Not Computerised
Integrated with the stores information system and most of the process are computerised.
Administration Payroll is handled by the computer application
Payroll which is a part of accounts is computerised, other activities do not use computers
Veterinary Visit Booking
Computers are not used for this service
Computers are used extensively in capturing data, allocating doctors for the visit and for generating billing
Cattle Feed Plant Data is not integrated with the union.
Fully Computerised – computing facilities used in production planning, purchase and other activities. Input supply module is also computerised in the chilling centres.
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TABLE 5.11 MILK PRODUCTIONS IN GUJARAT AND TAMIL NADU
Year
Gujarat
(in ‘000
tonnes)
Tamil Nadu
(in ‘000
tonnes)
97-98 4913 4061
98-99 5059 4273
99-00 5269 4586
00-01 5312 4910
01-02 5862 4988
02-03 6089 4622
03-04 6421 4752
04-05 6745 4784
05-06 6960 5474
06-07 7533 6277
07-08 7911 6540
08-09 8386 6651
09-10 8844 6787
10-11 9321 6831
Source: BAHS, Department of Animal Husbandry, Dairying & Fisheries, Ministry
of Agriculture, GoI.
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CHART 5.2 MILK PRODUCTION IN GUJARAT AND TAMIL NADU
Chart 5.2 clearly compares the milk production between Gujarat and Tamil
Nadu. In the year 1994, Amul has took the computer initiative and thereafter in
State of Gujarat almost all the Unions are started to implement the computer
applications. From the chart it is clear that there is a tremendous variation in the
milk production between Gujarat and Tamil Nadu. Even though the correlation
co-efficient gives the positive correlation between the milk production of Gujarat
and Tamil Nadu, but from the periods between 2006-2011, Tamil Nadu Milk
production was marginally increased when compared to the Gujarat Milk
production during the same period. There is phenomenal growth in the case of
Gujarat Milk production during the same period and among the other reasons this
97-98
98-99
99-00
00-01
01-02
02-03
03-04
04-05
05-06
06-07
07-08
08-09
09-10
10-11
Gujarat 49135059526953125862608964216745696075337911838688449321
Tamil Nadu 40614273458649104988462247524784547462776540665167876831
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000A
xis
Tit
le
Milk Production in ('000 tonnes)
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may be mainly due to the computerization of all the operation of the Dairy sector
in that State.
TABLE 5.12 PER CAPITA AVAILABILITY OF MILK
IN GUJARAT AND TAMIL NADU (gms/day)
Year Gujarat Tamil Nadu
91-92 236 164
92-93 245 167
93-94 249 168
94-95 277 175
95-96 229 180
96-97 289 183
97-98 290 185
98-99 290 199
99-00 297 210
00-01 280 211
01-02 317 219
02-03 321 198
03-04 330 198
04-05 344 204
05-06 349 231
06-07 372 263
07-08 385 272
08-09 402 274
09-10 418 278
10-11 435 278
Source: BAHS, Department of Animal Husbandry, Dairying & Fisheries, Ministry
of Agriculture, GoI.
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Chart 5.3
PER CAPITA AVAILABILITY OF MILK IN GUJARAT AND TAMIL NADU (gms
/ day)
When compare to the per capita availability between Gujarat and Tamil Nadu
there is lots of variation from the year 1991-2011. The Gap has increased
significantly from the period between 2001-02 and 2010-2011. The concentration
of the business by Tamil Nadu dairy cooperatives is not on par with the
development of Gujarat dairy cooperatives. One among the reasons for slow
growth of per capita availability of milk is lesser utilization of computerization and
administration of Artificial Insemination and other measures. But the correlation
co-efficient between the per capita availability of milk Gujarat and Tamil Nadu is
positively correlated i.e. 0.905.
0
50
100
150
200
250
300
350
400
450
500
Gujarat Tamilnadu