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

1. QUARRY MANAGEMENT SYSYEM
(QMS)
Presentation before the Jury Committee for
The National Award on e-Governance
22-Dec-2014
M. Vallalar, I.A.S.
Managing Director
Tamil Nadu Minerals Limited
(A Government of Tamil Nadu Undertaking)
31, Kamrajar Salai, Chepauk
Chennai 600 005

2. Agenda
• About TAMIN
• Key Issues and Challenges Faced
• E-Governance Interventions Implemented
• Benefits Realized
• Future Directions
• Conclusion and Summary
Quarry Colombo Zubrana

3. About TAMIN
• Established in April 1978, wholly owned
by the Government of Tamil Nadu.
• Workforce of 1311 personnel including
Administrative, Technical and Workers
(Skilled, Semi-skilled, etc.)
• Exploits, processes and markets raw
granite blocks and granite value added
products
• Processes and markets major minerals
such as Graphite, Silica Sand,
Vermiculite, Limestone and Quartz &
Feldspar
• Mines, quarries, divisional offices and
factories are spread over in various
parts of the State (600 Kms)
• Exporting to countries as USA, Spain,
Italy, China, Japan, Dubai, Poland,
Slovenia, Croatia etc.
Corporate Office
(Chennai)
Divisions
(10)
Quarries (33)
Mines (9)
Mini Tile Plants
(2)
Industrial Units
(6)
Show Room
Central
Workshop at
Salem

4. Key Issues and Challenges Faced
Issues of
Transparency,
Efficiency and
Accountability
(Manual System)
Local Management of individual
Quarries, Divisional Offices and
Factories caused lack of
effective controls / monitoring
Reports were sent to the TAMIN
Head Office from mines &
quarries on weekly basis and
subsequently compiled
Low Focus / Visibility on ground
operations due to non
availability of data on daily
basis
Day-to-day monitoring not
possible
Manipulation / mis-interpretation
of data
Manual system caused low
visibility, inaccuracy and
unreliable reports from the
field

5.  TAMIN has introduced a new web based software “Quarry
Management System” called QMS during Nov.2012.
 It is a centrally managed software that collects data of
production / sales / despatches etc. in the quarry / mine / factory
on a daily basis
 It converts the data into reports for efficient and transparent
management with high accuracy.
 It is a unique software, designed and developed based on
TAMIN’s requirement
 QMS is not mere computerization of office. It was designed to
integrate various kinds of mining activities like production,
recovery percentage, mine wastage, sales, mine safety and
optimum utilization of men & machinery
E-Governance Initiative
QMS – An innovative effort

6. E-Governance Initiative
Implemented
 Low cost in-house equipment provided
for implementation.
 Alignment of software system
developed and the processes
followed
 Provided Adequate Training and
Capacity Enhancements by providing
equipment's and support
 Removed manual processes after
implementation of e-governance
solution
 Constituted a Mine Auditing
Committee to physically validate data
entered in QMS
TAMIN Granites, Chennai

7. E-Governance Initiative
Implemented
Platform Details
 Project cost: Rs. 6 Lakhs
 Used Open Source Technology
 Developed Platform (Front end): PHP
 Database (Back end): MySQL
 Hosted at: TAMIN Server at Head
Office
 Utilized BSNL for connectivity
 Security System:
 Hardware firewall: SonicWall 2040
 Software: Symantec Endpoint
Protection
Home Page of QMS

8. E-Governance Initiative
Implemented
Software Features
 Entries made in Divisional Offices – Single Entry on daily basis and Multiple View,
Locking of entries after certain time
 Multiple MIS reports are generated daily
• Production Performance, Sales Performance, Stock Availability
• Shift-wise Men & Machinery Performance, Under-utilized Machinery List
• Non-working Machinery with its Service Status
• Fuel Consumption Details
• Important Materials / Machinery Requirements for Continuous Quarry
Operation
• Follow up of Court Cases, Tender Status
• Statutory Requirements of Mines
 Consolidation of Data at Head Office Level
 Daily Dashboard Report for MD Generated by System and interaction enabled
with field by online chatting
 Daily Review and consequent Decisions made at Head Office.
 Portal Provided for Sales Function.
 Analysis -> Discuss -> Directs online

9. E-Governance Initiative
Implemented
Training and Capacity Building
 Provided equipment – Laptop, Cameras,
Data Card and Connectivity to all required
officers / quarries / mines / factories.
 Provided Training in Computer Systems and
Applications to all officers and staff.
 Provided Training in Photography to staff.
 Designated one day in a month for training
activities
Quarry Site Training Programme,
Yellikaradu Quarry, Mettur Dam

10. E-Governance Initiative
Implemented
Process Alignment
 System determined process for Immediate
conversion of unfinished blocks to finished
blocks chronologically.
 Recording of waste generated in each stage
of quarry & mine operation.
 Selection of blocks in chronological order by
Buyer
 Payment within stipulated time
 Verification of Granite Block Measurement with
help of digital photographs
Verification of Block Measurement using
Digital Photograph

11. E-Governance Initiative
Implemented
Process Alignment
 This e-Governance initiative especially measurement checking of granite
blocks by digital photographs helps to avoid revenue loss.
 Ex. If 10 Centimeter of measurement is omitted intentionally or by error in
each side of one cubic meter granite block, there will be loss of about 20%
in volume of the block.
 The revenue loss may be in crores.
Verification of Block Measurement using Digital Photograph

12. E-Governance Initiative
Implemented
Mine Auditing Committee
 Composition: Geologists , Mine Engineers, Mines Surveyors and
external experts (retired Director from GSI)
 Audits each mine physically once in two months
 Cross checks the data in the QMS entered with reference to
the actual volume mined.
 Each Mine / Quarry has a 3 Member Core Committee
(consisting of Officer, Supervisor and Worker) – Daily activities
are monitored and data validated by them. Maintain Core
Committee Register.

13. Benefits Realized
Key Process Benefits
 Faster Decision Making Capability Provided to TAMIN
 Automatically analysis various data and generate daily
performance report of each quarry, mines and factories.
 These reports are sent by way of emails followed by SMS
alerts to Field / Divisional Office staff (about 80% of the
workforce are getting SMS alerts on daily basis). These
reports assist the Divisional Managers to fine tune daily
operations of the quarries / mines / factories resulted in
increase in revenue and performance.

14. Benefits Realized
System Benefits
 All data including photographs are documented on daily basis
and that can be retrieved at any point of time
 Optimum use of natural mineral wealth is ensured
 Optimum utilization of men & machinery is ensured
 Improved Quality of service provided to the buyers
 Verification of the measurements of the granite blocks lying in
a remote quarry from the Head Office is made possible.
 A sense of alertness, vigil, vigour, competitiveness,
achievement and self reverence was instilled in the minds of
the working force and management.
 Increase in revenue due to accuracy of measurements and
close monitoring of operations

15. Benefits Realized
Key Quantitative Benefits (2013-14)
PROFIT
₹ 24.69 Crores [603% Increase over previous year]
SALES
₹ 188.87 Crores [55% Increase over previous year]
EXPORT SALES
₹ 45.81 Crores [182% Increase over previous year]

16. Sales, Export Sales and
Profit (Before Tax) Growth Data
Sales Turnover Export Sales Profit before tax
Before
QMS
After
QMS

17. Benefits Realized
Key Qualitative Improvements
In Previous System (manual system) In Present System (QMS)
There was no mechanism to monitor the size of
the Granite blocks produced from primary cutting
stage which resulted in low level production of
higher size blocks which cause revenue loss.
Now, every granite block is monitored from
the stage of primary cutting to finished product
which enables production of large size blocks
and reduction in cost of production and high
cost realization
Blocks are selected by the buyers as they wish
rejecting most of the granite blocks which
resulted in revenue loss
The blocks are sold in chronological order
only. Hence we are able to sell all the blocks
without omission.
The Head Office cannot see the measurement of
the granite blocks and had to fully depend upon
the statements of the field. There was chance for
malpractices, inaccuracy in measurement and
other complaints.
Every block is digitally photographed with
measurement tape and uploaded which can
be seen in HO with measurement.
Men & machinery were not effectively monitored
due to poor MIS as the quarries are remotely
situated.
QMS sets standard for effective utilization of
men & machinery and any shortfall in utilization
is indicated in the next day report which helps
management take appropriate timely action.
Delayed Mine Auditing Almost daily Mine Auditing and Management
intervention in case of exception. CCTV
Cameras installed in mines / quarries. SMS
alerts are given

18. Benefits Realized
Additional Benefits
 All time high production in black granite, graphite ore, limestone, silica sand, Indian standard sand,
raw vermiculite and exfoliated vermiculite
 All time high sales turnover in black granite, graphite, limestone, Indian standard sand, exfoliated
vermiculite
 Idle men & machinery were identified and reduced considerably.
 Efficiency of men & machinery has increased
 Fuel consumption in each machinery in the quarry is closely monitored
 Quarry-wise recovery percentage of granite has been closely monitored
 Accuracy of measurement of granite block has been ensured
 Upload of photograph of each granite block with measurement
 Undressed block & finished block stock has been reduced considerably
 Turnover & profit has increased
 Work flow in the processing of sales has been simplified
 Close monitoring of each stone and every machineries in the quarry / mines are made possible from
Head Office
 Day-to-day activities of all quarries / mines / factories like production, sales, dispatch, waste
generation has been monitored from Head Office
 All reports like selection list, invoice, dispatch challan, tax report etc. are being generated through
this software. Hence, duplication of work is avoided and accuracy & transparency are ensured.

19. Future Directions
In-House
• Mobile & Tablet Computing
External
• Extension to other government organizations who are dealing
with mines and minerals
• Extension to Private Players – to increase transparency

20. Conclusion and Summary
 This Quarry Management System is a prelude to effective monitoring of
mineral wealth.
 TAMIN has demonstrated the effective use of ICT and e-Governance in
achieving organizational efficiency and effectiveness.
 This software with some modification can be utilized in other organizations,
who are dealing with mining and quarrying activities.
 The Principal Secretary to Government, Industries Department,
Government of Tamil Nadu, appreciated the efforts taken by TAMIN in
bringing transparent management system through this QMS Software and
suggested to introduce this system in other departments as TANMAG /
TANCEM.
 This has been achieved through in-house efforts
 With additional assistance and resources, more improvements can be
made in the working of TAMIN.
“Transparency is the key to good governance.
E-Governance is the only effective way of transparent
governance.”
- Shri Narendra Modi,
Prime Minister of India

21. Annexure
E-Governance Software Reports – Screen Prints
Quartz FeldsparRaw Vermiculite Exfoliated Vermiculite
Limestone Silica Sand Graphite
Major Minerals quarried and processed by TAMIN

22. SALES TURNOVER
(Rs. in Lakhs)
1 24 69 98 168242407592830
1175
1072
1422
1873
2606
3578
4020
4008
3436
3132
4070
5317
6651
6670
6705
8002
9021
10015
10991
10147
9389
10505
11041
10222
10091
12223
18887
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
20000

23. EXPORT SALES
(Rs. in Lakhs)
0 21 59 85 147
221
328
453
695
999942
1326
1781
2507
3404
3822 3765
3081
2319
2474
2745
2492
2870
2205
2152
1233
1762
1866
672
217
355
281
124108
1623
4581
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000

24. PROFIT BEFORE TAX
(Rs. in Lakhs)
-8 6 11 14 28 28 45
135154
215229
593
929
1622
1954
2151
1529
267
101
725
985
753
1127
623
370397
521
381
427
258
101 67 69 78
351
2469
-500
0
500
1000
1500
2000
2500
3000
24

25. SALES – BLACK GRANITE
(Rs. in Lakhs)
0 20 44 65 101167222325
522
685
541
900
1074
908
1579
1624
1634
837
13
2273
2188
2950
2811
2437
2814
2894
3131
3642
3474
4538
3873
3862
4462
4513
5240
9107
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
2

26. SALES – LIMESTONE
(Rs. in Lakhs)
0 2 3 5 2 8 49
99 86 119
60 38 30 17 29 35 38 22 0
129
182 155 173 191
125
62 76
152 151 157
291 260
746
429
2240
2862
0
500
1000
1500
2000
2500
3000
3500
26

27. SALES – EXFOLIATED VERMICULITE
(Rs. in Thousands)
9 0 1 1 10 27 52 16 22 230 293
631
1157
1197
1119
1823
2306
1851
2261
3923
3972
4578
5238
6391
8308
9348
9593
12413
11047
12543
18220
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
20000
27

28. SALES – GRAPHITE FLAKES
(Rs. in Lakhs)
1 0 2 0 0 0 0 0 4 3
121
231
250
352
444
375
518
618
776
745
1028
1020
1045
1400
1251
1403
2547
2590
2835
0
500
1000
1500
2000
2500
3000
28

29. SALES – INDIAN STANDARD SAND
(Rs. in Lakhs)
0 0 0 0 0 0
16 20 24 28 31 29 31 29
50 42 50 56 61 61 67 67
83 83 83 85
97 94
121
136
192
203
244
346
457
613
0
100
200
300
400
500
600
700
29

30. PRODUCTION – BLACK GRANITE
(Quantity in Cubic Metre)
17
931
2044
1787
1356
2630
3579
4487
74307203
4798
4474
5272
4076
3679
4161
4225
2054
2763
6835
6834
9597
8434
7808
8647
10990
12405
15106
13619
17629
22217
18408
17998
15915
16062
23817
0
5000
10000
15000
20000
25000
30000
30

31. PRODUCTION – LIMESTONE
(Quantity in Metric tonne)
5536
11438
12014
8240
6991
7772
74154
144563
122262
152242
74512
45136
27041
19492
23201
22301
22551
15900
0
73830
100740
110562
127692
158793
94147
49385
55750
76550
76730
115275
221500
155600
353470
180400
674682
701413
0
100000
200000
300000
400000
500000
600000
700000
800000
31

32. PRODUCTION – RAW VERMICULITE
(Quantity in Metric tonne)
233
550
702
1202
1167
1860
1131
1065
954
900
918
1106
865
761
877
761
481450
0
1102
1230
1331
1596
1951
1765
1458
1855
1417
1491
1687
1921
1603
2154
1697
1373
2201
0
500
1000
1500
2000
2500
32

33. PRODUCTION – SILICA SAND
(Quantity in Metric tonne)
45 75
1584
3709
7231
11795
3238
113
568
352 480 609
359 312
824 946
710
1254
1908
1234
2722
1583
3755
2180
2507
2520
2419
2961
2707
3094
3129
3329
3901
3206
4212
7500
0
2000
4000
6000
8000
10000
12000
14000
33

34. PRODUCTION – GRAPHITE ORE
(Quantity in Metric tonne)
101
1091
959
1136
1926
2029
3484
3274
265
3550
0 0 0
21330
15609
4642
39391
32656
17867
32464
50320
41320
42627
42840
57200 58961
49308
59227
50764
49329
57205
67959
87995
0
10000
20000
30000
40000
50000
60000
70000
80000
90000
100000
34

35. PRODUCTION – EXFOLIATED VERMICULITE
(Quantity in Metric tonne)
6 3 2
35 19 10 10
91 111
255
400408
299
545
671
436
464
758
703
880
961
1054
1234
1335 1355
1680
1334
1218
1752
0
200
400
600
800
1000
1200
1400
1600
1800
35

36. PRODUCTION – INDIAN STANDARD SAND
(Quantity in Metric tonne)
658
782
1037
1127
1236
1201
1231
1173
1352
1380
1720
1739
1766
1735
1858
1298
1852
2006
2162
1728
2217
2118
2231
2535
2381
2859
3486
3078
3300
3714
0
500
1000
1500
2000
2500
3000
3500
4000
36

37. Daily Reports for review
Division / Unit wise production target, achieved production &
sales, stock details etc.
Highlights of the above statement:
•By clicking the each figure, we can see the detailed reports
•Division-wise production achievement against target
•Monitoring undressed blocks which are not dressed more than 15 days
•Monitoring selected blocks which are not paid more than 15 days
•Invoiced blocks which are not delivered from the quarry within 20 days from the permit date
•Stock of dummy blocks, finished blocks, sold but not dispatched blocks in the quarry site

38. Daily Reports for review
Top 10 un-utilized machineries
The above statement will be helpful to the management for the following aspects:
•Identify the idle machineries and divert to the needy places
•Pre-planning tendency has improved, resulted in increase in production

39. Daily Reports for review
Non-working machineries
The above statement will be helpful to the management to follow the repair work which
resulted in drastic reduction of break-down days / hours.

40. Daily Reports for review
Quarry daily requirements
The above statement is helpful to take immediate action for
procurement of materials.

41. Daily Reports for review
Mine-wise Performance (Major Minerals)
The above statement is helpful to know the stock details, production & sales
performance, pending supply details etc.

42. MACHINERY PERFORMANCE Report
Daily machine / Vehicle wise performance, utilized man power,
utilized consumables

43. RECOVERY Report
Quarry-wise recovery percentage report

44. PERFORMANCE Analysis Report
(AUTO GENERATED)

45. Task Manager - Discussion Board

46. Proposals – Discussion Board

47. Pending Proposals

48. Thank You!
Granite Processing Unit at Melur, Tamil Nadu