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MOTHER DAIRYREPORT

OPERATIONS MANAGEMENT-1

SUBMITTED BY:

GURPREET SINGH (15)

NEHA DIWAKAR (20)

PRACHI SHARMA (25)

SAVI CHARAYA (32)

SHWETA DIXIT (35)

SECTION-A,PGDM


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xecutive summaryThe project was started on 2013-09-23, gradually developing and compiling

information about various operational and strategic aspects of the mother dairy

plant under the guidance of our mentor professor Anchal Gupta. The first part of

the report involves the study of brief history, operational strategy and supply

chain management. The second part includes product design and effective

product design strategies used my mother dairy. The third part includes process

design and analysis as well as facility layout, capacity utilization other expansion

strategies, assembly line layout at mother dairy. The Fourth part captures the

variants of product development process and product designing including mother

dairys facility location (patparganj,New Delhi) and factors affecting the location

decision. For all the above mentioned parts help from internet sources as well s

newspaper articles were taken.


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MOTHER DAIRY:

INTRODUCTION:

Mother Dairy was set up in 1974 under the Operation Flood Programme. A wholly

owned company of the National Dairy Development Board (NDDB).

It is Mother Dairys constant endeavour to ensure that milk producers and farmers

regularly and continually receive market prices by offering quality milk, milk products and

other food products to consumers at competitive prices and uphold institutional

structures that empower milk producers and farmers through processes that are

equitable.

It was set up initially to cater to the demand of the Kolkata urban agglomeration spreadover the Kolkata Metropolitan area, later it reached out to the consumers of other

districts also. The commissioning of the Dairy started in July 1978. Initially, the

management of Mother Dairy was looked after by the National Dairy Development Board

. On 24th March 1982 , the then Honourable Chief Minister Shri Jyoti Basu dedicated

Mother Dairy Calcutta to the rural milk producers and urban milk consumers of West

Bengal.

Mother Dairy has over the past 3 decades, harnessed the power of farmer cooperatives

to deliver a range of delicious products and bring a smile on your face.

ORGANISATION FUNCTIONS:

Mother Dairymanufactures, markets & sells milk and milk products under the Mother

Dairy brand (Milk, Cultured Products, Ice Creams, Paneer and Ghee), Dhara range of

edible oils, Safal range of fresh Fruit & vegetables, Frozen Vegetables, Processed Fruit

& Vegetable Products, Fruit Pulps & Concentrates in bulk aseptic packaging and fruit

juices at a national level through its sales and distribution networks for marketing food

items.

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Varieties in Milk :Sl.No

Product Fat content Solid not Fat (SNF) Water

1 Double Toned Milk 1.5% 9.0% 89.5%2 Toned Milk 3.0% 8.5% 88.5%

3 Full Cream Milk 6% 9% 75%4 Cow Milk 3.5% 8.5% 88%

5 Skimmed Milk 0.5% 9.5% 90%

VALUE ADDITION CONCEPT:

Mother Dairy transforms milk into various dairy products like

1. Dahi

2. Lassi

3. MishtiDahi4. Ghee

5. White Butter

6. Table Butter

7. Cheese

8. UHT Milk

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PRODUCTION SYSTEM:

Processing of milk is controlled by process automation whereby state-of-the-art

microprocessor technology is adopted to integrate and completely automate all functions

of the processing areas to ensure high product quality, reliability and safety.

At mother dairy, the processing of milk is done by process automation whereby state ofthe art microprocessor technology is adopted to integrate and completely automate all

functions of the milk processing areas to ensure high product quality/reliability andsafety. There are four ways of milk processing

Firstly,Clarification, in which milk is spun at very high speed, removing all dust particlesthat are invisible to the naked eye.

Secondly,Standardisationwhich help to maintain uniformity by raising or lowering its fatand SNF (solid not fat) percentage to a desired levels, so as to deliver milk to consumersas per prescribed PFA norms.

Thirdly, it is Homogenizationwhich improves palatability of milk and Finally,

Pasteurization, which kills all pathogenic bacteria present in the milk and thus making it

safe for consumption.

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The Centre is fully equipped with state of the art modern laboratory equipped with

sophisticated lab scale processing equipment. In order to support the analytical and

shelf life studies associated with product development activities, the Centre is equipped

with highly sophisticated instruments. Packaging innovations are also taken up at

Innovation Centre with various packaging materials and those are tested for variousparameters which include Tensile and Seal Strength, Bursting Strength, Automated Leak

Detection, Compression Strength etc.

OPERATION STRATEGY:

Implementing robust Mother Dairy Management System, which is an Internal System,

developed to meet the all Process Requirements based on National & International

Standards.

Implementing International Management System Standards (ISO)

Bench Marking, Best-In-Class requirements

Process Optimization: Constantly working on latest innovative Technologies

Capability Development across the Organization

Auditing &Assessments: Mother Dairy has established a frame work for Auditing &

Assessments of Complete Food ChainConsumer Satisfaction

It is our endeavour to create a culture of Total Quality where continuous improvement

of our people, processes and products becomes a way of life.

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STRATEGIES FOR COMPETITIVE ADVANTAGE:

The companys derives significant competitive advantage from its unique distribution

network of bulk vending booths, retail outlets and mobile units. Mother Dairy ice creams

launched in the year 1995 have shown continuous growth over the years and today

boasts of approximately 62% market share in Delhi and NCR. Mother Dairy also

manufactures and markets a wide range of dairy products that include Butter, Dahi,

Ghee, Cheese, UHT Milk, Lassi&Flavored Milk and most of these products are available

across the country.

STRATEGY FORMULATION PROCESS:

Mother Dairy has commitment with excellence. The evolving needs of customers drive tocontinual improvement in processes and systems.

1. Apply state of the art technology and processes to enhance productivity that ensuresquality at competitive price.2. Apply processes for clean production, pollution prevention and optimize resourceutilization in all operations.3. Follow food safety management system and apply HACCP (Hazard Analysis CriticalControl points) principles to provide safe products to customers.4. Develop and empower our people for maintaining a vibrant work environment, whichencourages excellence.5. Comply with applicable regulations and legislations.

ORDER QUALIFIER AND ORDER WINNER:

Order Qualifier:

Milk and milk products which are the essential requirements for daily household.

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Order Winner:

Mother Dairy maintains stringent measures to ensure the quality and purity of the milk

provided to its consumers. Each batch of incoming and outgoing milk is subjected to 21

quality tests including presence of foreign matter and bacteriological tests. The quality of

milk accepted and dispatched meets certain predetermined standards. The milk goes

through various processes such as Clarification, Homogenization, Standardization and

Pasteurization, to ensure that it is safe for human consumption. Our motive for following

such strict quality measures is to ensure that there is no contamination while processing

or packaging.

Mother Dairy promises its consumers that it will continue to produce products of the

highest quality standard. Its Dairy products are processed & packed in ISO certified

plants & strict controls are exercised by quality assurance department on all the plants.

Most of our plants are certified for FOOD SAFETY MANAGEMENT SYSTEM.

Quality Assurance Laboratory at Mother Dairy Delhi is certified by National AccreditationBoard for Testing and Calibration Laboratory (NABL)-Department of Science and

Technology, Government of India.

All the operations in our organization are manned by qualified & highly experienced

personnel.

We at Mother Dairy focus on motivated & hard working, well qualified & trained

personnel in front end as well as back end operations. The dedicated Field QA team

ensures that the products manufactured at the plant are handled properly once the

products dispatched from manufacturing units.

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QUALITY CONTROL

Stringent quality control methodologies are employed in Mother Dairy:

a) The milk is tested for adulterations and quality at the time of collection from the

farmers.

b) The Milk that comes from the collection points to the Mother Dairy plant is ensured to

have a temperature of not more than 4C and is subjected to 15 product and quality

checks.

c) The Milk quality is checked repeatedly after each processing phase and the

temperature is judiciously maintained less than 4C always.

d) Before the milk leaves the plant for the delivery/distribution outlets the milk is tested

again.

e) The temperature of milk in the delivery trucks is always maintained less than 4C.

f) All the trucks that deliver milk have specified guidelines to bring back 100 litres of milk

after distribution. This is done in order to test the delivered milk and to ensure that the

tankers are not adulterated during distribution.

g) Since all the employed processing procedures are automated, no contamination by

human hands takes place.

h) To ensure milk freshness the collection and distribution points are always chosen

such that the travel time between them is always less than 36 hours.

Out of the total production about 9% goes directly to the institutions ,23% is the loose

token milk and the rest is distributed through LADs.

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Quality Process in depth

Procurement:

Fresh milk is sourced directly from state level co-operatives and Mother Dairy own NewGeneration Co-operatives (NGC). Milk received from individual producer is checked for

all basic quality parameters meeting company specifications & requirements atrespective collection & chilling centers.

Milk is then supplied to the Dairy units through insulated Milk Tankers under refrigeratedconditions to maintain the freshness.

Strict Quality checks are performed for all incoming Milk received at Dairy units. Theseincludes organoleptic (Taster, Odor& Appearance), Physico-chemical (e.g. Temperature,Foreign matter, % Fat, % SNF, %Acidity, % Protein etc.), microbiological (e.g. MBRT),also presence of any adulterations in Milk (e.g. Formalin, urea, starch, sugar, Glucose,maltodextrin, nitrate, Salt, Hydrogen Per-oxide, neutralizer, ammonium compounds andFat adulterations).

Commodities, ingredients & packaging material used for our products are checked,approved and released by Quality functions as per company specifications andrequirements.

GMP & Hygiene:

Good manufacturing Practices (GMP) for our manufacturing units are a given, they arepart of our heritage of producing best quality and safe products. They maintain highestlevel of GMP and hygiene requirements for production and handling of safe products forour valued customers and consumers

Processing:

The products are manufactured in state of the art manufacturing facilities usinginnovative Process & Technologies. The Milk received at the plant undergoes variousprocessing steps before it reaches to the customer. Process steps include filtration,clarification, pasteurization, chilling, filling, packing and storage for our liquid milkcategory. For other dairy product category, few of the process steps arehomogenization, vacreation, ultra heat treatment, evaporation, dehydrationetc. Cleaning & Sanitation of the processing equipment is ensured using automaticCleaning in Place (CIP) systems by applying 5T principles viz. Technology, Time,Temperature, Turbulence and Testing.

Critical control points (CCP), Operational Prerequisite Programs (OPRP) are identified

for each process using scientific methodology and appropriate control measures areapplied to ensure compliance of Quality and Food Safety requirements.

Process control parameters are monitored, recorded and reviewed as per the QualityPlan to ensure right product right at first time.Manufacturing processes are benchmarked against best-in-class standards towardscontinual improvement for infrastructure and system requirements.

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Packing:

The Filling and packing is considered to be most sensitive operation having appropriateaccess control. Zoning principles are applied in these areas to avoid any crosscontaminations in our Finished Product. Online quality control checks (e.g. net weight,leakages, seal integrity, batch coding, packing material quality, filling temperature etc.)

are carried out and recorded by our Packing In-charges.

Only QC approved and released Packaging materials are used for packing operations.

Packaging material used for our products is with the objective of retaining taste,freshness and unique natural appeal.

Product Testing & Release:

Finished product is tested for the specified quality parameters of each product categoryas per our internal standardized sampling plan and test procedure. Test results arerecorded, reviewed by Quality functions. It is ensured that only good quality product is

released for dispatch and reaches our valued customer & consumer.

MERCHANDIZING

Products are marketed through a chain of our own Milk Shops, retail outlets and mobilevending units maintaining best-in-class hygiene standards. They ensure that productsare available, displayed appropriately and cold chain conditions are maintained to retainproduct quality & freshness.

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PRODUCT CAPACITY

The company markets an array of fresh and frozen fruit and vegetable products under

the brand name SAFAL through a chain of 400+ fruit and vegetable shops and more

than 20,000 retail outlets. Fresh produce is handled at the companys modern

distribution facility in Delhi with an annual capacity of 200,000 MT. An IQF facility with

capacity of around 75 MT per dayis also operational in Delhi. A state-of-the-art fruit

processing plant with a handling capacity of 120 MT per day, a 100% EOU, set up in

1996 at Mumbai supplies quality products in the international market. With increasing

demand another state-of-the-art processing plant has been set up at Bangalore with fruit

handling capacity of around 250 MT per day.

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SUPPLY CHAIN MANAGEMENT:

1. Milk Procurement:- Mother Dairy sources its requirement of liquid milk from dairy

co-operatives and producer institutions. Milk is received from farmer cooperatives

through insulated tankers at 2C temperature in order to retain its freshness.

2. Milk distribution:-Tankers in the morning and in the evening bring in milk from the

regional collection centres. After collection the same tankers are utilized for the delivery

of the processed milk to the distributors. Mother Dairy has about 51 Distributors in the

city of Kolkata. Each of these LADs(Local area distributor ) place their demand by

raising an invoice one day in advance. The demand is also calculated using the

Calendar Scheme, in this depending on the pre-calculated seasonal demands the

outlets place their orders accordingly. In order to satisfy immediate demand, 20 to 25

tankers are provided with a buffer stock of 500 litres each day so that they can be

mobilized to cater the demand in an area. To coordinate its operations all the tankers are

equipped with HAM radios.

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3. Distribution Channels:

a) Token Distribution: Also, termed as Lohekibhains (metal buffalo), is anautomated milk vending machine.

b) Distributors: The packaged milk is distributed via the distributor network

throughout the city.

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PRODUCTS AT MOTHER DAIRY

Milk

Dairy Products

Ice cream

Edible oils

Fresh fruits and Vegetables

Frozen

Juices and Fruit beverages

Processed food

Grossary

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Based upon the parameters of pure/impure, slow/fast Perishable, Mother dairy lies in the

fourth quadrant which means that its products are perceived by the customers as pure

and slow perishing.

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Based upon the four parameters of taste-good or bad, healthy or unhealthy, the Mother

Dairy lies in the first quadrent, which means that customers perceive mother dairy as a

healthy and tasty product.

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OUTSOURCING

Galaxy Management services has signed an agreement with Mother dairy in July2009 to

provide a suite of recruitment services including job outsourcing work and Customer

care operations for the specific business needs and under cost saving exercise.

ASSEMBLY LINE LAYOUT


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LIST OF MAIN EQUIPMENT:

Turbo Mixers / Blenders.

Plate Heat Exchangers

Butter melting vat

HTST Pasteurizer with FDV

Two stage Homogenizer

Aging vats

Continuous Freezers with PLC control, make Tetra Pak, Denmark

Candy making & flow wrapping machine, make Tetra Pak. HOYER.

Cup & Cone filling machines

Hardening Tunnel for Novelties

Semi Automatic CIP system

Metal separator

Cold rooms

Allied Service Equipment like Refrigeration, Boilers, Generators, etc.

PRODUCT DEVELOPMENT PROCESS

The product is developed after thorough market analysis and consumer preferences with

the aim of providing healthy choices at reasonable price. This has also enabled

improvising the existing product packaging and taste to constantly delight our

consumers.

New Product Development process includes Concept Development, Lab trials, Shelf life

Studies, Consumer Research. Packaging Material Development is also carried out at

Innovation Centre. We select quality ingredients from reputed manufacturers across the

globe meeting all Quality and Food Safety requirements.

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Food Safety is of utmost importance while designing the manufacturing process for each

new product. R&D Scientists monitor and control first few batches of commercial

production to ensure conceptualized quality and organoleptic characteristics of new

products.

INNOVATION STRATEGIES

For the first time in India, we introduced Probiotic Dahi b -Active and Probiotic Drink

Nutrifit. As a result of extensive research, they enriched the Probiotic products with

dietary fiber to have Synbiotic effect and made it as a healthier option.

Dietz Sugar Free icecream was launched which is suitable for diabetic patients, calorie

conscious and containing high dietary fiber. Products developed in the in fresh dairy

product range includes: Kheer, Bottled Lassi (variants: Plain, mango and strawberry),

MishtiDoi, TadkaChach etc.

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In the frozen category, Kulfi in traditional flavors viz., Rose, Pan and Rabri, Dollies in

Raspberry & Guava chilly, Indian Classics, Western Classics and Dietz Sugar Free are

the most recent product ranges.

Innovation in Dairy Products

Probiotic Dahi

The first Synbiotic (combination of pro- and prebiotic) fermented product in India

The most ideally suited vehicle to carry millions of beneficial bacteria as well as fiber to

consumers on a regular basis

Proven Probiotic Strains Bifidobacteriumanimalis Bb12 and Lactobacillus acidophilus

A-5 with strong clinical evidence

Improves Gastro Intestinal ( GIT) health

Inhibits enteric pathogens

Improves phagocytosis &Ig levels Texture & taste liked by Indians

Low fat fermented products

Provides 8 % dietary fiber need as per ADA

Sensory quality comparable to indigenous Dahi

Post acidification negligible throughout shelf life

Marketed as B-Active Plus Dahi

Probiotic Drink

Probiotic Strains Bifidobacteriumanimalis Bb12 and Lactobacillus acidophilus A-5

Probiotic strains BB-12 and LA-5 which helps improve immunity

Containsreal fruit with natural goodness Assurance of bottle sterility for packaging

Provides 8% daily dietary need as per ADA

Favorably modulate GI microflora

Sold under the brand Name Nutrifit

Paneer

Traditional Culinary Dairy product

Soft, good slicing /cutting properties & excellent taste

Extended Shelf life after vacuum packaging

MistiDoi Traditional Bengal Delicacy

Newly improved formulation with better sensorial properties

Product attributes similar to home made product.

Rice Kheer

Popular Indian dessert

Creamy rich taste with goodness of dry fruits and nuts

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Lassi

In three varieties plain, mango fruit and strawberry fruit

Convenient trendy bottle packaging

Most suited for on-the go consumption

Innovation in Ice creams

Natural Vanilla Chocofudge Cake

Product with natural vanilla Flavour & chocolate sauce throughout ice cream

Better taste & appearance Chocolate cake as base to relish the product

Kulfi Range

Indian flavors Kesar, Pista, Rose and PaanKulfi to meet the local tastes

New shape of Kulfi on stick high selling value

Richness & creaminess due to high solid content

Fruit Classics

Goodness of real fruit in product

No added artificial Flavour

No added synthetic foodcolor

Fortified Ice Candies

Fortification with Vitamin-C meant for kids & youths

Provides 25% RDA (Recommended Dietary Allowance)

Benefits of Vitamin-C

Indian Classics

Icecream with traditional indigenous flavors KajuKishmish, Basundi and Kheer

,kesarpista

Filled with nuts and fruits

Western Classics

An all new range with a true western experience packed with chocolate, cookies and

cake to delight and enrich the experience of ice cream

Launched exclusively for the indulgent ice cream consumers

Dietz Sugar Free

No added sugar with low fat

Sensory attributes at par with regular ice cream

Clinical study carried out satisfactorily by Diabetic Foundation of India

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Innovation in Fruit & Vegetable products:

RTS Fruit Drinks

Peach Drink

Plum Drink Pineapple Drink

Mango Drink

Guava Drink

Litchi Drink

Orange Drink

Apple Juice, Natural 100%

Peach Jam with pieces Natural (No added Colour, Flavour & preservatives)

AlooTikki Frozen

Masala Sweet Corn Frozen

o Plain Saltedo Indian Magic Masala

Innovation in Product Packaging

Sterility of Bottles

The bottles are formed at high temperature and sealed immediately to maintain sterility

The sterile bottles are cut open, filled and sealed under aseptic condition maintained by

Laminar Air Flow of 0.3 Micron filtered air

The filled product is immediately transferred to refrigerated storage.

New Bottle Holders / Collators

Convenient to customer Better POP effect

Better shelf display

Economy of operation

Multilayer Pouch

UV treatment to pouches to avoid microbiological contamination

Specialized multilayer pouch for vacuum packing of paneer to extend shelf life

Comparable barrier properties of latest polymer structure

Improved economy

IcecreamMonocarton/ Paper Tubs

Introduced food grade virgin paperboard for packaging Ice Creams

Poly extrusion and water resistant food grade varnish coating

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Innovative Thermoformed Tray

First to introduce in India

Hygienic SecondaryPackaging for 90, 200 and 400 g Dahi SKUs

Most convenient and economical secondary packaging

Reusable and recyclable

Microwavable Cups

Forkheer and corn chatkara

The contents can be microwaved in the same cup without emptying

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FACILITY LOCATION ANALYSIS

MOTHER DAIRYPatparganj, Delhi

Unit Profile

Mother Dairy is the single largest brand of milk in Delhi, India as well as in Asia,marketing about 1.9 million litres of milk per day. Mother Dairy commands 40% marketshare in the organized sector in and around Delhi, primarily because of consistentquality and service whatever be the crisis-floods, transport strike, curfew etc. MotherDairy, Patparganj, Delhi, is presently manufacturing & selling around 8.5 lakh litres oftonned milk through bulk vending shops.

Mother Dairy, Delhi is an IS/ISO-9001:2000 and Hazard Analysis Critical Control Points(HACCP) and IS- 14001:1996 Environment Management System (EMS) Certifiedorganization .Mother Dairy was the first industry in country to implement ISO-14031(environment Performance Evaluation) project. The companys Quality AssuranceLaboratory is ISO/IEC-17025:1999 certified by NABL (National Accreditation Board forTesting and Calibration Laboratory), Department of Science & Technology, India. Thisprovides assuranceto the consumer in respect of Quality and Safety of products manufactured andmarketed by Mother Dairy.

The National Dairy Development Board (NDDB) commissioned Mother Dairy in the firstphase of Operation Flood in 1974. Considering the success of Dairy industry NDDB

established Fruit & Vegetable Project in Delhi in 1988 with SAFAL as its umbrellabrand.

With a view to separating the commercial activities from developmental activities, theNDDB merged Mother Dairy and the Fruit & Vegetable project into a wholly ownedcompany named Mother Dairy Fruit & Vegetable Ltd (MDFVL) in April 2000. Thisbecomes the holding company of Mother Dairy India Ltd (MDIL) - a marketing companyand Mother Dairy Foods Processing Ltd (MDFPL)- a processing company. MDFPL is amulti-unit company, with units at various locations in India. Mother Dairy, Delhi is one ofthe units of MDFPL.

The company is a highly trusted household name for its wide range of milk products likeMilk, Flavored Milk, Ice-Cream, Dahi, Lassi, Table Butter, Dairy Whitner, Ghee etc.

Mother dairy has taken up the concept of Total Productive Maintenance (TPM) wholeheartedly. The number of employees involved in KAIZENS and the no of KAIZENS peremployee are very encouraging. Mother Dairy is a member of CII-TPM Club and theKAIZENS done by Mother Dairy employees have been selected and presented in 2ndand 3rd National Kaizen Conferences held on 7-8 October, 2003 & 1-2 September, 2004respectively. The TPM efforts have resulted in increase in MTBF and decrease in MTTR.

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Mother Diary has received "Best Productivity Performance" award for three consecutiveyears starting from 1987-88 to 1989-90 and again from 1995-96 to 1997-1998 fromNational Productivity Council and a commendation Certificate for Rajiv Gandhi National

Quality Award.

Energy Consumption

There has been steady decrease in Electrical & Thermal consumption per equivalentlakh liters of milk due to implementation of various energy conservation improvements

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DESCRIPTION UNIT 2001-02 2002-03 2003-04

Annual milk production Lakh litres 2657.2 2525.8 3073.3

Total electrical energy consumption/annum Lakh Kwh 102.85 98.25 117.28

Specific energy consumption-Electrical Kwh/Lakh 3870.62 3889.86 3816.09

Total Thermal(Fuel) consumption/annum Mkcal 6160.46 5653.63 6650.13

Specific energy consumption-Thermal(Fuel) Mkcal/Lakh 2.32 2.24 2.16

YEAR ELECTRICITY THERMAL(FUEL)

Consumption (Kwh/LakhLitres) % reduction Consumption % reduction

over 2001-2002 (Mkcal/Lakh)

over 2001-2002

2001-02 3870.62 -- 2.32 --

2002-03 3889.86 -0.50 2.24 3.45

2003-04 3816.09 1.41 2.16 6.67

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Energy Conservation Commitment, Policy and Organizational Set up

Mother Dairy has a single comprehensive policy named "MANAGEMENT SYSTEMSPOLICY"incorporating the elements of Energy Conservation, Environment Management, FoodSafety(HACCP), Quality Management System, Safety & Hygiene.

MANAGEMENT SYSTEMS POLICY

Mother dairy is committed to:

Apply state of the art technology and processes to enhance productivity thatensures quality at Competitive price.

Apply processes for clean production, pollution prevention and optimizeresource utilization in all operations

Follow food safety management system and apply HACCP (Hazard AnalysisCritical Control Points) principles to provide safe products to customers

Comply with applicable regulations and legislations.

Pledge to provide quality and safe products under clean and hygienicenvironment.

Environment and SafetyMother Dairy, Delhi is committed to the protection of environment by Prevention ofPollution andContinual improvement in our processes and systems to improve EnvironmentalPerformance. The company is ISO14001:1996 (EMS) certified by BVQI. Mother Dairy

was the first industry in country to implement ISO-14031(Environment PerformanceEvaluation) project.

The following steps are taken and ongoing efforts are continuously made as per our"Management Systems Policy"

Minimize Waste generation Conservation of resourcesUse of renewable energy Recycling & re-use

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The Effluent Treatment Plant (ETP) was installed at the inception of the Dairy Plant. Thecompany complies with applicable regulations and legislations of Delhi Pollution ControlCommittee (Department Of Environment, Govt. of NCT of Delhi). The Dairy has reducedtotal effluent generation by 24% and water consumption by 29% during the period 2001-02 to 2003 -04

The water consumption has been reduced over the year as a result of theimplementation of following initiatives:

Installation of water recuperation system in the year 2001-02 where in the finalwater rinse quantity after Cleaning in Place (CIP) is taken in the waterrecuperation tank for reuse as the initial rinse in the subsequent CIP operation.

In-house water audit is carried out every year and by a continual process ofeducating the employees about the importance of water conservation andmotivating them to do KAIZENS directed to reduce water consumption.

Water consumption in all the activities in the Dairy is regularly monitored with the

help of data furnished by magnetic flow meters installed at various locations.

The Dairy has installed a Solar Plant for hot water generation and solar heatrecovery to the tune of 200 to 250 M kcal per annum is achieved through it.

The Dairy has constructed Rain Water Harvesting by dividing the entire premisesinto six zones to harvest maximum possible potential of rain water run-offavailable in the campus.

Accordingly unit has constructed rain water harvesting structures at the locationsthat experience water logging in each of the zones during rainy season. By thisunit has achieved increase in water table ranging from 30 cms to 150 cms in ourexisting tube wells in the Dairy.

Industrial safety is of paramount importance at Mother Dairy. A Safety Committeeheaded bySr. Manager (Mfg.) as Chairman and members drawn from workmenand officers cadre from different sections meet regularly to review and initiatesafety measures in all the activities of the Dairy. Numbers of mock drills arecarried out from time to time. Internal safety audits are carried out to locateunsafe conditions, acts and thorough investigation of accidents if any, strictenforcement of safety rules and procedures including work permit system anduse of Personal Protective Equipment (PPE).The Dairy is member of NationalSafety Council and also celebrates safety week every year. The Dairy has ZEROfatal accident since the date of its inception

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BIBLIOGRAPHY

http://en.wikipedia.org/wiki/Mother_Dairy

http://www.mannventures.com/mother-dairy-ice-cream-

division.html

http://www.motherdairy.com/MotherDairyPages/home.aspx

http://www.motherdairy.com/MotherDairyPages/branddetailpag

e.aspx?HLID=7

http://www.deccanherald.com/content/224908/mother-dairy-

expand-operations.html

http://www.hrgms.com/news.html

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