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The Akshaya Patra
What is Akshaya Patra
– The Akshaya Patra Foundation is a not-for-profit organisation headquartered in Bengaluru, India.
– The organisation strives to fight issues like hunger and malnutrition in India, by implementing the Mid-Day Meal Scheme in the government schools and government-aided schools.
– Since 2000, the organisation has worked towards reaching more children with wholesome food on every single school day.
– It operates on a Public-Private-Partnership model. As an implementing partner of the Mid-Day Meal Scheme, there is continuous support from the Government of India, the various State Governments and associated organisations.
– Akshaya Patra reaches out to 1,689,871 children in 26 locations across 11 states of India
– It provides them with freshly cooked meals on all school days. Currently, they implement the Mid-Day Meal Programme in 13,210 schools of the country
– The Akshaya Patra uses a hub-and-spoke model, they cooked mass quantities of food and distribute smaller amounts to individual schools in the surrounding slum and village areas.
– Centralised Kitchens were developed to help cook massive quantities food for the distribution among children.
– As Akshaya Patra expanded services to the rural districts, a centralized model proved inefficient.
– Because of the dispersed geography of the villages in the rural districts, Akshaya Patra designed a decentralized model in which they built small kitchens to serve the local school children in each village
– Akshaya Patra Kitchens have adopted Six Sigma Methodologies
– The Process starts from Supplier Selection, Supplier Qualification, Supplier Rating etc. to ensure that the right and best raw materials are procured
– In order to ensure all the raw materials are fresh, all the kitchens follow the FIFO (First In First Out)and FEFO (First Expiry First Out) methods while issuing the raw material for production.
– Methods like Logistic charting for route optimisation, GPRS to track the delivery vehicles for safety and on-time delivery are adopted to ensure timely delivery.
– The staff have been trained on 5S, GMP, Lean and Kaizen, and ISO 22000 Awareness for kitchen employees across all locations for more than 6,000 man hours.
Procurement Process Akshaya Patra’s kitchens open at 2:30 a.m. and cooking starts at 3:00 a.m.
The pre-cooking shift begins with sorting of all ingredients, from vegetables to spices, into the necessary quantities.
– The first vehicle carrying food rolls at 5:30 a.m.
– Cooked foods are transported through heat-insulated, dust-free special purpose vehicles.
Procurement Process (Continued)
– It uses Hub-and-Spoke Model to distribute small amount of food to individual schools in the surrounding slum and village areas. For urban areas, they provide the food through a centralized kitchen located in Bangalore.
– In the urban areas, vegetables are procured from local markets through an ongoing relationship with 3rd Party Vendors. After procurement, sorting of vegetables is done to retain the best quality.
– The criteria for the selection of vendors is governed by market rate, offer rate, quality of samples based on the raw material specification, and the past performance of the supplier.
Supply of Food– They make the requirements of food grains like rice
one month before.
– Grain and flour requirements are calculated on the basis of the attendance of the students in each month.
– Pulses, oil and spices are purchased locally at subsidized rates.
– Turmeric, chilly, coriander and cumin seeds are procured from different markets across the country.
– The purchase requirement is raised by the store department when the stock reaches its reorder level.
Procurement Cost (in Rs.)
– Average cost of pulses per kg : 34.26 Average cost of vegetables per kg : 25.75 Average cost of oil & fats per kg : 53.00 Average cost of groceries per kg : 29.10 Average cost of spices per kg : 138.96
Limitations
– These large kitchens are not suitable for feeding school children in rural and other outlying areas because there are not enough no. of children in these villages to make large scale production feasible.
– Bad roads make it difficult for food to be distributed widely.
– Each kitchen has its own sourcing, so there is no consolidated buying which can decrease the cost further.
Drivers of Supply Chain
– Facilities- Size of the decentralized kitchen is small and of centralized kitchen is bigger to achieve better efficiency.- Hub and Spoke Model helps us to increase the responsiveness of the system.- SHG (Self Help Groups) are developed in the remote areas to improve the responsiveness of the system.
Drivers of Supply Chain (Continued)
– Inventory
MATERIAL NAME REORDER LEVEL (kg)
DAL 1500
PULSES 500
OIL 2000
SPICES 5 to 50
SALT 400
SUGAR 200
Because of the large quantity of requirement daily, Akshaya Patra has to maintain huge safety stock to have large responsiveness. Inventory = 5*175000= 8,75,000 meals of capacity should be there in the system.
Drivers of Supply Chain (Continued)
– Transportation - Around 40 vehicles travel 3000km per day from Hubli to different locations across India.- SHG acts as 3rd Party Logistics Provider to increase the responsiveness. LOCATION COST OF HIRED VEHICLES
HUBLI Rs 16000 per month
BANGALORE Rs 20000 per month
MANGALORE Rs 22000 per month
HYDERABAD Rs 25000 per month
Production Facility
Facility Area
Food Cooked for 1,75,000 Students in 5
Hours
12000kg Rice & 2500kg Pulses are Prepared Everyday
Production facility area is Flexible
Facility area divided into two parts Pre Processing Area, Cooking area.
Pre Processing Area includes all the items that are required for Next day
Cooking Area includes the making of all food items
Gravity Flow Technology18 Recipes of
Sambhar
• Unique technology to move food from upper pre processing area to cooking area
• Long and big pipes are used to transfer the food
• Capable of Producing 1200 liters of Sambhar/Rice in 2 hours
• Helpful in Producing different recipes for different days
• The total production and cook-to-consume times varied between 5-6 hours and 6-7 hours respectively.
Green Energy
• 788.95 Megatons of carbon emission has been saved from being released in the atmosphere by using thermite briquette boilers
• Briquettes are made up of sustainable agri-waste (groundnut shells and grain husks)
• High Pressure steam from boilers is used to cook food which decreases time
Storage
Storage:-
– In pre-processing perishable vegetables like tomatoes are cut on the same day of cooking while vegetables which have a longer life like carrot are physically inspected and cuts a day earlier and stored into cold storage.
– It uses around 12000 to 15000 kg of rice daily. Once the rice are cleaned they are stored in silos of capacity 160 MT. silos are equipped with sensor which keep track of stock.
– They use stainless steel container to stored cooked food which keep it warm.
Technology system
– main technology which ensure proper functioning of this kitchen are:-
1. Batch tracking system
2. Gravity Flow technology
3. Cooking fuel
4. Silos
5. GPS
Quality Check
– Quality check is done at each and every stage of its supply chain from procurement of goods to delivery of cooked foods
– Once procure goods is arrived they uses physical inspection to check quality of goods.
– Temperature is continuously monitored throughout cooking process as well as at the last moment where food is delivered.
– They uses warm water to check whether there is any leakage on milk packet or not
Quality lab and experiment team
– They have their own dedicated team for experimenting with food in order to find new taste.
– If a new recipe is found to cook the food. First it is test by its administrator who rates it over several features once all agree then it is produced for masses.
– Recent study in Karnataka have shown that Food was one of the main reason of increment in enrolment of students in government school in villages
Quality lab and experiment team
– Akshaya Patra has opened its first Food Safety and Quality Control Lab (FSQC Lab) in Ahmedabad
– Aimed to evaluate food from farm to plate
– the technology featuring in the lab are the Atago make table top refractometer which will be used to analyse total soluble solids, fat purity, adulteration of oil etc.
– Another interesting machine is the Shimadzu make spectrophotometer which will be used to evaluate DNA/protein concentration, absorbance, transmittance and more.
Packing Practices at TAPF
Stainless steel containers are used
to transport the food.The food in each
container is based on the number of beneficiaries.
Each container is given a unique label
to identification.This keeps track of what food is in the
container, the route (truck) it is part of, quality checks and
destination
The requirement for each school is
determined in terms of the no. of containers based on the average
beneficiaries.Milk and roti deliveries are also done alongside
the other processes.
Distribution of the food
Each truck has 4
members – Driver,
route manager,
Two Helpers
Every TAPF owned
delivery vehicle has
custom fittings
inside it to place the
containers
Routes are
designed to ensure
food is delivered at 60◦C
Fixtures
Reports are maintained to ensure the correct no. as
well as quality of food
Cook to consume time < 6 hours
Two trips per day: @7:30am and @9:30am
Fleet of Vehicles– TAPF owns a fleet of specially designed
vehicles procured from Mahindra & Mahindra Ltd., Tata and Eicher
– A large number of the trucks are usually donated by both companies and individuals
Quality Practices
Good Hygiene Practices• Using safety gloves, shoe covers, foot wears, aprons, hand
sanitizers; and proper hand washing• Washing of equipment with soap solution; and sterilization of
cauldron, and distribution containers
Good Manufacturing Practices
• Prerequisite Programme for food safety and following the production process stated in the Standard Operating Process.
Good Storage Practices
• Maintaining good storage conditions for the raw materials to keep them cool, dry, and clean • Following the rule of First Expiry First Out (FEFO)
Good Procurement Practices
• Extensive vetting process of suppliers• Rejection of low quality supplies
Conclusion– Akshaya Patra is an ode to one of humanity’s greatest challenges –
Avoiding Hunger
– Despite its humble beginnings in 2000, TAPF has managed to cater to 1.6 million students across 13,201 schools
– Its Supply Chain and Production operations are unparalleled, handling almost 2 lakh meals in some of their kitchens
– They have also showed their community sense by keeping the plans and designs of both their machines and facilities free for people to use