PREFACE

AMUL is the pride not only of Gujarat but also of entire country. It is a
matter of great pleasure in preparing this project on such esteemed
organization. A person aspiring to enter in management profession must
have practical knowledge of the subject. The objective of industrial visit is to
gain insight into practical knowledge in a student to supplement the
theoretical study of management as well as industrial.

This project is been prepared under course objective of the subject

Production and Operations Management under guidance of MS.Richa
Pandit(Facullty Guide).It has been a great learning experience visiting Amul
plant at Anand,Gujarat.

I have tried my best to present all the aspects related with the topics of
Productions and operations management. However I accept the sole
responsibility of any possible error of omission and will be grateful to the
readers of this project who bring mistakes to my notice.

Aruna Lambha,

Roll no.45,Division-A,

CPIMR 2012-14

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EXECUTIVE SUMMARY:
Anand Milk Union Limited popularly known as Amul Dairy is a US $ 500
million turnover institution. It is a institution built up with a network of
over 10000 Village Co-operative Societies and 500,000 plus members.

Formed in the year 1946 Amul is the leading food brand in India.

Amul initiated the dairy co-operative movement in India and formed

an apex co-operative organization called Gujarat co-operative Milk
Marketing Federation (GCMMF)and today 70,000 villages and 200
districts in India are part of it.

AMUL has spurred the WHITE REVOLUTION of India, which has made
India the largest producer of milk and milk products in the world and
the WHITE REVOLUTION has finally created a billion dollar brand.
Today AMUL dairy is no. 1 in ASIA and no.2 in the world.

Managed by an apex cooperative organization, Gujarat Co-operative

Milk Marketing Federation Ltd. (GCMMF), which today is jointly owned
by some 2.41 million milk producers in Gujarat, India

Amul is the largest food brand in India with an annual turnover of

US $1068 million(2007-08)

Currently Amul has 3.11 million producer members with milk collection
average of 6.04million liters/day.

Every day Amul collects 447,000 liters of milk from 2.12 million
farmers , converts the milk into branded, packaged products, and
delivers goods worth Rs 6 core (Rs 60 million) to over 500,000 retail
outlets across the country.

Amul products are available in over 500,000 retail outlets across India
through its network of over 3,500 distributors. There are 47 depots
with dry and cold warehouses to buffer inventory of the entire range of
products.

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 GCMMF transacts on an advance demand draft basis from its wholesale
dealers instead of the cheque system adopted by other major FMCG
companies. This practice is consistent with GCMMF's philosophy of
maintaining cash transactions throughout the supply chain and it also
minimizes dumping. Wholesale dealers carry inventory that is just
adequate to take care of the transit time from the branch warehouse
to their premises. This just-in-time inventory strategy improves
dealers' return on investment (ROI). All GCMMF branches engage in
route scheduling and have dedicated vehicle operations

Amul uses E- SUPPLY CHAIN MANAGEMENT

Amul has installed over 3000 automatic milk collection system units
(AMCUS) at village societies to capture member information, milk fat
content and amount payable to each member.

Amul has recently entered into direct retailing through AMUL utterly
delicious parlors created in major cities. AMUL has plans to create
large chain of such outlet to be managed by franchisee through the
country.

The Product Range

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Bread spreads Amul Butter, Amul Lite, Delicious Table Margarine
Amul Pasteurized Processed Cheddar Cheese, Amul Processed
Cheese Spread, Amul Pizza (Mozzarella) Cheese, Amul Emmental
Cheese Range
Cheese, Amul Gouda Cheese, Amul Malai Paneer (cottage cheese),
Utterly Delicious Pizza
Amul Gold Full Cream Milk 6% fat, Amul Shakti Standardized Milk
Fresh Milk 4.5% Fat, Amul Taaza Toned Milk 3% fat, Amul Slim & Trim, Amul
Cow Milk
Amul Gold 4.5% fat Milk, Amul Shakti 3% fat Milk, Amul Taaza
UHT Milk Range
1.5% fat Milk, Amul Lite Slim-n-Trim Milk, Amul Fresh Cream
Amul Full Cream Milk Powder, Amulya Dairy Whitener, Sagar
Milk Powders Skimmed Milk Powder, Amul PRO Infant Milk Food, Sagar Tea and
Coffee Whitener
Amul Kool Flavoured Milk, Amul Kool Cafe, Amul Kool Koko,Amul
Milk Drink
Kool Milk Shake, Amul Kool Chocolate Milk,Nutramul Energy Drink
Health Drink Stamina Instant Energy Drink
Brown Beverage Nutramul Malted Milk Food
Amul Masti Dahi (fresh curd), Amul Masti Spiced Butter Milk,Amul
Curd Products
Lassee, Amul Flavor Yoghurt
Pure Ghee Amul Pure Ghee, Sagar Pure Ghee
Sweetened
Amul Mithaimate
Condensed Milk
Mithaee Range Amul Shrikhand, Amul Mithaee Gulabjamuns, Amul Basundi,Avsar
(Ethnic Sweets) Ladoos
Ice-cream Sundae Range, probiotic,,sugarfree and probiotic
Chocolate & Amul Milk Chocolate, Amul Fruit & Nut Chocolate, Amul Chocozoo,
Confectionery Amul Bindass, Amul Fundoo

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 CONTENS:
Introduction of company
History
Facility layout & facilities at Amul plant
The three-tier Amul model
Village dairy cooperative society (VDCS)
Production process
E- supply chain management of Amul
Conclusion

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INTRODUCTION OF COMPANY:
The brand name "Amul," from the Sanskrit "Amoolya," (meaning Precious)
was suggested by a quality control expert in Anand.), formed in 1946, is a
dairy cooperative in India. It is a brand name managed by an apex
cooperative organization, Gujarat Co-operative Milk Marketing Federation
Ltd. (GCMMF), which today is jointly owned by some 2.8 million milk
producers in Gujarat, India.

AMUL is based in Anand, Gujarat and has been an example of a co-operative

organization's success in the long term. It is one of the best examples of co-
operative achievement in the developing economy. "Anyone who has seen
the dairy cooperatives in the state of Gujarat, especially the highly
successful one known as AMUL, will naturally wonder what combination of
influences and incentives is needed to multiply such a model a thousand
times over in developing regions everywhere."The Amul Pattern has
established itself as a uniquely appropriate model for rural development.

Amul has spurred the White Revolution of India, which has made India the
largest producer of milk and milk products in the world. It is also the world's
biggest vegetarian cheese brand. Amul is the largest food brand in India and
world's Largest Pouched Milk Brand with an annual turnover of US $1050
million (200607). Currently Unions making up GCMMF have 2.8 million
producer members with milk collection average of 10.16 million liters per
day. Besides India, Amul has entered overseas markets such as Mauritius,
UAE, USA, Bangladesh, Australia, China, Singapore, Hong Kong and a few
South African countries. DrVerghese Kurien, former chairman of the
GCMMF, is recognized as a key person behind the success of Amul.

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 HISTORY:
In 1929, Peston Edul Polson established Polson Model Dairy at Anand to
manufacture butter, ghee and casein and in 1944; the Bombay Municipal
Corporation Milk Supply was inaugurated. Monopoly rights were awarded to
Polson for Procuring milk from Kaira.
Amul's genesis is linked to the freedom movement in India. Sardar
Vallabhbhai Patel, an eminent Indian freedom fighter encouraged the dairy
farmers from the Kaira district in Gujarat to form a cooperative to counter
the 'exploitatively' low prices offered for their milk by the monopoly milk
Supplier of the area, Polson's Dairy. The dairy farmers met in Samarkha
(Kaira district, Gujarat) on the 4th of January 1946, and decided to set up a
milk producers' cooperative that would deal directly with the Bombay
government, the final buyer of their milk. This was the origin of the Anand
model.
Initially, when the Bombay government refused to deal with the
cooperative, the farmers called a strike. The government finally relented
when Bombay went without milk for a fortnight. The successful union
registered itself as the Kaira District Cooperative Milk Producers' Union Ltd.
(KCMPUL), Anand, in Gujarat in December 1946. And so did GCMMF and
brand AMUL establish consequently.
The main motto of Amul is to help farmers i.e. Milk producers. Amul
system works under objective of highest possible compensation to the milk
producers and lowest possible price to consumers. Farmer are paid money in
cash payment for the milk. Milk gives them money for the daily necessities.
Amul is the one who started using their profits for the milk producers
common good.

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 FACILITY LAYOUT:
Plant layout is the overall arrangement of the machine tools, handling
equipments, storeroom and other various accessories required for facilitating
production in a factory. These arrangements are pre-planned with the results
that the building has been constructed to fit a layout of a given process.

AMUL plant is indigenously worked out with facilitation of various production

processes and production of multi products under one plant. The total plot is
nearly about 2.27 kms. Separate buildings are provided with required
arrangements of machine tools handling and computers connection through
the control room to fit for varying product-manufacturing departments.

The plant is engaged in producing milk, ice creams, milk powder and ghee.
Entire department is uniquely provided with facilities for the processing each
product. There are 4 production departments and packaging departments
pertaining to each product respectively.

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IMAGES OF FACILITIES AT AMUL PLANT

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Amul Ice Cream

Product Details
Product Name Amul Ice Cream

Utterly delicious ice cream made from fresh milk available in a wide
Description
range of flavours and packs.

Cone 120 ml, 100ml, 80 ml & 50 ml

Cup 125 ml, 100 ml, 80 ml, 90 ml & 40 ml

Plastic
1 litre, 750 ml, 500 ml, 125 ml, 100 ml, 80 ml & 60 ml
Container
Packing
Stick 70 ml, 60 ml, 40 ml

Bulk / catering packs (5 litre, 4 litre), take home packs

Take
(2.2 litre, 1.5 litre, 1.25 litre, 1 litre), combo packs (750
Home
ml+750ml Free) and family packs (500 ml, 250 ml)

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Product Specifications
Fat :13%
Protein :4%
Composition Added Sugar :15%
Also, added stabilizers, emulsifiers, colors, flavours. (Nuts, fruits, fruit
pulp, topping etc. depending on flavor of ice cream).

Nutritional Information*

Amount per 100 ml

Energy, kcal 115.0

Energy from Fat, kcal 64.0

Total Fat, g 7.1

Saturated fat,g 4.9

Nutritional
Information Cholesterol, mg 18.9

Total Carbohydrate, g 10.7

Added Sugar, g 8.0

Protein, g 2.0

Calcium, mg 95.0

* Approx. value for vanilla flavour ice

cream.

Ice Candies, Plain flavor (No added nut, fruit, fruit pulp, topping
etc.) - 12 Months
Shelf Life Nuts/ Fruits Flavour - 6 Months
Ice Cream Cake - 4 Months
(Please see individual pack for shelf life)

Storage condition -18C or below

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Product Features

Made from Fresh Milk (Real Milk, Real Ice cream): No added vegetable
oil, hence no Frozen Dessert.

No Differentiation in Quality Standards of Consumer & Catering/

Institutional Packs: Stringent Standards than Specified by PFA & BIS for
more fat and less overrun (less air) to give creamier feeling.

Best Ingredients: Fresh milk, superior fruits & nuts.

Manufacturing Facility: Made in ISO & HACCP certified state of the art
plants with stringent hygienic standards to ensure food safety.

Prolife & SUGAR FREE Probiotic: The first company in India to introduce
probiotics in ice cream (IDF Award for Best Nutrimarketing Category, Oct '07)
& SUGAR FREE Probiotic products.

Product Application
Individual consumption (impulse), Take home, Catering at parties, marriages etc. celebration and
Recipe preparation for sundaes, shakes, etc.

Available in (Segments/Markets)
More than 800 cities across India at Amul Preferred Outlets, Amul Scooping Parlours, retail
shops, vending push carts, hotels, restaurants, canteens, caterers etc.

GCMMF
Gujarat Cooperative Milk Marketing Federation Ltd. (GCMMF), is India's largest food
product marketing organisation with annual turnover (2016-17) US$ 4.1 billion. Its daily milk
procurement is approx 18 million lit per day from 18,700 village milk cooperative societies,
18 member unions covering 33 districts, and 3.6 million milk producer members.

It is the Apex organisation of the Dairy Cooperatives of Gujarat, popularly known as

'AMUL',which aims to provide remunerative returns to the farmers and also serve the interest of
consumers by providing quality products which are good value for money. Its success has not
only been emulated in India but serves as a model for rest of the World. It is exclusive marketing
organisation of 'Amul' and 'Sagar' branded products. It operates through 56 Sales Offices and

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has a dealer network of 10000 dealers and 10 lakh retailers, one of the largest such networks in
India. Its product range comprises milk, milk powder, health beverages, ghee, butter, cheese,
Pizza cheese,Ice-cream, Paneer, chocolates, and traditional Indian sweets, etc.

GCMMF is India's largest exporter of Dairy Products. It has been accorded a "Trading
House"status. Many of our products are available in USA, Gulf Countries,Singapore, The
Philippines, Japan, China and Australia. GCMMF has received the APEDA Award from
Government of India for Excellence in Dairy Product Exports for the last 16 years. For the year
2009-10, GCMMF has been awarded "Golden Trophy" for its outstanding export performance
and contribution in dairy products sector by APEDA. In 2013-14, GCMMF took giant strides in
expanding its presence in International markets. Amuls presence on Global Dairy Trade (GDT)
platform in which only the top six dairy players of the world sell their products, has earned
respect and recognition across the world. By selling milk powders on GDT, GCMMF could not
only realize better prices as per market demand but it also firmly established Amul in the league
of top dairy players in world trade.

For its consistent adherence to quality, customer focus and dependability, GCMMF has received
numerous awards and accolades over the years. It received the Rajiv Gandhi National Quality
Award in1999 in Best of All Category. In 2002 GCMMF bagged India's Most Respected
Company Award instituted by Business World. In 2003, it was awarded the The IMC
Ramkrishna Bajaj National Quality Award - 2003 - certificate of merit- for adopting noteworthy
quality management practices for logistics and procurement. GCMMF is the first and only Indian
organisation to win topmost International Dairy Federation Marketing Award for probiotic ice
cream launch in 2007. For the innovations, GCMMF has received AIMA-RK Swamy High
Performance brand award 2013 and CNN-IBN Innovating for better tomorrow award in 2014.
World Dairy Innovation Awards- 2014 for Best Marketing Campaign - "Eat Milk with Every
Meal". For the tree plantation activity GCMMF has received seven consecutive Good Green
Governance award from Srishti during 2007 to 2013.

The Amul brand is not only a product, but also a movement. It is in one way, the representation
of the economic freedom of farmers. It has given farmers the courage to dream. To hope. To live.

GCMMF - An Overview

Year of Establishment 1973

Members 18 District Cooperative Milk Producers' Unions
No. of Producer Members 3.6 Million
No. of Village Societies 18,700
Total Milk handling capacity per day 30 Million litres per day
Milk Collection (Total - 2016-17) 6.57 billion litres
Milk collection (Daily Average 2016-17) 18.0 million litres
Cattlefeed manufacturing Capacity 7800 Mts. per day

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Sales Turnover -(2016-17) Rs. 27085 Crores (US $ 4.1 Billion)

THE THREE-TIER AMUL MODEL

DAIRY COOPERATIVE SOCIETY AT

VILLAGE LEVEL

MILK UNION AT DISTRICT LEVEL

MILK FEDERATION AT STATE LEVEL

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The Amul Model is a three-tier cooperative structure. This structure consists
of a Dairy Cooperative Society at the village level affiliated to a Milk Union at
the District level, which in turn is further, federated into a Milk Federation at
the State level. The above three-tier structure was set-up in order to
delegate the various functions, milk collection is done at the Village Dairy
Society, Milk Procurement & Processing at the District Milk Union and Milk
& Milk Products Marketing at the State Milk Federation. This helps in
eliminating not only internal competition but also ensuring that economies of
scale are achieved. As the above structure was first evolved at Amul in
Gujarat and thereafter replicated all over the country under the Operation
Flood Programme, it is known as the Amul Model or Anand Pattern of Dairy
Cooperatives.

Village Dairy Cooperative Society (VDCS)

The milk producers of a village, having surplus milk after own consumption,
come together and form a Village Dairy Cooperative Society (VDCS). The
Village Dairy Cooperative is the primary society under the three-tier
structure. It has membership of milk producers of the village and is
governed by an elected Management Committee consisting of 9 to 12
elected representatives of the milk producers based on the principle of one
member, one vote. The village society further appoints a Secretary (a paid
employee and member secretary of the Management Committee) for
management of the day-to-day functions. It also employs various people for
assisting the Secretary in accomplishing his / her daily duties.

The main functions of the VDCS are as follows:

1) Collection of surplus milk from the milk producers of the village &
payment based on quality & quantity
2) Providing support services to the members like Veterinary First Aid,
Artificial Insemination services, cattle-feed sales, mineral mixture sales,
fodder & fodder seed sales, conducting training on Animal Husbandry &

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Dairying, etc.
3) Selling liquid milk for local consumers of the village Supplying milk to
the District Milk Union
Thus, the VDCS in an independent entity managed locally by the milk
producers and assisted by the District Milk Union.

PRODUCTION PROCESS:
Collection of Raw Milk:
Raw milk is collected from different co-operatives of Gujarat.
About 12,22,000 liters of raw milk is collected per day. Before this milk
is sent to the laboratory for testing the FAT & SNF proportion, the milk
is separated from the raw milk. The milk is taken from the chilling
centers to Collection of Raw Milk Raw milk is collected from different
co-operatives of Gujarat. About 12,22,000 liters of raw milk is
collected per day. Before this milk is sent to the laboratory for testing
the FAT & SNF proportion.

Testing of raw milk:

After collecting the samples of milk they are taken to the
laboratory where two types of test are conducted:
1). ELECTRONIC MILK TEST Before pasteurizing the milk the samples
are taken to the laboratory . In the laboratory with the help of machine
called electronic milk tester, the proportion of SNF & FAT is checked

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 with phosphate solution. When the color of the milk become yellow, it
is sent for pasteurization.
2). METHYLINE BLUE REDUCTION TEST This test is conducted for
checking for how long the milk will remain fresh. To check this, 10 ml
of milk is taken and 1 ml of METHYL solution is added to it. It is then
kept under water at 57 degree Celsius. After one hour if the solution
losses its color then it is called raw milk. If the solution remains the
same even after 5 hours than it is considered fresh milk, which
remains constant for a long period of time.

The dairy fixes the proportion of SNF & FAT. After laboratory gives
green signal and conforming the raw milk at reception dock is brought
into the house connected with pump is sent to the milk processing
plant. This is then chilled below 4 degree Celsius and then stored in
the milk silos. After that milk is processed which has two steps:
Pasteurizing and Standardizing

Pasteurizing and standardizing:

To pasteurize the milk means to kill the germs in the milk by a
particular method which was invented by a scientist called JAMES
PASTEUR and so the name pasteurization. In the pasteurization
method the milk is first heated at 72 degree c to 76 degree c for 15
seconds and then it is immediately cooled below 4 degree c by this
method they destroy the pathogenic bacteria present in the raw milk.
But if the right degree of temperature is not provided there are
chances that milk might contain germs. After this process some milk
goes to separator machine and remaining is proportionately sent for
standardization.
Standardization process bifurcates the milk in 3 categories
varying according to the SNF & FAT contents. The equipment named
OSTA. Auto Standardization Adjusts the FAT directly. The computer is
just ordered whether gold or standard milk is to be rationed and the
same will be received with appropriate contents.

SEPARATION PROCESS:
Separation Process Separator machine separates two kinds of
products, skimmed milk and cream, through channels. There are 100
disks fixed in separator machine, which revolve at 5000 rpm(revolution
per minute). It is taken to the tanks, which has the capacity of 20000

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 liters. Whenever the milk is needed from the tank , it is tested in the
laboratory and the deficit proportion FAT is added by mixing cream.
This process continues for 24 hours.

QUALITY CHECK:
Pasteurized milk is sent to the quality Assurance laboratory of
the dairy plant. Within 14 seconds the FAT & SNF proportion is
received regarding 30 lack liters of milk. The total investment put into
the lab by the dairy plant is Rs. 6 crores. The laboratory only checks
and analyses the powder, milk and ghee. There is a separate ice cream
analyzing laboratory.5). Packaging Process After the milk is sent for
the packaging to the milk packing station in the dairy plant. In the
milk packaging stations there are huge pipelines and behind them
there is polyfil machine from which the material to pack milk comes
out. From each of these 12 machines 100 pouches are packed in one
single minute.

STORAGE:
Then the milk is sent to the cold storage of the dairy where the
milk is stored until it is dispatched. Here the milk is stored is
temperature ranging from 5 degree c to 10 degree c, it is maintained
with the help of exhaust fans having silicon chips. About 40000 liters
of milk is dispatched from the cold storage of the dairy plant everyday.
The damaged pouches are kept aside and the milk is once again put to
the storage tank.

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E- SUPPLY CHAIN MANAGEMENT OF AMUL
AMUL uses E- SUPPLY CHAIN MANAGEMENT

Amul has installed over 3000 automatic milk collection system units
(AMCUS) at village societies to capture member information, milk fat
content and amount payable to each member.

Each member is given plastic card for identification

Computer calculate amount due to the farmer on the basis of the fat
content

The value of the milk is printed out on the slip and handed over to the
farmer ,who collects the payment from the adjacent window

Thus with the help of it farmer gets the payment within the minutes
On the logistic more than 5000 trucks move milk from the villages to
200 dairy processing plants twice a day according to a carefully
planned scheduled

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 Every day Amul collects 7 million liters of milk from 2.6 million farmers
(many illiterate), converts the milk into branded, packaged products,
and delivers goods to over 500,000 retail outlets across the country

ERP software named as enterprise wide integrated application system

covers a operation like planning advertisement and promotion and
distribution network planning.

Each Amul office are connected via internet and all of them send daily
reports on sales and inventory to the main system at Anand,

At the supply end a computerized database has been setup of all

suppliers & their cattle

Computer equipment measures & records qualities & quantities

collected.

At the distribution end stockiest have been provided with basic

computer skills. Amulexperts assist them in building promotional web
pages.

Amul has linked distributors to the network & also incorporated web
pages of top retailers on their website

Distributors can place their order on website amulb2b.com

Automated supply & delivery chain

Practices just in time supply chain management with six sigma

accuracy

CONCLUSION:
Reasons for Amuls success are its Robust Supply Chain, Low Cost
Strategy, Diverse Product Mix, Strong Distribution Network, Technology
advancements & e-initiatives and service availability. Because of all
these competences Amul is the largest producer of milk and milk
products in the world. It has set world best practices for dairy
producers.

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BIBLOGRAPHY:
Notes written as on Industrial visit to Amul Plant

Internet Sources:

www.amul.com

www.wickepedia.com

www.managementparadise.com

www.studymode.com

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