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7 7 Farm equipment supply chains Guidelines for policy-makers and service providers: experiences from Kenya, Pakistan and Brazil Experience has shown that a basic prerequisite for successful Farm equipment supply chains mechanization of the agricultural sector requires a well-functioning supply chain. To draw lessons for achieving this goal, the FAO Rural Infrastructure and Agro-Industries Division commissioned three mechanization supply chain case studies. The studies were conducted in Kenya, Pakistan and Brazil, and the information contained in them has been used as the basis for the analysis presented in this Technical Report. Historically, public sector efforts to supply mechanization services have often failed, as costs greatly exceeded income and the maintenance of ageing machinery fleets became too great a burden. However, it is evident that the public sector does have a role to play in complementing the activities of the private sector in a synergistic partnership. The main role of the public sector is to have the vision of a national mechanization strategy and to cultivate an enabling environment that allows the private sector to operate effectively. One key possibility described in the Report is that of linking equipment supply chains across continents. This is exemplified by an account of the evolution of no-till technology in Brazil, which is now being successfully used by farmers in Asia and Africa. A key stakeholder in this supply chain development has been FAO in conjunction with the international donor community, as they have been in a position to take a holistic view to encourage private sector actors and so disseminate profitable mechanization technologies from one continent to another. The main recommendations of the Technical Report are aimed at policy-makers in the public sector, although there is plenty to interest other stakeholders, especially machinery suppliers and mechanization service providers. However, the ultimate beneficiaries are small- and medium-scale farmers who are the recipients of the services provided. ISBN 978-92-5-106431-3 9 ISSN 1814-1137 789251 064313 I1209E/1/10.09/1000 Guidelines for policy-makers and service providers: experiences from Kenya, Pakistan and Brazil ISSN 1814-1137 AGRICULTURAL AND FOOD ENGINEERING TECHNICAL REPORT AGRICULTURAL AND FOOD ENGINEERING TECHNICAL REPORT I1209E_frontespizio.pdf 1 02/11/2009 17:31:16 AGRICULTURAL AND FOOD ENGINEERING TECHNICAL REPORT 7 Farm equipment supply chains Guidelines for policy-makers and service providers: experiences from Kenya, Pakistan and Brazil C M by Y CM MY Brian G. Sims FAO Consultant CY CMY K and Josef Kienzle FAO Rural Infrastructure and Agro-Industries Division FOOD AND AGRICULTURE ORGANIZATION OF THE UNITED NATIONS Rome, 2009 The Agricultural and Food Engineering Technical Reports bring to a broad audience the results of studies and field experience related to agricultural and food engineering within agrifood systems. The reports help us take stock of what we know and clearly identify what we do not know; and in so doing they provide information to both the public and private sectors. The Agricultural and Food Engineering Technical Reports serve to direct further work within agrifood systems. Plates 1–5: © FAO/B.G. Sims The designations employed and the presentation of material in this information product do not imply the expression of any opinion whatsoever on the part of the Food and Agriculture Organization of the United Nations (FAO) concerning the legal or development status of any country, territory, city or area or of its authorities, or concerning the delimitation of its frontiers or boundaries. The mention of specific companies or products of manufacturers, whether or not these have been patented, does not imply that these have been endorsed or recommended by FAO in preference to others of a similar nature that are not mentioned. The views expressed in this information product are those of the author(s) and do not necessarily reflect the views of FAO. ISBN 978-92-5-106431-3 All rights reserved. Reproduction and dissemination of material in this information product for educational or other non-commercial purposes are authorized without any prior written permission from the copyright holders provided the source is fully acknowledged. Reproduction of material in this information product for resale or other commercial purposes is prohibited without written permission of the copyright holders. Applications for such permission should be addressed to the Chief, Electronic Publishing Policy and Support Branch, Communication Division, FAO, Viale delle Terme di Caracalla, 00153 Rome, Italy or by e-mail to copyright@fao.org © FAO 2009 iii Contents Foreword vii Acronyms viii Acknowledgements x Executive summary xi 1. Introduction and background 1 1.1 Background to the present study 4 1.2 Report structure 5 2. Supply chain and machinery management issues and a summary of the constraints encountered 7 2.1 Supply chain focus 7 2.2. Summary of constraints 8 2.3 Testing agricultural machinery 3. Guidelines and opportunities for agricultural machinery supply chain stakeholders 10 13 3.1 Policy-makers 14 3.2 Manufacturers, importers and retailers 17 3.3 Machinery hire services 20 3.4 Machinery repair services 21 3.5 Farmers 21 4. The case studies 25 4.1 Introduction 25 4.2 Kenya 25 4.3 Pakistan 34 4.4 Brazil 38 References 47 iv List of figures 1. Farm power and machinery supply chain stakeholders xii 2. An example of a farm machinery supply chain in Kenya 2 3. The traditional view of supply chain processes: cycles (the triangles represent inventories of products) 3 4. Interactions between farmers and farmer groups with public and private sector stakeholders 13 5. Possible interrelationships in the farm power input supply chain to farmer groups 22 6. Location of Rift Valley province, Kenya 25 7. Location of Nakuru and Laikipia districts, Kenya 25 8. Farm power and machinery supply chain for Laikipia and Nakuru, Kenya 26 9. Input supply chain for local manufacturers and machinery retailers in Laikipia and Nakuru, Kenya 27 10. Input supply chain for farm machinery hire service providers in Laikipia and Nakuru, Kenya 29 11. Input supply chain for farm equipment repair services 31 12. Pakistan showing the Punjab province 34 13. Schematic supply chain of farm machinery in Pakistan: from raw material to end users 35 14. The three states of southern Brazil: Paraná, Santa Catarina and Rio Grande do Sul 38 15. Machinery supply chain for tractor powered equipment in southern Brazil 41 16. Production lines of a range of manufacturers of human and animal traction (AT) powered agricultural equipment 41 17. Simplified supply chain for small- and medium-sized manufacturers of human and animal traction powered no-till equipment in southern Brazil 42 18. The dramatic rise in NT area (ha) in the decade 1992–2002 in Rio Grande do Sul state 43 v List of plates 1. Policy-makers are updated on technical innovations xiii 2. Testing of a no-till planter by a manufacturer xiii 3. Machinery services for hire must closely follow farmers’ needs xiv 4. Roadside repair of combine harvester xiv 5. Farmer field-testing of a prototype planter xv 6. Direct planting through stubble maintains a permanent protective cover on the soil 4 7. Sprayer production at the Jacto factory in Brazil 8 8. Sfil SS 10000 planter at a dynamic evaluation event of no-till seeders in 2003 in Guaíra Paraná State, Brazil 12 9. Batch orders placed with private sector manufacturers 15 10. High density carrot crop on raised beds 16 11. Smallholder farmers practise crop establishment with jab planters 16 12. Two-row animal-drawn no-till planter of the type now being imported into East Africa from South America 18 13. Simon Ngero explains the design of the Femo pedestrian-pulled sprayer 19 14. Direct drilling wheat into rice stubble with a Brazilian no-till seed drill 20 15. The Ndume factory near to Nakuru manufactures heavy-duty agricultural equipment 27 16. The KickStart Moneymaker pump being manufactured by a medium-scale manufacturer 28 17. Hammer mill production in Nairobi, Kenya 28 18. Holman Brothers imports machinery from Europe and Brazil and, in common with other retailers, caters for larger-scale farmers 28 19. Artisan training at RTDC, Nakuru 30 20. Vertically integrated machinery manufacturers reduce outsourcing to a minimum 35 21. Farm machinery dealer showcourt in Punjab, Pakistan 37 22. Sophisticated no-till tractor mounted planter produced by Sfil 39 23. Matracas produced by the Krupp factory as its sole product line 40 24. A hand operated sprayer being demonstrated by a Knapik company director at his factory 40 25. The Gralha azul animal traction no-till planter and fertilizer applicator developed at IAPAR in the mid-1980s 43 26. Fertilizer and lime distributor of the type offered free to small- and medium-scale farmers in Aratiba 45 vi List of boxes 1. The "cycle-view" of the supply chain and supply chain management 3 2. Agro-industrial supply chain management 8 3. Legitimate versus inferior hand-hoes 11 4. Tractor hire services for raised beds and reduced soil compaction 16 5. The Government of Kenya through the Ministry of Agriculture: getting serious with conservation agriculture 16 6. Brazafric venture into conservation agriculture equipment 18 7. Femo Works Engineering, Nairobi, Kenya 19 8. Rice–wheat systems in Pakistan 20 9. Fixed and variable costs for operating agricultural machinery and an example of partial budgeting from Uganda 33 10. Machinery supply to small-scale farmers in Rio Grande do Sul, Brazil 45 List of tables 1. Summary of constraints for each category of stakeholders 9 2. Fixed and variable costs of operating agricultural machinery and draught animals 33 3. Partial budgeting for the change over from conventional tillage to conservation agriculture 33 vii Foreword There is a pressing need to liberate smallholder farmers in sub-Saharan Africa (SSA) from the back-breaking yoke of hand-hoe cultivation. Currently about 65 percent of the agricultural land in SSA is worked with hand labour and the hoe is the principal tool used, while in southern Asia this rate is 40 percent and in Latin America and the Caribbean, 25 percent. The low productivity of the human work force in Africa, frequently exacerbated by pandemics and rural-urban migration, makes it very unlikely that the UN Millennium Development goal of eradicating extreme poverty and hunger can be met by the 2015 target. Mechanization of agricultural tasks will raise labour and land productivity and is an urgent necessity to enable Africa to feed its people. Previous efforts to mechanize African farms, especially in the small- and medium-sized range, have not always been successful. What is clear from past experience is that a well-functioning supply chain is a basic prerequisite for successful mechanization to take place. With this in mind, the FAO Rural Infrastructure and Agro-Industries Division commissioned three mechanization supply chain case studies in three continents. The studies were conducted in Kenya, Pakistan and Brazil, and the information contained in them has been used as the basis for the analysis presented in this Technical Report. What is clear is that all the stakeholders in farm machinery supply chains are vital links to ensure the smooth functioning of the chain as a whole. And also that all stakeholders must earn their livelihoods, totally or partially, from their activities in the provision of mechanization services to farmers. Public sector efforts to supply mechanization services have often fallen short of their goals. However it is evident that the public sector does have a role to play in complementing the activities of the private sector in a synergistic partnership. The main role of the public sector is to have the vision of a national mechanization strategy and to cultivate an enabling environment that allows the private sector to operate effectively. One key possibility described in the Report is that of linking equipment supply chains across continents. This is exemplified by an account of the evolution of no-till (NT) technology in Brazil, which is now being successfully used by farmers in Asia and Africa. FAO, in conjunction with the international donor community, has been a key stakeholder in this supply chain development, being in a position to take a holistic view to encourage private sector actors and so disseminate profitable mechanization technologies from one continent to another. The main recommendations of the Technical Report are aimed at policy-makers in the public sector, although there is plenty to interest other stakeholders, especially machinery suppliers and mechanization service providers. However the ultimate beneficiaries are small- and medium-scale farmers who are the recipients of the services provided. viii Acronyms ACT African Conservation Tillage Network, Kenya ADC Agricultural Development Corporation, Kenya AFC Agricultural Finance Corporation, Government of Kenya AGST Agricultural and Food Engineering Technologies Service, FAO AMRI Agricultural Mechanization Research Institute, Pakistan AMS Agricultural Machinery Service, Government of Kenya AS Agriculture Secretary, Government of Kenya BNDES Banco Nacional de Desenvolvimento Econômico e Social (Brazilian Bank for Economic and Social Development) CA conservation agriculture CAMARTEC Centre for Agricultural Mechanization and Rural Technology, the United Republic of Tanzania EMATER Empresa de Asistencia Técnica e Extensão Rural (Brazilian technical assistance and extension corporation) EMBRAPA Empresa Brasileira de Pesquisa Agropecuária (Brazilian Agricultural Research Corporation) FAO Food and Agriculture Organization of the United Nations FEBRAPDP Federação Brasileira de Plantio Direto na Palha (Brazilian No-Tillage Federation) FFS Farmer Field School FINAME Linha de Financiamento de Máquinas e Equipamentos do BNDES (Credit line – from BNDES – for agricultural machinery purchase) FMD Massey Ferguson Dealer in Kenya FMI Farm Machinery Institute, Pakistan FOS Farm Operation Services in Pakistan FSK Farming Systems of Kenya GoB Government of Brazil GoK Government of Kenya GoP Government of Pakistan IAPAR Instituto Agronômico do Paraná (Paraná State Agricultural Research Institute, Brazil) IPCC Intergovernmental Panel on Climate Change, WMO UNEP KENDAT Kenya Network for Dissemination of Agricultural Technologies KFA Kenya Farmers’ Association Ksh Kenyan shilling MDG Millennium Development Goal MoA Ministry of Agriculture, Brazil, Kenya, Pakistan NAAIP National Accelerated Agricultural Input Project, Kenya ix NALEP National Agriculture and Livestock Extension Programme, Kenya NEPAD The New Partnership for Africa’s Development NGO non-governmental organization NMK Njaa Marufuku Kenya NT no-till PARC Pakistan Agricultural Research Council PR Paraná State, Brazil PRONAF Programa de Apoio a Agricultura Familiar (National family farmers support programme, Brazil) PSQCA Pakistan Standards Quality Control Authority R&D research and development RS Rio Grande do Sul State, Brazil RTDC Rural Technology Development Centre, Kenya SARD Sustainable Agriculture for Rural Development (a Government of Germany funded FAO project in East Africa) SC Santa Catarina State, Brazil SCM supply chain management SSA sub-Saharan Africa UEMOA Union Economique et Monétaire Ouest Africaine (West African Economic and Monetary Union) UNEP United Nations Environment Program Ush Ugandan shilling UNIDO United Nations Industrial Development Organization VO Village Organization, Pakistan WMO World Meteorological Organization