A

PROJECT REPORT
ON
TO IDENTIFY AND DESIGN PROBABLE PRODUCTIVITY
IMPROVEMENT TECHNIQUES
AT
MAHINDRA & MAHINDRA Ltd.
(FES, PUNE.)
SUBMITTED TO
PUNE UNIVERSITY
In Partial Fulfillment of Requirements
For the Award of Requirement of
Masters of Business Administration

BY
KAMRAN JAVED AMAN
Under the guidance of
Prof. MOHAN R. VIDYA
ACADEMIC YEAR 2011-2013

EAGLE EDUCATION SOCIETYS

UNIQUE INSTITUTE OF MANAGEMENT
KATRAJ, PUNE

CERTIFICATE

This is to certify that the Project Report titled TO IDENTIFY

AND DESIGN PROBABLE PRODUCTIVITY IMPROVEMENT
TECHNIQUES which is being submitted herewith for the award of
Master in Business Administration, Pune is the result of the original
research work completed by Kamran Javed Aman under my supervision
and guidance and to the best of my knowledge and belief the work
embodied in this Project Report has not formed earlier the basis for the
award of any degree or similar title of this or any other University or
examining body.

Project Guide:
Prof. Mohan R. Vidya

Place: Pune
Date:

Director:
Prof. Kumbhar.

DECLARATION

I, the undersigned, hereby declare that the Project Report titled

TO IDENTIFY AND DESIGN PROBABLE PRODUCTIVITY
IMPROVEMENT TECHNIQUES written and submitted by me to the
University of Pune , in partial fulfillment of the requirement for the award
of Master in Business Administration is my original work and the
conclusions drawn therein are based on the material collected by myself.

Date :
Place: Pune

Kamran Javed Aman

ACKNOWLEDGEMENT

This report is a brief account of the work carried out during the period of 60
days of training in Mahindra & Mahindra Limited, Farm Equipment Sector. The
Training period comprised of lot of learning experience for which I am thankful to
many people who helped me throughout the training duration.
I am grateful to Mr. Ashish Khole, Manager, HR for giving me the opportunity
to do my Summer Internship Project at Mahindra & Mahindra Limited,
I show special gratitude towards my Project Guide Mr. Mohan Vidya for their
continuous guidance and encouragement.
I am thankful to Mr. Pramod Najpande and Mr. K.P.Kale for their involvement
and inputs in my project.
I express my sincere gratitude to Prof. Mohan Vidya of Unique Institute of
Management for guiding me throughout my training period.
I extend my sincere thanks to all those people who have helped me in the
successful execution of this project with their valuable suggestions.
Finally I would like to pay regards to my parents without whose inspiration
and monetary aid this project was impossible.

Kamran Javed Aman

EXECUTIVE SUMMARY
Productivity improvement and cost control have become key objectives of
manufacturing companies in recent years due to intense competition in the businesses.
As a result, many organizations have introduced productivity improvement programs
in their factories.
This project is a very small attempt to study and understand the
implementation of the productivity improvement techniques in the world class
organization like Mahindra and Mahindra. During the summer internship at Mahindra
and Mahindra Ltd., Farm Equipment Sector, Pune, I got great opportunity to work on
the live project of implementation of some of such productivity improvement
techniques in their Tractor Assembly Plant in Pune.
This project aimed to implement the productivity improvement techniques
namely Kanban System, Poka-Yoke, Kaizen event in the plant.
The project is divided into three sections. First is the deploying the Kanban
System to the process of material procurement namely Painted components to the
assembly line. Second is the design of the Poka-Yoke at the Break pedal oil seal
fitment of the assembly line and Third one is to design and conduct a Kaizen Event of
Idea generation drive in the plant as a part of all employee involvement in the
continuous improvement drive.
The project report is divided into six chapters. The first chapter gives the
introduction about the project as well about the organisation and it also includes the
objective and limitations of the study. The second chapter gives details about the
conceptual background of the techniques and terms used in the project and also about
the research methodology used for this project. The third chapter includes the detailed
data about the project work. The forth chapter include findings from the project work,
suggestions and the conclusion of the project report. The fifth chapter is appendices
and sixth chapter is Bibliography used for the project.

TABLE OF CONTENTS
Sr No
1

Contents

Page No.

Introduction
i.

Introduction of topic

ii.

Organizational Profile

iii.

Statement of Problem

16

iv.

Objectives of study

17

v.

Research Methodology

18

vi.

Limitations of study

20

Conceptual Background
i.

Kanban System

22

ii.

Poka Yoke

28

iii.

Kaizen event

29

Data Presentation, Analysis and Interpretation

i.

Designing Kanban System

31

ii.

Designing Poka Yoke

43

iii.

Designing Idea generation drive

47

Major Findings, Suggestions and Conclusion

i.

Major findings

52

ii.

Suggestions

53

iii.

Conclusion

55

Annexure and Bibliography

i.

Appendix I : Sample Kanban Card

57

ii.

Bibliography

58

LIST OF TABLES
Table
No.
1.2.1
2.1
2.2
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8

Title
Sales and Market Share of last two years
Waste Elimination by Kanban Application
Symbols used in Process Flow Chart
Painted components of H1 Model
Painted components of H2 Model
Painted components of Export Model
Previous Process Flow Chart
Current Process Flow Chart
Kanban Size for all components
Proposed Process Flow Chart
New Process Flow Chart

Page No.
14
26
27
32
32
33
34
35
38
39
41

LIST OF FIGURES
Figure
No.
1.2.1
1.2.2
3.2.1
3.2.2
3.2.3

Title
Mahindra group an overview
Profits by Business Sector
Diagram of Pressing machine and Oil Seal
Cause Effect Diagram
Model Circuit Diagram

Page No.
6
6
43
44
45

ABBREVIATIONS
M&M
ML

:
:

Mahindra & Mahindra

Mahindra Logistic

SCPC

Supply Chain Planning & Control

SM

Supply Module

DOL

Direct On Line

IUTN

Inter Unit Transfer Note

DOL

Direct On Line

BOM

Bill Of Material

CMRD

Central Material Receiving Discrepancy

RQA

Receiver Quality Assurance

SQA

Supplier Quality Assurance

SKU

Stock Keeping Unit

MHE

Material Handling Equipment

BOPT

Battery Operated Pallet Truck

HOPT

Hand Operated Pallet Truck

TQM

Total Quality Management

TPM

Total Productivity Maintenance

WIP

Work In Progress