RESEARCH METHODOLOGY:

Adoption of appropriate methodology is an essential characteristic of quantity research studies

irrespective of the discipline with which they are relative. Methodology provides a way and
guiding principles for research. It is defining and redefining and evaluating data, making
deduction & giving conclusion.

RESEARCH PROCESS FLOW CHART

Review The literature

Review concept
Concept
& theories
and theories
Define Collect Analyze Interpret
Design
research Review previous data data & report
F F Research F
problem research finding

1) Definition of problem statement:

During the initial days of internship it was noticed that all the work procedures
were running smoothly, but there was much scope for improvements in some
aspects of the procedures
Much of the valuable production time was being lost in non value adding
procedures.
Problem Statement:
1) Time loss during the issue of tools and materials from the stores.

2) Time loss during finding the root cause of the problem in the machine
maintenance

3) Time loss during loading & unloading of material.

2) Review the literature:

A) Review concept and theories:
1) The theory about the Kaizen process, Standardisation , codification and
classification, and various Root Cause finding techniques were studied.

B) Review previous research finding:

There was no research done on kaizen before in the organisation.
 3)Design Research:

Conducting a project without a research is akin to sail without a compass. Without any master
plan it might be clueless about exact tasks to be done and the proper fashion in which they need
to carried out. Aim at just the right kind of accuracy required, neither too high nor too low than
what is necessary .It helps to clarify the various assumptions underlying the study and the
practical contingencies involved.

For this project Descriptive type Research Methodology is used.

4)Data Collection of the study:

Primary source:

 Data is collected by interviewing the employees at various levels in the factory.

 Large amount of data is also collected by discussing with the Department Heads of
Maintenance, Machining and Production Department.

Secondary source:

 Through the records such as stock register, material issue receipts, Maintenance Records,
Monthly Maintenance Reports, Books and Web sites are used to collect the data.

5)Analysis of data:

Analysis of the data is done depending upon the state of condition before implementing Kaizen
improvements and the state of condition after the Kaizen improvements. The calculations of the
time saved due to the classification of tools were used for analyzing the data.

6) Interpretation and Report:

Interpretation is carried out from table and mathematical calculations.