Introduction To Manufacturing Systems
Introduction To Manufacturing Systems
Introduction To Manufacturing Systems
T. Gutowski 2.810
Systems Topics
1. History and Reoccurring Problems 2. Toyota Production System 3. Time and Variation 4. Quality and Variation
1819 Hall signs contract to manufacture 1000 breechloading rifles of his design
1914 Moving chassis assembly line achieves 8:1 reduction in assembly time
History
Springfield and Harpers Ferry (1830s) Ford, Models T & A (1920s) WWII Aircraft (1940s) Transfer Lines (1950s) Flexible Manufacturing Systems (FMS) (1960s) Toyota Production System (TPS) (1980s)
Reoccurring Problems
Standardization Vs Flexibility Benefits and Costs of Inventory Just in Time Delivery, Supply Chain Dock to Dock Flow Time Pull Vs Push Inspection Techniques
Readings
David A. Hounshell, From the American System to Mass Production, 1800-1932, The John Hopkins University Press, 1984. Introduction, Chapters 1, 6 and 7 David A. Hounshell, Automation, Transfer Machinery, and Mass Production in the US Automobile Industry in the post WWII Era, appeared in The Society for the History of Technology, August 1996. optional
Those who do not learn from history are doomed to repeat it. Proverb
Harpers Ferry Armory, where John Hall first demonstrated interchangeablility on his breech loading rifle in 1827
Refs: 1. Merritt Roe Smith, Harpers Ferry Armory and the New Technology, Cornell University Press, 1977. 2. David A. Hounshell, From the American System to Mass Production, 1800-1932, The John Hopkins University Press, 1984.
U.S. Model 1816 Musket produced at the Springfield and Harpers Ferry Armories by craft method
See Video
Machine for boring gun Barrels with various Augers from 1814 U.S. patent application
Rendering of early drop press used at Philadelphia lamp Factory in 1833 and Thomas Blanchards eccentric lathe for turning gun stocks circa 1819
Blanchards reply to Roswell Lees letter of Jan 1819 requesting a demonstration of his new process at the National Armory
Yours of the 21 ultame. come safe to hand you wished me to wright you respecting macenory I conclude you meen a machine I have recently invented for turning gun stocks and cuting in the locks and mounting. Doubtless you have heard concerning it But I would inform you that I have got a moddle built for turning stocks and cuting in the locks and mounting. I can cut a lock in by water in one minute and a half, as smooth as can be done by hand. The turning stocks is very simple in its operation and will completely imatate a stock made in proper shape. I shal bring the moddle to Springfield in the course of three weeks I shal want your opinion of its utility. (ref. Hounshell)
1775
1785 1765 1794
1800
1798 1815 1819
1825
1822 1827 1834
le systeme Gribeauval
John Halls Breech loading rifle, produced at Harpers Ferry from 1823 to 1841
Ref.
Merritt Roe Smith Harpers Ferry Armory and the New Technology, U. Cornell Press, 1977, p. 227.
Corollary:
1. 2. 3. 4. 5.
Locate and Load Tool(s) Clean Machine Bed Locate and Mount Fixture(s) Fixture Part Locate (Reference) Tool to Part
Fords response
Ford's continuous improvement
Labor hours per car 500 400 300 200 100 0 1908 1910 1912 Year 1914 1916 1918
70% reduction
1910
1906 1908 1911 1913 1914
1920
1921 1923 1927
1930
1929
Punch Press operations, Highland Park plant 1913 Much of Fords punch press machinery came from John R. Keim Company from Buffalo, which Ford purchased in 1911 and moved to Detroit. Ref. Hounshell
Fords Highland Park Plant where the moving assembly line was first developed for automobiles in 1913
Westinghouse Foundry in 1890 Machine made molds are moved past pourer on conveyor system. A similar system was used at Ford
THE FIRST OPERATION TO BE CONVERTED TO THE MOVING ASSEMBLY LINE WAS THE THE MAGNETO ASSEMBLY IN 1913
HIGHLAND PARK
THE CONVERSION OF THE CHASSIS FROM STATIC (12.5 hr) TO MOVING (93 min) RESULTED IN AN 8:1 IMPROVEMENT. WITHIN 18 MO. ALL ASSEMBLIES AND SUBASSEMBLIES WERE CONVERED TO MOVING ASSEMBLY.
General view of the line Highland Park 1914 This is the assembly line that assembled a car in 93 minutes
However, Fords turnover rate increased dramatically. In 1914 Ford needed To hire 963 people To fill 100 jobs
Fords River Rouge Plant; 27 miles of conveyor, the epitome of vertical integration.
1927 change over to model A. 1949 strike. Now the site of Bill Fords Heritage program.
Those curved lines contributed to manufacturing problems which delayed the changeover
Labor leaders Walter Reuther and Richard Frankensteen after beatings by Harry Bennetts service men at the battle of the overpass. May 26, 1937 at the Ford River Rouge Plant.
The photos taken by the Detroit News photographer Scotty Kilpatrick on the overpass did not qualify for a Pulitizer Prize because there was no such category at the time. But they caused the Pulitzer committee to institute a prize for photography and in 1942 Detroit News photographer Milton (Pete) Brooks won a Pulitzer for this of a beating on a Ford picket line. Ironically, it shows picketers beating a Ford Motor Co. security man.
4.
5. 6.
Number of Aircraft
UK US Germany
1944
1946
16:1 !!!
Division of labor Redesign for mfg Interchangeable parts Pre-fabrication strategy Moving assembly line
Assembly of Pratt and Whitney R-2800 (2000hp, 2800 cu in) Engine at the Ford Dearborn Plant in 1944
Will it run?
1.
2.
3.
4. 5. 6.
Mass production techniques applied to military products including; division of labor, redesign for casting and forging, interchangeable parts, and moving assembly line. Fords Willow Run plant called will it run? due to long startup delay. Many of Fords tools not used, retrospective modification required at separate plant. Experience with automotive and aircraft companies with military aircraft production shows aircraft companies better suited to introduce new system in both U.S. and England. multiline production developed at Boeing. Continuous learning and the learning curve documented. Strategy to introduce change into the line; U.S. & U.K.
Refs: David A. Hounshell, Automation, Transfer Machinery, and Mass Production in the US Automobile Industry in the post WWII Era, appeared in The Society for the History of Technology, August 1996. David A. Hounshell, Planning and Executing Automation at the Ford Motor Company, 1945-65: The Cleveland Engine Plant and Its Consequences, proceedings in Fordism Transformed, Editors, Haruhito Shiomi and Kazuo Wada, published by Oxford University Press in 1995.
Automatic screw machine developed in 1871 by Charles van der Woerd. In production until 1981, capable of producing 800 finished screws per hour.
Automatic lathe controlled by cams, Levers and lead screw designed by Charles van der Woerd in 1866.
FMS
Something between dedicated Mass Production and a Job Shop Goals: highly automated, can work on several part types at a time Group parts, automate toll changing, work handling Seen in the 1970s in Germany and the U.S., later in Japan
Readings
David A. Hounshell From the American system to mass production, 1800-1932 Ch 1, 6 & 7 Hounshell, David A. "Automation, Transfer Machinery, and Mass Production in the US Automobile Industry in the PostWorld War II Era," Enterprise & Society 1 (March 2000):100-138.