Manufacturing 110 Introduction to Manufacturing Bruce Poole Sean
Manufacturing 110 Introduction to Manufacturing Bruce Poole Sean Howard (IBEST Instructor)
Definition � To manufacture 1) : to make into a product suitable for use or sale 2) : to make from raw materials by hand or by machinery 3) : to produce according to an organized plan with division of labor
Why Do Companies Do What They Do?
What is Important in Manufacturing? � History – How did we get where we are today? � Forces – What shapes manufacturing environments. � Organization – How and why of different organizations. � Quality – • The role of quality in manufacturing • Quality tools • The cost of quality � Lean Manufacturing – • Lean verses traditional models • Lean tools • Challenges • Pros and cons � Project management and the importance of teamwork.
History � Began with craftsmen or Guild systems as early as (circa 1500 but as early as 300 – 600 AD) � Putting-out System � English System (circa 1800) � American System (circa 1830) � Mass Production (Ford’s Assembly Line, circa 1900) � Statistical Process Control (circa 1950) � Modern Systems (JIT, Lean, Flexible) � Process Control Systems (Six Sigma, SQC, TQC)
Medieval Guilds � Early version of a union. � Formed to create and ensure quality work. � Served to protect craftsmen from merchants and cheap labor
Putting-Out or “Workshop” System � First sub-contractors � Textiles � Shoemaking � Small arms
English System � Skilled machinists � Produced from designs and models � Parts built to fit � Portsmith Block Mills
American or “Armory Practice” System � Interchangeable parts � Mechanization � Efficient labor � Machine tools and jigs
Mass or “Flow” Production � Standardized products � Assembly lines
The 4 Industrial Revolutions
Industrial Revolutions (cont)
Organization “The How and Why”
Organization (Operations)
Historical Timeline � 1574 – King Henry III of France watches the Venice Arsenal build complete galley ships in less than an hour using continuous flow. � 1799 – Whitney perfects the concept of interchangeable parts when he took a contract from the US Army for the manufacture of 10, 000 muskets at a price of $13. 40 each. � 1807 – Marc Brunel in England devised equipment for making wooden rope blocks for the Royal Navy using machines that produced identical items in process sequence. � 1822 – Thomas Blanchard at the Springfield Armory devised a set of 14 machines laid out in a cellular system to build gun stocks using patterns. No human labor in a single piece flow!
Historical Timeline (cont) � 1850 – All of the American armories were making standardized metal parts for weapons, but only with enormous amounts of handwork. Machines could not tool hardened metals. � 1890 – Sakichi Toyota invents a wooden handloom. � 1902 – Jidoka concept established by Sakichi Toyota. � 1905 – Frank and Lillian Gilbreth investigate motion economy in brick laying. (prelude to Lean manufacturing) � 1906 – Italian economist Vilfredo Pareto creates a mathematical formula to describe the distribution of wealth discovering 80% of the wealth lies with 20% of the population.
Historical Timeline (cont) � 1908 – Ford introduces the Model T. � 1910 – Ford moves into Highland Park, the “Birthplace of Lean Manufacturing”. � 1911 – Sakichi Toyota visits the US and sees Model T for the first time. � 1910 - 1912 – Ford develops gauging technology and the continuous flow of parts that allowed consistent fit in assembly. This was the breakthrough that allowed mass production. � 1914 – Ford creates the first moving assembly line, reducing chassis assembly time from over 12 hours to less than 3 hours.
Historical Timeline (cont) � 1924 – Walter Shewhart launches the modern study of process control with the invention of the control chart. � 1928 – Fords River Rouge plant completed becoming the largest assembly plant in the world with over 100, 000 employees! � 1929 – Kiichiro Toyota visits Ford and European companies to learn the automotive business. � 1937 – JM Juran conceptualizes the Pareto Principle emphasizing the importance of sorting out the vital few from the trivial many, name for Vilfredo Pareto. � 1938 – Just-in-time concept established at Toyota. JIT was later severely disrupted by WWII.
Historical Timeline (cont) � 1939 – Walter Shewhart publishes “Statistical Methods from the View Point of Quality Control” introducing the concept of Plan. Do-Study-Act. In the 50’s his colleague Deming alters the term to Plan-Do-Check-Act. � 1940 – Deming develops statistical sampling methods for the 1940 census, then teaches process control techniques to wartime production workers. � 1946 – Ford adopts GM management style and abandons lean manufacturing. � 1947 - 1949 – Ohno implements product flow lines, multiprocess handling, process and cycle time studies, time and motion studies, reduction of waste and work in process inventory, and in-process inspection. � 1950 – Deming invited to Japan to assist with census. He givens the first of dozens of lectures on statistical process control, emphasizing to Japanese management that improving quality will reduce expenses and improve productivity.
Historical Timeline (cont) � 1951 - 1955 – Ohno refines the TPS (Toyota Production System); visual control, management training programs, suggestion systems, reduction of batch sizes and change over time, first Kanban implemented. � 1960 – Deming receives the “Second Order of the Sacred Treasures” award. Japan attributes the rebirth of their industry to his work. � 1961 – Toyota introduces corporate wide TQC (Total quality Control) program. � 1962 – Kanban and “Pull System” are completed company wide. � 1965 – Toyota wins the Deming prize for quality.
Historical Timeline (cont) � 1975 – First English TPS handbook is published. � 1977 – Nick Edwards publishes a paper describing the fallacies of MRP (Manufacturing Resource Planning). � 1979 – First US study missions to Japan to see the Toyota Production System. APICS (Association for Operations Management) begins to bring US MRP systems under serious scrutiny. � 1980 – “Kanban: The Coming Revolution” is published. It is the first book describing TPS as JIT. � 1983 – First broader description of TPS by an American author, “Zero Inventories” by Robert Hall is published. � 1984 – Toyota and GM form the joint venture NUMMI (New United Motor Manufacturing Inc) plant in Fremont California.
Historical Timeline (cont) � 1984 – APICS begins a “Zero Inventory Crusade” what is now called Lean Manufacturing. � 1985 – The Association for Manufacturing Excellence is formed by a splinter group from ACIPS. � 1985 - 1989 – Several more books are published on Toyota production systems (SMED, Poka Yoke etc. ) � 1990 – “The Machine That Changed the World” by Womack and Jones is published. Lean manufacturing is thrust upon the American conscience. � 1996 – Womack and Jones publish “Lean Thinking”
Graphical History
Automobile Evolution; The History of Ford � The first automobile was developed in Europe and is attributed to Gottlieb Daimler and Karl Benz. � The first American car was developed by the Duryea brothers; Frank and Charles. � The first U. S. car race was held Thanksgiving day in 1895. Average speed was 6. 6 mph. � Henry Ford and several backers formed the Detroit Automobile Company, the first Detroit car company in 1899. It failed a year later. � Ford entered and won his first car race in 1901 defeating the current world record holder. His car simply “outlasted” the competition.
History of Ford (cont) � Stamped steel axel housings were so important for the manufacture of the model T that Ford purchased the Kerm Mills company outright. When a strike threatened production, Ford closed the plant and moved the equipment to his plant at Highland Park � Interchangeability began at the Piquette plant with the logical management of machines to create sequential flow. This was brought along to Highland Park. � Taylor published “The Principles of Scientific Management”. The use of time and motion studies to make workers as efficient as possible. � Ford introduced the first moving assembly line at Highland Park in 1913. The first “continuous motion” production line.
Mass Production � Also called; flow, repetitive flow, serial or series production. � Production of large amounts of standardized products especially on assembly lines. � Can apply to everything from food products, to electronics, to cars, planes etc. � The first modern mass production lines are generally credited to Henry Ford. � Made possible with the advent of the electrified factory and interchangeable parts.
Ford and The Machine
The Car That Changed the World � Ford History Videos
Mass Production Advantages/Disadvantages � Significant economies of scale; reduction of effort and labor in all areas. � Reduction of human error and variation. � Not very flexible. � Very difficult to modify or alter production lines once they are implemented. “Any customer can have a car painted any color that he wants so long as it is black. ” Henry Ford
Vertical Integration � The practice of gaining complete control over production from raw material to final assembly. � Early problems included shipping of finished goods and government trade barriers. � Ford built the River Rouge Complex with the idea of making the companies own iron and steel in the same plant that made car parts and assembled them. The plant also produced it’s own electricity. � Makes for a very self sufficient operation but can add a lot of cost. � What is a modern example of a vertically integrated company?
The Advent of Modern Systems and the Evolution of the Modern Factory � One of the most significant pre-war developments was the electrification of factories. � Post-war Toyota develops product flow lines and begins to do process time and movement analysis. � The introduction of Statistical Process Control by Deming in the 50’s began a slow evolution of manufacturing into the realm of quality control and lean. � The first robots were introduced in the late 50’s by Unimation founded by George Devol. The first robots used hydraulic actuators and were accurate to within 1/10, 000 of an inch. By the late 70’s, robot were advancing in technology and taking off quickly as a dominate tool on manufacturing floors. � Arguably the most significant development impacting factory capability and productivity in the last 30 years is the advancement of computers, software and in turn advanced automation and information systems.
JIT (Just in Time) � Developed in the 40’s by Toyota by studying the shelf stocking methods of grocery stores. � Strategy to reduce in-process inventory and thus cost. � Relies on signals or Kanban cards between product process steps that tell operators when to build. � Kanban literally means sign or billboard. � The cards signal the need for production based on upstream consumption of material. � This creates a demand driven system which helps companies better manage inventory levels.
Kanban Example
Flexible Manufacturing System (FMS) � Manufacturing systems that provide flexibility to adapt to changing demand. � Two types of flexibility; machine and routing. � Flexible machines allow for easy and fast change-over of fixtures, die sets, tooling etc. � Flexible routing means the ability to use multiple machines or production routes for the same demand, allowing factories to easily adapt to changing capacity demand. � Usually consists of three main components ; the machines, a material handling system, and a central control system (computer). � Examples: CNC, robotic cells etc.
Flexible Manufacturing Example Process Step 3 Process Step 2 Process Step 1 LINE 1 Process Step 3 Process Step 2 Process Step 1 LINE 2 Process Step 3 Process Step 2 LINE 3 Process Step 1
Mass Customization �A method of: “effectively postponing the task of differentiating a product for a specific customer until the last possible moment in the supply network” (Chase, Jacobs & Aquilano 2006, p. 419) � Specialized customization at mass production costs. � An example in use today is software-based product configurators. � Limited adaption today.
Agile and Rapid Manufacturing � Agile – Having the tools, processes and internal training to respond quickly to customer needs while still controlling quality and cost. � Requires systems that allow marketing, engineering and production access to the common database of products and parts. � Often viewed as the next step beyond Lean. � Rapid – Also called direct digital manufacturing, rapid, instant or on-demand. � Concepts were developed from rapid-prototyping in the 1980’s or the rapid construction of parts from 3 -D design software.
References � Wikipedia � The Machine That Changed the World Womack and Jones Think Lean Womack and Jones � Lean Production Simplified Pascal Dennis � “A Lean Approach to Production Planning” Fred Langer � Ford, The Men and the Machine Robert Lacey
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