Introduction to Manufacturing Systems“Structural” “Historical”PowerPoint PresentationReadingsDevelopment of the System of Interchangeable Parts at the U.S. ArmoriesSlide 6Technology development in early AmericaSlide 8Blanchard’s reply to Roswell Lee’s letter of Jan 1819 requesting a demonstration of his new process at the National ArmorySpringfield MA & Harper’s Ferry VA US ArmoriesSlide 11Slide 12Fixturing of Parts – as described by John H. Hall to the Secretary of War in 1840Fixturing Principles from John Hall;Interchangeable Parts at U.S. Armories circa 1800-1860The Ford Motor Co. and Mass ProductionFord’s early production was increasing as fast as he could build carsFord’s response………Ford’s continuous improvement 1909-1916Slide 20Slide 21Slide 22Slide 23Slide 24Slide 25Slide 26Slide 27Slide 28Slide 29Slide 30Charlie Chaplin in “Modern Times”Crowd wanting to apply for $5/day jobs at Ford 1914Slide 33Slide 34Ford Service men in action May 26, 1937Labor leaders Walter Reuther and Richard Frankensteen after beatings by Harry Bennett’s “service” men at the “battle of the overpass”. May 26, 1937 at the Ford River Rouge Plant.Slide 37Mass Production at Ford, 1907- 1932Common elements between Ford and “lean”High Volume Aircraft Production during WWII, 1939 - 1945How did they do it?B-24 Assembly line in Ft. WorthSlide 43Slide 44Slide 45Slide 46Slide 47Slide 48Will it run?Slide 50Transfer Lines, 1890 - 1955Block “Cradle” at Ford’s Cleveland Engine Plant, 1952Machine Tools developed at Waltham Watch Co. circa 1860Slide 54Slide 55Summaries for three major manufacturing systemsHow where these new systems designed?SummaryIntroduction to Manufacturing SystemsTim GutowskiM.I.T.Oct 21, 2002“Structural”“Historical”Job shopsFlow shopsMass productionTransfer linesFMSToyota ProductionInterchangeable PartsMass ProductionAircraft WW IITransfer LinesFMSToyota Production1819 Hall signs contract to manufacture 1000 breech-loading rifles of his design1827Hall’s rifles are certified interchange-able by U.S. Commission1914Moving chassis assembly line achieves 8:1 reduction in assembly time1961Andon installed at Motomachi plant1800 1850 1900 1950 2000Historical Development of Major Manufacturing Systems from ~1800 to 2000 System of InterchangeablePartsMass ProductionAt FordToyotaProductionSystemReadingsDavid A. Hounshell, From the American System to Mass Production, 1800-1932, The John Hopkins University Press, 1984. Introduction, Chapters 6 and 7David 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.“Those who do not learn from history are doomed to repeat it.”ProverbDevelopment ofthe System of Interchangeable Parts at the U.S. Armories Harper’s Ferry Armory, where John Hall first demonstrated interchangeablility on his breech loading rifle in 1827 Refs:1. Merritt Roe Smith, Harper’s 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 Springfieldand Harper’s Ferry Armories by craft methodSee VideoTechnology development in early America“Earliest known milling Machine in America”circa 1816 by Simeon NorthRef Smith Machine for boring gunBarrels with various Augers from 1814 U.S. patentapplicationRendering of early drop press used at Philadelphia lampFactory in 1833 and Thomas Blanchard’s eccentric lathe for turning gun stocks circa 1819Blanchard’s reply to Roswell Lee’s 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)Springfield MA & Harper’s Ferry VAUS ArmoriesRoswell LeeScarcity of trained gunsmithsVery good transportationPuritan ethicsGood schools Rapid adoption of new technologyJames StubblefieldWho’s who of gunsmithsPaternalistic societyPoor transportationPoor public schoolsPoor adoption of new technologyRef Merritt Roe SmithHistorical Developments for System of Interchangeable Parts1775 1800 1825178517941798 181518191822182718341765le systeme GribeauvalFirst demo Honore Blanc using hand tools 1785Springfield Armory establishedHarper’s Ferry Armory established1798Roswell appt. superintendent at Springfield Armory, 1815Earliest known milling machine in North America Simeon North 1816Hall signs contract to make 1000 breech loading rifles of his design1819Blanchard’s lathe 1822Halls rifles are certified interchangeable by US CommissionSimeon North’s rifles interchange with Hall’sJohn Hall’s Breech loading rifle, produced at Harper’sFerry from 1823 to 1841Invented in 1811, certified interchangeable in 1827 by military commisionFixturing of Parts – as described by John H. Hall to the Secretary of War in 1840 “In making a part of an arm like a prescribed model, the difficulty is exactly the same, as that which occurs in making a piece of Iron exactly square. In such a case, a man would Square the 2d. side by the 1st, the 3d. by the 2d. and the 4th by the 3d., but on comparing the 4th side with the 1st, it will be found that they are not square; the cause is that in squaring each side by the preceding side, there is a slight but imperceptible variation and the comparison of the 4th with the 1st gives the sum of the variations of each side from a true square. And so in manufacturing a limb of a gun so as to conform to a model, by shifting the points, as convenience requires, from which the work is gauged & executed, the slight variations are added to each other in the progress of the work, so as to prevent uniformity. The course which I have adopted to
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