Introduction to Manufacturing SystemsT. GutowskiT. GutowskiT. GutowskiT. GutowskiT. GutowskiT. GutowskiT. GutowskiT. Gutowski2.810Systems Topics1. History and Reoccurring Problems2. Toyota Production System3.Time and Variation3.Time and Variation4. Quality and Variation18001850190019502000Historical Development of Major Manufacturing Systems from ~1800 to 2000 System of InterchangeablePartsMass ProductionAt FordToyotaProductionSystem1819 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 plant18001850190019502000History• Springfield and Harper’s Ferry (1830’s)• Ford, Model’s “T” & “A” (1920’s)• WWII Aircraft (1940’s)•Transfer Lines (1950’s)•Transfer Lines (1950’s)• Flexible Manufacturing Systems (FMS) (1960’s)• Toyota Production System (TPS) (1980’s)Reoccurring Problems• Standardization Vs Flexibility• Benefits and Costs of Inventory• Just in Time Delivery, Supply Chain•Dock to Dock Flow Time•Dock to Dock Flow Time• Pull Vs Push• Inspection TechniquesReadings• 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 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.”ProverbDevelopment ofDevelopment ofDevelopment ofDevelopment ofthe System of Interchangeable Parts at the U.S. the System of Interchangeable Parts at the U.S. the System of Interchangeable Parts at the U.S. the System of Interchangeable Parts at the U.S. ArmoriesArmoriesArmoriesArmoriesHarper’s Ferry Armory, where John Hall first demonstratedinterchangeablility 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 Northcirca 1816 by Simeon NorthRef SmithMachine 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 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 Armories• Roswell Lee• Scarcity of trained gunsmiths• Very good transportation• James Stubblefield• Who’s who of gunsmiths•Paternalistic societytransportation• Puritan ethics• Good schools • Rapid adoption of new technology•Paternalistic society• Poor transportation• Poor public schools• Poor adoption of new technologyRef Merritt Roe SmithHistorical Developments for System of Interchangeable Parts1775180018251798181518221834Springfield Armory establishedRoswell appt. superintendent at Springfield Armory, 1815Hall signs contract to make 1000 breech loading rifles of his design1819Halls rifles are certified interchangeable by US Commission177518001825178517941798181518191822182718341765le systeme GribeauvalFirst demo Honore Blanc using hand tools 1785Harper’s Ferry Armory established1798Earliest known milling machine in North America Simeon North 1816Blanchard’s lathe 1822Simeon 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 commissionFixturing 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 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 avoid this difficulty, was to perform & gauge every operation on a limb, from one point calleda bearingso that the variation in any operation could only the single one from that point”.Ref. Merritt Roe Smith “Harper’s Ferry Armory and the New Technology”, U. Cornell Press, 1977, p. 227.Fixturing Principles from John Hall;Principle: Fixture Part from a single reference or “bearing”Corollary: Once fixtured, perform as Corollary: Once fixtured, perform as many operations as possible.1. Locate and Load Tool(s)2. Clean Machine Bed3. Locate and Mount Fixture(s)4. Fixture Part5. Locate (Reference)
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