Introduction to Manufacturing SystemsSystemsT. Gutowski2 8102.810Oct 20, 2008Systems TopicsSystems Topics1History and Reoccurring Problems1.History and Reoccurring Problems2. Toyota Production System3. Time and Variation4. Quality and VariationHistorical Development of Major pjManufacturing Systems from ~1800 to 2000 System ofMassToyotaSystem of InterchangeablePartsMass ProductionAt FordToyotaProductionSystem1800 1850 1900 1950 20001819 Hall signs contract to manufacture 1000 breech-loading rifles of his1827Hall’s rifles are certified interchange-able by U.S. Commission1914Moving chassis assembly line achieves 8:1 reduction in1961Andon installed at Motomachi plantloading rifles of his designU.S. Commissionreduction in assembly timeHistoryHistory•Springfield and Harper’s Ferry(1830’s)Springfield and Harper s Ferry (1830 s)• Ford, Model’s “T” & “A” (1920’s)WWII Ai ft(1940’ )•WWII Aircraft (1940’s)• Transfer Lines (1950’s)• Flexible Manufacturing Systems (FMS) (1960’s)()• Toyota Production System (TPS) (1980’s)Reoccurring ProblemsReoccurring Problems•Standardization Vs FlexibilityStandardization Vs Flexibility• Benefits and Costs of InventoryJtiTi Dli S lChi•Just in Time Delivery, Supply Chain• Dock to Dock Flow Time• Pull Vs Push•Inspection TechniquesInspection TechniquesReadingsReadings• 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 p,pp yyTechnology, August 1996. optional“Those who do not learn from history are doomed to repeat it.”ProverbProverbDevelopment ofth S t fI t h bl P t tth USthe System of Interchangeable Parts at the U.S. ArmoriesHarper’s Ferry Armory where John Hall first demonstratedHarper 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, 1977.2D id A H h ll F th A i S t t M P d ti 180019322.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 h”Machine in America”circa 1816 by Simeon NorthRfS ithRef SmithMachine for boring gunBarrels with various Augers from 1814 U.S. patentgpapplicationRendering 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 Ja 8 9 equest g a de o st at o o s eprocess 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. Doubtlessstocks 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 bycuting 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 ofthe course of three weeks I shal want your opinion of its utility.” (ref. Hounshell)Springfield MA & Harper’s Ferry VASpringfield MA & Harper s Ferry VAUS Armories• Roswell Lee•James Stubblefield• Scarcity of trained gunsmithsJames Stubblefield• Who’s who of gunsmiths• Very good transportationPit thig• Paternalistic society•Poor transportation•Puritan ethics• Good schools •Rapid adoption ofPoor transportation• Poor public schools•Poor adoption of new•Rapid adoption of new technology•Poor adoption of new technologyRef Merritt Roe SmithHistorical Developments for System of pyInterchangeable PartsHall signs contractSpringfield 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 Commission1775 1800 1825178517981815 1822 18341794 1819 18271765le systemeFirst demo HonoreHarper’sEarliest known millingBlanchard’sSimeon North’sle 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 1841ey o 83to8Invented 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 thatIn 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 4ththe 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 uniformityThecoursewhichIhaveadoptedtoin 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
View Full Document
Unlocking...