Continuous Process Improvement: The Lessons of History BADM 701 Dr. Ron Lembke

Cotton Gin at Work

Eli Whitney Introduced interchangeable parts in large musket contract for U.S. Army Introduced interchangeable parts in large musket contract for U.S. Army Interchangeable parts the true secret of Ford’s success Interchangeable parts the true secret of Ford’s success Made possible by advances in measurement and tool steel Made possible by advances in measurement and tool steel

Tool Steel Advances

Beginning of Standards Before standardized parts, need Screws Before standardized parts, need Screws 1860s Machine Tool industry: Silicon Valley of its day 1860s Machine Tool industry: Silicon Valley of its day All screws custom made by tool & die shops according to what they thought best All screws custom made by tool & die shops according to what they thought best William Sellers: 1864 “On a Uniform System of Screw Threads” William Sellers: 1864 “On a Uniform System of Screw Threads”

Sellers objectively better Easier: simple angle vs. difficult; rounded top vs. straight Easier: simple angle vs. difficult; rounded top vs. straight 3 cutters & 2 lathes vs. 1 cutter & 1 lathe 3 cutters & 2 lathes vs. 1 cutter & 1 lathe Sellers vs. Whitworth

Not Just What you Know Machine tool makers didn’t want to be commoditized like gun makers Machine tool makers didn’t want to be commoditized like gun makers The standard people expect to win usually does. The standard people expect to win usually does. Navy Board found it superior, asked Singer Sewing Machine, Baldwin Locomotive which would win (already adopted). Navy Board found it superior, asked Singer Sewing Machine, Baldwin Locomotive which would win (already adopted). Pennsylvania RR adopted (Sellers on the Board) Pennsylvania RR adopted (Sellers on the Board) British tanks & trucks couldn’t be repaired in WWII because Britain adopted Whitworth British tanks & trucks couldn’t be repaired in WWII because Britain adopted Whitworth

Frederick W. Taylor Scientific Management Scientific Management Searching for the “One Best Way” to do a process Searching for the “One Best Way” to do a process Find ways to improve work environment and work processes Find ways to improve work environment and work processes Quantify, measure & track everything: Quantify, measure & track everything: Time required to haul wheelbarrow:

Factory Life Henry Noll “Schmidt” Taylor’s Factory

Frank and Lillian Gilbreth Systematically study a work environment and find the best way to achieve a particular task Systematically study a work environment and find the best way to achieve a particular task With Taylor, pioneered “industrial engineering” -- time and motion studies With Taylor, pioneered “industrial engineering” -- time and motion studies “Cheaper by the Dozen” “Cheaper by the Dozen”

Motion Capture Lights illuminate key motion joints Lights illuminate key motion joints For Computer Generation, convert to 3D For Computer Generation, convert to 3D

Barry Zito

Chronocyclegraph light-1914

Bricklayer Hourly output up from 125 to 350

Typesetter

Drill Press

The Entire Work Environment Color coded slots Color coded slots Groove for grabbing pencil Groove for grabbing pencil

Ergonomics Today

Ergonomics Then

Continuous Process Improvement Eli Whitney and Interchangeable Parts Eli Whitney and Interchangeable Parts William Sellers and the rise of standards William Sellers and the rise of standards Frederick Winslow Taylor and Scientific Management Frederick Winslow Taylor and Scientific Management Frank & Lillian Gilbreth and time and motion study Frank & Lillian Gilbreth and time and motion study