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Production Systems Mr. Kerins
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Mass Vs. Lean Production
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Mass Production
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Mass Production - Characteristics 1. Quantity not quality 2. Poorly skilled workers 3. Huge Factories 4. Non- flexible workers 5. Lots of storage space required 6. Focus on worker and self not company
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Mass Production Mass Production Developed by Henry Ford in 1913. Definition- Production of items in large quantities by groups of workers in factories ◦Expensive and lots of machinery ◦1880 electrification of factories
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Mass Production Developed in USA, by Ford Motor Co. Only supervisor can stop the assembly line Most important quality – amount of items produced Poorly skilled workers- only trained in one job
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Mass Production Quality Control depends on accuracy of the machine set up by workers Jig – holds and guides material as its being processed Fixture – keeps items being processed in proper position
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Mass Production Mass Production uses high volume shipping methods- 3 months of parts in warehouse Quick fact- Model T was produced every 10 seconds Mass Production Video Clip
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Lean Production Produced and developed by Japanese Definition- System which focues on producing a high number of items with exceptional quality and limited yet efficient workers. Developed 1930-1940s
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Lean Production Characteristics Just in time Supplies Quick Change over Compressed Space Highly skilled workers Empowered workers Flexible workers
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Lean Production Any worker can stop the line Uses just in time shipping ◦No storage ◦Less workers ◦cheaper Go-no-Go Gauge- used to check size / quality of produced product Kan-ban ◦Shipping idealogy ◦1 item on line ◦1 item ready for line ◦1 item being shipped
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Lean production- Kaizain Japanese proverb: small incremental improvements toward a common goal each day This was the Japanese workers philosophy each day! Japanese put the company first
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Lean Production
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Lean Production Systems Lean Production system Video Lean Production system Video
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Video- Gung HO Lean Vs. Mass Production Cultural philosophies Company vs. worker Who can stop the line? Quality vs. Quantity Workers skill level
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Production Systems Project Test Video Lean production Assembly line
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