1. Assembly Lines DVD

2. What the DVD Shows: History of operations management (OM) from 1910; How to arrange men, machines, materials, components in an operation; The essential role of OM; How OM has evolved: Issues OM focused on at different time.

3. How to Organize Manufacturing, Not How to Manufacture This DVD shows the state of art of organizing and managing process of manufacturing, instead of manufacturing technology. The ideas presented in this video can be extended to services

4. OM Topics Touched in DVD Productivity Mass Production Division of labor and interchangeable parts Production process Layout Quality Human factor Flexible system and Lean system.

5. Adam Smith, 1723-1790

6. Assembly Line Each worker does a few pieces of simple tasks repeatedly; Workers stay at their workstations; Products are moved intermittently on a conveyer. A product stay with a workstation for a fixed time (cycle time), which was as short as 10 seconds.

7. Automobile Assembly Process A:Front-end body-to- chassis assembly H:Hood attachment F:Fluid filling S:Start-up testing Midsized 6 cylinder ASHF Midsized 6 cylinder Figure 1.7

8. Henry Ford, 1863-1947

9. Characteristic of Assemble Line All products on conveyer move together; Workload of a workstation <= Cycle time;

10. Bottleneck of Assembly Line The cycle time is limited by the slowest workstation; The line cannot start unless every workstation is ready; If one workstation is stuck (due to broken machine, bad quality, sick worker,...), whole line is stuck.

11. Effect of Assembly Line Lowered product cost; Raised quality; Increased productivity; Generating jobs.

12. Frederick W. Taylor, 1856-1915

13. Problems Occurred With increased line speed in Ford at early years of using assembly line, there came problems: –Workers were bored by doing simple tasks repeatedly. But the company did not care what workers thought but the pace of line; –More absentees, and high turnover rate. Solution of Ford (1920’s): –Raise worker’s salary.

14. Human Factor Raising salary solved the problem for a while, but not forever. Improved role of human after WWII: –Job enlargement; –Job enrichment; –Total quality management.

15. What Toyota Did in 1960’s – 1970’s Involve workers into operation process: –Value analysis; –Total quality control; –Just-in-time production; –Kanban system. Japan passed US in auto production and quality in 1980s.

16. Kiichiro Toyoda, 1894-1952

17. Response of US US auto industry responded: –Taking the approaches of OM which was proved effective in Japan; –Computer aided design and manufacturing. The most flexible elements in production is “people”.