1. Production Systems Mr. Kerins

2. Mass Vs. Lean Production

3. Mass Production

4. 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

5. 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

6. 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

7. 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

8. 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

9. 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

10. Lean Production Characteristics Just in time Supplies Quick Change over Compressed Space Highly skilled workers Empowered workers Flexible workers

11. 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

12. 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

13. Lean Production

14. Lean Production Systems Lean Production system Video Lean Production system Video

15. Video- Gung HO Lean Vs. Mass Production Cultural philosophies Company vs. worker Who can stop the line? Quality vs. Quantity Workers skill level

16. Production Systems Project Test Video Lean production Assembly line