a brief presentation on mass production

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4 2 5 1 0011 0010 1010 1101 0001 0100 1011 A brief report on MASS PRODUCTION Sandeep Bagul

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A brief look on Mass Production

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Page 1: A Brief Presentation On Mass Production

42510011 0010 1010 1101 0001 0100 1011

A brief report on MASS PRODUCTION

Sandeep Bagul

Page 2: A Brief Presentation On Mass Production

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History review of Mass Production• During the golden era of 1900 where Craft Production

was hinted to losing its larger picture in many ways.

• A young enterpreneur named Henry Ford was trying to design an automobile that was easy to manufacture and easy to repair.

• Ford finally achieved his goal with his 1908 Ford Model T.

• It was initially Fred Winslow Taylor who laid the foundation for mass production through Scientific Management.

• Alfred Sloan’s managerial innovations and the role of organized labour in controlling work tasks and job assignments completed the system.

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Characterstics of Mass Production • Mass production (also called flow production,

repetitive flow production, or series production) is the production of large amounts of standardized products on production line.

• The primary cause is a reduction of nonproductive effort of all types.

• In mass production, each worker repeats one or a few related tasks that use the same tool to perform identical or near-identical operations on a stream of products unlike craft production.

• Moreover, The worker spends little or no time retrieving and/or preparing materials and tools, and so the time taken to manufacture a product using mass production is shorter than when using traditional methods.

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Continued……..

• The probability of human error and variation is also reduced, as tasks are predominantly carried out by machinery.

• A reduction in labour costs, as well as an increased rate of production, enables a company to produce a larger quantity of one product at a lower cost than using traditional, non-linear methods.

• Also, Management plays a respective role in mass production work.

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Ford’s Assembly unit at Detroit

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The Current situation of mass production

• Boredom sets in as the job is monotonous and recurring.

• Large number of workers are replaced by huge machines.

• Increasing working hours leading to strikes.• Large gap is developed between management and

workers.• Quality took a back seat to production and defect

rates were very high by current standards.

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Continued……..

• Batch production and finished goods inventories showed enormous cash asset on company balance sheet.

• Growing miscommunication and dysfunction between engineers lead to design problems.

• Product handling,transportation and storage were the major issues of mass production.

• Rework of Products were also the major issue in mass production.

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Number of Manufacturing Defects

Annual Production Chart

96%

2%2%

Products name

Number of products

Rework products

Defective

Actuator 8000 200 160

Pneumatic Cylinder

12000 300 240

DRC 1000 40 40

Statistics on Monthly Basis

Annually Rotex is losing 18% profit,as cost on rejected products are high.

Page 9: A Brief Presentation On Mass Production

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Replacement of Mass Production by Lean Production

• In 1937, Both Japan and Toyota Motor Company were in crisis.

• The domestic market was small but the demand was high for large varities of automobile vehicle .

• Owing to Japanese falling capital economy.A huge investment in the lastest Western technology was impossible.

• Moreover, outside world of established carmakers were ready to capture the japanese market.

• Eiji Toyota and production genius Taiichi Ohno, concluded that mass production was not possible to work in japan.

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Continued……..• The unavailability of capital spurred the

development of flexible, right-sized machinery, and quick changeovers.

• The legal restrictions on worker layoffs created the image of the company as community and laid the foundation for intense employer involvement and problem solving.

• Hence the necessary of lean production was the solution to Toyota’s problem.

• Lean manufacturing is a generic process management philosophy derived mostly from the War Manpower Commission which led to the Toyota Production System (TPS).