a brief presentation on mass production
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A brief look on Mass ProductionTRANSCRIPT
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A brief report on MASS PRODUCTION
Sandeep Bagul
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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.
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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).