Continuous Process Continuous Process Improvement: Improvement:

The Lessons of HistoryThe Lessons of History

BADM 701BADM 701

Dr. Ron LembkeDr. Ron Lembke

Cotton Gin at WorkCotton Gin at Work

Eli WhitneyEli Whitney Introduced interchangeable Introduced interchangeable

parts in large musket contract parts in large musket contract for U.S. Army for U.S. Army

Interchangeable parts the true Interchangeable parts the true secret of Ford’s successsecret of Ford’s success

Made possible by advances in Made possible by advances in measurement and tool steelmeasurement and tool steel

Tool Steel AdvancesTool Steel Advances

Beginning of StandardsBeginning of Standards

Before standardized parts, need ScrewsBefore standardized parts, need Screws 1860s Machine Tool industry: Silicon Valley 1860s Machine Tool industry: Silicon Valley

of its dayof its day All screws custom made by tool & die shops All screws custom made by tool & die shops

according to what they thought bestaccording to what they thought best William Sellers: 1864 “On a Uniform System William Sellers: 1864 “On a Uniform System

of Screw Threads” of Screw Threads”

Sellers objectively betterSellers objectively better Easier: simple angle vs. difficult; rounded top vs. straightEasier: simple angle vs. difficult; rounded top vs. straight 3 cutters & 2 lathes vs. 1 cutter & 1 lathe3 cutters & 2 lathes vs. 1 cutter & 1 lathe

Sellers vs. WhitworthSellers vs. Whitworth

Not Just What you KnowNot Just What you Know

Machine tool makers didn’t want to be Machine tool makers didn’t want to be commoditized like gun makerscommoditized like gun makers

The standard people expect to win usually does.The standard people expect to win usually does. Navy Board found it superior, asked Singer Navy Board found it superior, asked Singer

Sewing Machine, Baldwin Locomotive which Sewing Machine, Baldwin Locomotive which would win (already adopted).would win (already adopted).

Pennsylvania RR adopted (Sellers on the Board)Pennsylvania RR adopted (Sellers on the Board) British tanks & trucks couldn’t be repaired in British tanks & trucks couldn’t be repaired in

WWII because Britain adopted WhitworthWWII because Britain adopted Whitworth

Frederick W. TaylorFrederick W. Taylor Scientific Management Scientific Management

Searching for the “One Best Way” to do a processSearching for the “One Best Way” to do a process Find ways to improve work environment and work Find ways to improve work environment and work

processesprocesses Quantify, measure & track everything:Quantify, measure & track everything:

Time required to haul wheelbarrow:Time required to haul wheelbarrow:

B p aL

0 51 0 004827

127. . .distance hauled

Factory LifeFactory Life

Henry Noll“Schmidt”

Taylor’s Factory

Frank and Lillian GilbrethFrank and Lillian Gilbreth Systematically study a work environment and find the best Systematically study a work environment and find the best

way to achieve a particular taskway to achieve a particular task With Taylor, pioneered “industrial engineering” -- time and With Taylor, pioneered “industrial engineering” -- time and

motion studiesmotion studies ““Cheaper by the Dozen”Cheaper by the Dozen”

Motion CaptureMotion Capture

Lights illuminate key motion jointsLights illuminate key motion joints For Computer Generation, convert to 3DFor Computer Generation, convert to 3D

Barry ZitoBarry Zito

Chronocyclegraph light-1914Chronocyclegraph light-1914

BricklayerBricklayer

Hourly output up Hourly output up from 125 to 350from 125 to 350

TypesetterTypesetter

Drill PressDrill Press

The Entire Work EnvironmentThe Entire Work Environment

Color coded slotsColor coded slots Groove for grabbing pencilGroove for grabbing pencil

ErgonomicsErgonomicsTodayToday

Ergonomics ThenErgonomics Then

Continuous Process Continuous Process ImprovementImprovement

Eli Whitney and Interchangeable PartsEli Whitney and Interchangeable Parts William Sellers and the rise of standardsWilliam Sellers and the rise of standards Frederick Winslow Taylor and Scientific Frederick Winslow Taylor and Scientific

ManagementManagement Frank & Lillian Gilbreth and time and motion Frank & Lillian Gilbreth and time and motion

studystudy