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Assembly Lines
DVD
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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.
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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
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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.
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Adam Smith, 1723-1790
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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.
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Automobile Assembly Automobile Assembly ProcessProcess
A: Front-end body-to-chassis assembly
H: Hood attachmentF: Fluid fillingS: Start-up testing
Midsized
6 cylinder
A SH F
Midsized 6 cylinder
Figure 1.7
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Henry Ford, 1863-1947
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Characteristic of Assemble Line
• All products on conveyer move together;
• Workload of a workstation
<= Cycle time;
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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.
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Effect of Assembly Line
• Lowered product cost;
• Raised quality;
• Increased productivity;
• Generating jobs.
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Frederick W. Taylor, 1856-1915
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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.
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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.
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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.
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Kiichiro Toyoda, 1894-1952
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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”.