04/19/2023 1Texas A&M Industrial Engineering

Introduction to Production and Manufacturing

Systems

Gary M. Gaukler

04/19/2023 2Texas A&M Industrial Engineering

What Is Manufacturing?

• Varying definitions of scope– Our focus is on manufacturing systems

• Technically complex manufacturing processes

• Machining characteristics, assembly instructions...

– Necessary to make the product

• Technically complex manufacturing system operations and coordination

• Facility layout, capacity planning, production control...

– Necessary to make money making the product

04/19/2023 3Texas A&M Industrial Engineering

Why Is Manufacturing Hard?

• Customer demands have increased– Traditional: “The customer can have any color

as long as it’s black.” - Henry Ford– Modern: Customers expect large product

variety, reasonable price, superior quality, comprehensive service, and responsive delivery

• Competition has increased– Low labor cost countries like China, Taiwan,

Eastern European states

04/19/2023 4Texas A&M Industrial Engineering

Evolution of Manufacturing

• Completely custom - craftsman (pre 1800)• English system (1800s)

– Introduction of general purpose machines that could be used for a variety of products.

• American system (1850s)– Emphasized precision and interchangeability.

Changed from a "best fit" to a "greatest clearance without loss of functionality" focus.

• Scientific management (1900s)– Prespecified worker motions - Moved the

control totally into the hands of management.

04/19/2023 5Texas A&M Industrial Engineering

Evolution of Manufacturing

• Process improvement (SPC) (1950s)– The identical procedure will produce different

results on the same machine at different times. It emphasized outliers rather that mean performance.

• Numerical control (1970s)– Combining the versatility of general purpose

machines with the precision and control of special-purpose machines.

• Computer integrated manufacturing (1980s)

• Logistics/Supply-chain management (1990s)

Eli Whitney

Born 1765; died 1825 In 1798, received government

contract to make 10,000 muskets Showed that machine tools could

make standardized parts to exact specificationsMusket parts could be used in any

musket

Frederick W. Taylor

Born 1856; died 1915 Known as ‘father of scientific

management’ In 1881, as chief engineer for

Midvale Steel, studied how tasks were doneBegan first motion and time studies

Created efficiency principles

Taylor’s Principles

Matching employees to right jobProviding the proper trainingProviding proper work methods and

toolsEstablishing legitimate incentives

for work to be accomplished

Management Should Take More Responsibility for:

Born 1863; died 1947 In 1903, created Ford Motor

Company In 1913, first used moving assembly

line to make Model TUnfinished product moved by

conveyor past work station

Paid workers very well for 1911 ($5/day!)

Henry Ford