A Brief Presentation On Mass Production


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A brief look on Mass Production

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A Brief Presentation On Mass Production

  1. 1. A brief report on MASS PRODUCTION Sandeep Bagul
  2. 2. History review of Mass Production <ul><li>During the golden era of 1900 where Craft Production was hinted to losing its larger picture in many ways. </li></ul><ul><li>A young enterpreneur named Henry Ford was trying to design an automobile that was easy to manufacture and easy to repair. </li></ul><ul><li>Ford finally achieved his goal with his 1908 Ford Model T. </li></ul><ul><li>It was initially Fred Winslow Taylor who laid the foundation for mass production through Scientific Management. </li></ul><ul><li>Alfred Sloan’s managerial innovations and the role of organized labour in controlling work tasks and job assignments completed the system. </li></ul>
  3. 3. Characterstics of Mass Production <ul><li>Mass production (also called flow production, repetitive flow production, or series production) is the production of large amounts of standardized products on production line. </li></ul><ul><li>The primary cause is a reduction of nonproductive effort of all types. </li></ul><ul><li>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. </li></ul><ul><li>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. </li></ul>
  4. 4. Continued…….. <ul><li>The probability of human error and variation is also reduced, as tasks are predominantly carried out by machinery. </li></ul><ul><li>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. </li></ul><ul><li>Also, Management plays a respective role in mass production work. </li></ul>
  5. 5. Ford’s Assembly unit at Detroit
  6. 6. The Current situation of mass production <ul><li>Boredom sets in as the job is monotonous and recurring. </li></ul><ul><li>Large number of workers are replaced by huge machines. </li></ul><ul><li>Increasing working hours leading to strikes. </li></ul><ul><li>Large gap is developed between management and workers. </li></ul><ul><li>Quality took a back seat to production and defect rates were very high by current standards. </li></ul>
  7. 7. Continued…….. <ul><li>Batch production and finished goods inventories showed enormous cash asset on company balance sheet. </li></ul><ul><li>Growing miscommunication and dysfunction between engineers lead to design problems. </li></ul><ul><li>Product handling,transportation and storage were the major issues of mass production. </li></ul><ul><li>Rework of Products were also the major issue in mass production. </li></ul>
  8. 8. Number of Manufacturing Defects Statistics on Monthly Basis Annually Rotex is losing 18% profit,as cost on rejected products are high. Defective Rework products Number of products Products name 40 40 1000 DRC 240 300 12000 Pneumatic Cylinder 160 200 8000 Actuator
  9. 9. Replacement of Mass Production by Lean Production <ul><li>In 1937, Both Japan and Toyota Motor Company were in crisis. </li></ul><ul><li>The domestic market was small but the demand was high for large varities of automobile vehicle . </li></ul><ul><li>Owing to Japanese falling capital economy.A huge investment in the lastest Western technology was impossible. </li></ul><ul><li>Moreover, outside world of established carmakers were ready to capture the japanese market. </li></ul><ul><li>Eiji Toyota and production genius Taiichi Ohno, concluded that mass production was not possible to work in japan. </li></ul>
  10. 10. Continued…….. <ul><li>The unavailability of capital spurred the development of flexible, right-sized machinery, and quick changeovers. </li></ul><ul><li>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. </li></ul><ul><li>Hence the necessary of lean production was the solution to Toyota’s problem. </li></ul><ul><li>Lean manufacturing is a generic process management philosophy derived mostly from the War Manpower Commission which led to the Toyota Production System (TPS). </li></ul>