Production Systems Mr. Kerins

Mass Vs. Lean Production

Mass Production

Mass Production - Characteristics

1. Quantity not quality2. Poorly skilled workers3. Huge Factories4. Non- flexible workers5. Lots of storage space required6. Focus on worker and self not company

Mass Production

Mass Production Developed by Henry Ford in 1913.

Definition- Production of items in large quantities by groups of workers in factories

◦Expensive and lots of machinery◦1880 electrification of factories

Mass Production

Developed in USA , by Ford Motor Co.Only supervisor can stop the assembly

lineMost important quality – amount of items

produced

Poorly skilled workers- only trained in one job

Mass Production

Quality Control depends on accuracy of the machine set up by workers

Jig – holds and guides material as its being processed

Fixture – keeps items being processed in proper position

Mass Production

Mass Production uses high volume shipping methods- 3 months of parts in warehouse

Quick fact- Model T was produced every 10 seconds

Mass Production Video Clip

Lean Production

Produced and developed by JapaneseDefinition- System which focues on

producing a high number of items with exceptional quality and limited yet efficient workers.

Developed 1930-1940s

Lean Production Characteristics

Just in time Supplies

Quick Change over

Compressed Space

Highly skilled workers

Empowered workers

Flexible workers

Lean Production

Any worker can stop the line

Uses just in time shipping ◦No storage◦Less workers◦cheaper

Go-no-Go Gauge- used to check size / quality of produced product

Kan-ban◦Shipping idealogy◦1 item on line◦1 item ready for line◦1 item being shipped

Lean production- Kaizain

Japanese proverb: small incremental improvements toward a common goal each day

This was the Japanese workers philosophy each day!

Japanese put the company first

Lean Production

Lean Production Systems

Lean Production system Video

Video- Gung HO

Lean Vs. Mass ProductionCultural philosophiesCompany vs. worker Who can stop the line?Quality vs. QuantityWorkers skill level

Production Systems Project

TestVideoLean production Assembly line