Chapter 3: Large-Scale Mass Production I.

Nature and Development of Mass Production

Mass production is based upon the extensive application of certain which have been concepts which have been less utilized from the beginnings of the industrial revolution, as embracing the general application of power in the production process, division of labor and transfer of skills. Productive Process Mass production embraces problems of specialization, of standardization, of diversification and of integration. Division of Labor Division of labor has become intensified as labor specialization. II. Large-Scale Automobile Washing

In the modern car-laundry method, the automobile went through practically the same process. However, by replacing the two-man crew with a force of 34 to 40 men and girls, each specializing on a certain operation, or part of an operation, the application of the principle of specialization of labor and use of specialized equipment made it possible to reduce the total time required for washing a car to 13 minutes. The standard auto service companys plant 100 by 100 feet, had an output capacity of one car a minute. Procedure: 1. A car to be washed was driven up the entrance ramp and onto a moving circular platform at the left. This track was propelled by an electric driving mechanism so adjusted that the platform made a complete revolution in 13 minutes. A car to be washed was driven by company employees to the entrance ramp, where loose articles within the car removed and placed in a locker provided for that purpose. Two men spent their entire time at this task.

2. As soon as the car had been emptied, it was driven by another employee up the ramp and onto the moving platform. One man specialized on this task. 3. Job 3 was carried on by one man who used compressed air to blow dust from the seats and floor of the car interior. 4. At that point, an overhead sprinkler flushed the entire car with water to loosen the grime and dirt. The valve which controlled this sprinkler was operated by a man on a raised platform. 5. At point 5, the chassis and underside of the fenders were thoroughly washed. Four men worked on this job, two on each side of the track. Each man was equipped with a hose which threw a heated emulsion of oil and water at high temperature. 6. At that next point, four men sponged the entire car, using warm soap suds. 7. The car moved on to operation 7 which consisted of a thorough rinsing, two men performed this task using hoses and clear water. 8. At point 8 on the track, two men used compressed air to blow all surplus water from the car surfaces. 9. The following operation was performed by a group of four girls who, with chamois and clothes, wiped and polished the entire car, inside and out. 10. Operation 10 was an exact duplication of operation 9 for double checking. 11. From the second polishing operation, cars progressed to the 11 station on the line, where two men equipped with specially designed vacuum cleaners thoroughly vacuumed the interior, after which ready for inspection. 12. Two men inspected each car. If ok, then cars released to the customers. 13. After the car had been inspected, it was driven from wash rack. One man could do this work and just keep up with the output of the wash rack when it was being operated at capacity then the man turned the car over to the last group of workers. 14. Operation 14 consisted of two men who replaced all articles previously removed from the car.

III.

Necessity for Replacement Workers

In addition to the 32 men and girls required on the working rack, only 4 to 6 workers were required to maintain and operate the mechanical equipment. They are also trained to take the place of other workers in case such workers were temporarily absent or left their jobs. 1. It took a much shorter time for a worker to learn one of the specialized jobs. 2. It was much more important to every specialized worker be an expert at his or her job. 3. Reserve supply of experienced workers was essential to effective operation of the entire system. IV. Importance of Inspection Inspection became important for the protection of the companys reputation for quality and in order to maintain individual responsibility for doing all that should be done. Inspection Responsibility Authority to pass or reject raw material, purchased parts, in-process materials and finished product is vested in the inspection department. Another part of this departments duties generally is the inspection of critical supplies, tooling and equipment items. It is also responsible for the issuance, control and inspection of all gages, instruments and other measuring devices used by both inspectors and production operator. Joint or possibly complete supervision of the salvage of rejected work and the disposition of scrap to ensure that no defective materials is returned to the production flow may be within the province of the inspection department. Inspectors pass on the process before actual production begins (setup acceptance), then decide periodically during the run whether the process may continue (process acceptance) and finally determine whether the resultant product is passable (product acceptance). The responsibility of the foreman here is simply to see that causes of difficulty with the process and product are promptly corrected.

V.

Process of Specialization y Land- is put to special uses. y Labor- to minutely specialized task. y Buildings, tools and machines- to particular

operations.

Specialization is pervaded by the principle of division of labor and its refinement. Division of labor means dividing up the work on the principle that different people and different places are best fitted for different things depending on influences. Stemming from geography, natural conditions, personal aptitudes, and skills. Specialization is a refinement of this principle and is carried furthest in the manufacturing industries. Advantages of Specialization 1. Has greater quantities of goods in less time and with effort 2. Wider varieties 3. Better quality 4. Less waste 5. More efficient employment of land, labor and capital 6. Rising standards of living