Showing posts with label Manufacturing management. Show all posts
Showing posts with label Manufacturing management. Show all posts

November 8, 2024

Kaizen eno Yon Dankai - Improvement in 4 Steps - History of Kaizen in Japan



The Economic and Scientific Section (ESS) group was given the  task with improving Japanese management skills and Lowell Mellen was invited to Japan to properly install the Training Within Industry (TWI) programs in 1951.

In 1951, even before the arrival of Mellen, the ESS group had a training film to introduce the three TWI "J" programs (Job Instruction, Job Methods and Job Relations)---the film was titled "Improvement in 4 Steps" (Kaizen eno Yon Dankai).

The term Kaizen was not popular in Toyota before 1950. It is only after the TWI courses that the term became popular.



Ud. 9.11.2023

September 21, 2024

Manufacturing Management - History

 Encyclopedia of Production and Manufacturing Management  

HISTORY OF MANUFACTURING MANAGEMENT

pp 264–274



Encyclopedia of Production and Manufacturing Management

James M. Wilson 



Babbage, Charles (1835). On the Economy of Machinery and Manufactures, Charles Knight, London, England.



 


Chandler, Alfred (1977). The Visible Hand: The Managerial Revolution in American Business. Belknap Press, Cambridge, Mass.



 


Cooper, Carolyn C. (1981–2). The Production Line at Portsmouth Block Mill. Industrial Archaeology Review. 6, 28–44.



 


Cooper, Carolyn C. (1984). The Portsmouth System of Manufactures. Technology and Culture. 25, 182–225.



 


 


Copley, Frank Barkley (1923). Frederick W. Taylor: Father of Scientific Management. Reprinted 1969, Augustus Kelley, New York, New York.



 


Defoe, Daniel (1697). An Essay Upon Projects. Reprinted 1887. Cassell & Co., London, England.



 


Evans, Oliver (1834). The Young Mill-wright & Miller's Guide. Reprinted 1989. Arno Press. New York, New York.



 


Faurote, Fay Leone and Harold Lucien Arnold (1916). The Ford Methods and the Ford Shops. Engineering Magazine Co., New York, New York.



 


Fazar, Willard (1962). The Origins of PERT. The Controller. Vol. 8, 598–602, 618–621.



 


Ford, Henry with Samuel Crowther (1926). My Life and Work. William Heineman, Ltd., London.



 


Ford, Henry with Samuel Crowther (1928). Today and Tomorrow. William Heineman, Ltd., London.



 


Gallagher, Colin (1978). Batch Production and Functional Layout. Industrial Archaeology. 13, 157–161.



 


Gantt, H.L. (1903). A Graphical Daily Balance in Manufacture. ASME Transactions, 24, 1322–1336.



 


Gilbert, K.R. (1965). The Portsmouth Block-Making Machinery. Her Majesty's Stationery Office, London, England.



 


Hounshell, David. (1984). From the American System to Mass Production, 1800–1932. The John Hopkins University Press. Baltimore, Maryland.



 


Kelley, James E. Jr., and Morgan R. Walker (1989). The Origins of CPM: A Personal History. PMNetwork, 3, 7–22.



 


Plato, (translated by Desmond Lee). (1987). The Republic. Penguin Classics, London, England.



 


Ohno, Taiichi (1988). Toyota Production System. Productivity Press, Cambridge, Mass..



 


Rosenberg, Nathan (1969). The American System of Manufactures. Edinburgh University Press, Edinburgh, Scotland.



 


Thompson, Clarence B. (1917). The Taylor System of Scientific Management. A.W. Shaw Co. Chicago, Illinois.



 


Toyoda, Eiji (1987). Toyota: Fifty Years in Motion. Kodansha International, Tokyo, Japan.



 


Wild, Ray (1974). The Origins and Development of Flow-Line Production. Industrial Archaeology Review. 11, 43–55.



 


Wilson, James M. (1995). An Historical Perspective on Operations Management. Production & Inventory Management Journal. 36, 61–66.



 


Wilson, James M. (1996). Henry Ford: A Just-in-Time Pioneer. Production & Inventory Management Journal. 37, 26–31.



 


Wren, Daniel (1994). The Evolution of Management Thought. John Wiley & Sons, New York, New York.



 




James M. Wilson

Glasgow University, Glasgow, Scotland, UK


Editor

P. M. Swamidass


https://link.springer.com/referenceworkentry/10.1007/1-4020-0612-8_406





https://engineering.interpro.wisc.edu/the-history-and-evolution-of-manufacturing/


https://www.qualitymag.com/articles/91504-history-of-lean-manufacturing


https://asq.org/quality-resources/history-of-quality


https://www.allaboutlean.com/firstlecture_hom_4/


https://www.manufacturing-operations-management.com/manufacturing/2021/06/a-brief-history-of-smart-manufacturing.html






September 20, 2024

Minimizing Machining Time and Cost of Machine Tools Operations - Carpenter - 1908

 Chapter VI. 


MINIMIZING THE TIME OF MACHINE-TOOL OPERATIONS. 


TWO fundamental principles of cheap production.

They are of the greatest importance, and yet nine times out of ten a searching investigation will prove that little consideration has been given them in ordinary shop practice in most of the companies at present. They are so closely related that their simultaneous discussion is advisable. They are both essentially "time savers." These two principles are: 


1. — The determination of "standard time" for each job and its tabulation, introduction, and enforcement. 

2. — The absolute elimination from the workman's routine of every duty but that of running his machine continuously and efficiently; the bringing to him of tools and stock for his next job before he is ready for it. 


The first and possibly the more vital of the two is the determination of standard time upon each job — that is, the shortest space of time in which each job should be completed (including setting up), under normal conditions and with due regard to the fullest possibilities and capacity of the machine tool, the cutting tool, and the stock. 

An appalling undertaking, this, in most shops, under existing conditions; appalling and seemingly impossible because of lack of knowledge of the best shapes for cutting tools, of the best methods of hardening and grinding, of the results to be secured from the use of high-speed steel cutting tools, of the best methods that can and should be adopted by a skilled workman, of the capacity of the machine tools in the shop, and, worst of all, because of the lack of men skilled in the best methods for handling these cutting tools — men capable of doing the work and of seeing that the workmen do it. 

It scarcely seems necessary to argue in favor of this determination of standard time. But in many manufacturing firms,  the question of the rapidity of production is determined by e foreman's judgment and skill alone. No man with real shop experience will assert that the average foreman does, or in fact can, know the best results that can be secured in machining today, unless he has been afforded and has accepted exceptional opportunities for making thorough tests of a really scientific character — something that rarely happens. Even should a foreman possess this desirable knowledge, it is beyond the power of any one man to supervise properly any group of men, even though small, so that the high point of efficiency may be assuredly reached, and at the same time do the other work that usually falls to the foreman's lot. 

Again, the use of high-speed steel for cutting tools is a development of recent years. Notwithstanding all that has been published on this subject, comparatively few shop foremen really know what the fullest possibilities of its use are, and fewer still ever force their departments to use it to its fullest efficiency even after its value has been recognized. In fact, there have been comparatively few tables ever published that show in a practical maimer just what can be done with it. The machine-tool builders themselves, singularly enough, seem to be unable to give any positive, accurate advice as to the actual conditions of cutting speeds, feeds, and depth of cut under which their own tools can best operate, and even the makers of the tool steels do not provide tables of much practical use. 

Nevertheless the work of such a man as F. W. Taylor, in his remarkably thorough and extremely valuable publication, " The Art of Cutting Metals," clearly shows the possibilities that lie in the use of these modem cutting tools — Messrs. Taylor and White being the discoverers of these possibilities and Mr. Taylor himself leading the van in the application to practical use of these principles. This one work makes clear not only the great possibilities but also the great difficulties that originally lay in the path of the investigator. With all of these points in mind, it is simply "rot" to give heed for a moment to any claim of any shop man that his knowledge of this subject is at all exhaustive. 

Standard times should be determined by some one, some how. Certainly no one can dispute the fact. Experiments and experience show that the present practices of foremen  gives results 40 to 60 per cent short of maximum efficiency. Inasmuch as your entire business is built upon and depends upon the cost of production — or, in its last analysis, simply "the time it takes each man to do his job of work," it is of fundamental importance that that standard time be first determined by methods that will ensure accuracy. 

The second cardinal principle of cheap production stated at the outset was " the absolute elimination from the workman's routine of every duty but that of running  his machine continuously and efficiently; the bringing to him of tools and stock for his next job before he is ready for it." 

The machine hand, assembler, or other worker must be forced to concentrate his skill and attention upon his own work and that work alone, making it impossible for him to waste his time (and thus the employer's money) upon work he should not do. Consider for a moment the many things that a machine hand, for example, will ordinarily do other than operate his particular tool, and then give a moment's thought to analyzing the result. The worst "time wasters" can be classified somewhat as follows: 


a. Rxmning to the supply room for stock for a new job. Result, the machine tool is shut down. 

b. Getting tools, clamps, etc., from the tool room for a new job. Result, the machine tool is shut down. 

c. Grinding his own tools (and very badly at that). Result, the machine is shut down. 

d. Excessive time in "setting up" a job, due to lack of proper instruction, or to a tendency to "soldier" because of lack of supervision. Result, the machine is shut down. 

e. To these add the fiurther tremendous loss of output because the workman fails to use the proper — the very best — cutting speeds, feeds, and depth of cuts, through either lack of knowl- edge or lack of supervision, and you have a combination that cuts the output of the ordinary shop far below what it should be. 


If your shop is running imder ordinary foremanship supervision, with no thorough method for bringing to the workman his stock; for providing him with tools for the next job before he is ready for it; with no method of instructing him what to do and how to do it, and no thorough way of comparing his output with what it should be according to the best standards of today, (mark me ! not your fore- man's standards) — then you can make up your mind that your output is far too low according to the best standards of production. 


You may imagine that "carefully calculated" piece-work rates will protect you; but if your piece-work rates have to allow for the conditions stated just above, you are deceiving yourself grossly as to the possibilities of your output. 

The important consideration is time! time! Time of the workman running his tool — that is the vital point. Every minute counts for profit if this tool is operating continuously and efficiently; for loss if it operates under the nullifying influences detailed above. 

Consider for a moment! Your entire factory investment — building, power plant, transmission plant, all probably built and selected with great care and expenditure of money — is simply to care for and operate the separate units of machine tools, or to house properly your assembling spaces. Your investment in machine tools repre- sents large sums. This vast expenditure is made with but one object  in view — that of producing work and producing it as cheaply as pos- sible. Calculate accurately your indirect charges of every character; proportion the total against each machine tool according to the "machine-rate" method of apportionment, and note carefully how large must be the rate per hour for each machine. This will be found to be an astonishingly large proportion of the labor rate per hour and will prove a good index of the great cost of lost time in the shop. 


Is it not clear, then, that each machine tool should be, nay must be, brought to as high a factor of operating efficiency as possible? Is not your entire investment made with that one end in view? Does it pay to have the efficiency of any collection of these units reduced 15 per cent to 25 per cent by the existence of such shop methods as those detailed, by which the men operating the machines are actually compelled to shut them down to hunt up their next job, to collect their tools, to grind their tools, and to do many things that should be done for them? Can you afford to suffer an even heavier reduction in effi- ciency due to lack of knowledge of the " best time for each job?" 


The importance of these points can be further emphasized by considering that all such delays, which in their total represent a large amount, directly affect cost and profits, output, indirect expense of every description, quick movement of stock, and hence ultimately the amount of working capital needed in the business, and the possibilities of quicker deliveries, with a resultant direct effect upon the sales department and customers. Indeed, aside from the question of costs and profits, nothing is more important to the separate mem- bers of a company— from the executives with their financial problems,through the sales departhient with their selling problems, to the harassed factory manager— than the quick movement of stock. 


The reason for the continual absorption of working capital into machinery or stock that worries many a financial officer, or for deliveries so delayed as to affect seriously the efficiency of the selling organization, or for excessive and unreasonable and possibly unex- pected costs that seem and, in fact, are out of reason — the reason for all lies hidden away back in the shop processes and methods. It crops out at the individual lathe, planer, shaper or assembling bench, and then only to the keen experienced eye. The workmen busy? Surely. Look at them hustling! But — see that group around the tool-supply window waiting for tools? How many are waiting at the tool grind- ers to grind their own tools each in his own "iadividual" manner? There is a mechanic who has taken twenty minutes to " set up" his job instead of ten. Then pause and wonder how in the world anyone or two or more foremen can be sure that the men now operating the machines are using proper speeds and feeds and getting the most out of the machine and the tool. 


In fact, the causes for all these serious troubles are located so far back toward the fundamentals of production — the individual units affording the causes are so seemingly unimportant, and such is the difficulty of recognizing these conditions, buried as they are in a busy shop — that they are overlooked or ignored. 

As a general proposition, the greater the difiiculty of solving such problems the more important and necessary becomes that solution, simply for the reason that in this you are dealing with humane elements to whom is given the opportunity of slowing up in production solely because of that very difficulty that lies within the problem itself and its solution. And yet so fundamental and vital is their importance that they cannot be ignored. 


The Starting Point for Minimizing Operation Costs. 


Investigation of Existing Machinery.— Any plan for the introduction of proper methods for the determination of standard time and the elimination of wasted time must begin by an investigation of the existing shop machinery — an individual report upon each machine tool, especially touching upon the defects, and a recommendation as to what types should be purchased in the future to meet modem production requirements. This is a matter of great importance, but machinery, designed to stand up under the latest high-production requirements, are recognized and listed up at the beginning of the introduction of any new plans, this important matter is liable to be lost sight of later, with the consequence that when the time for purchases of new machinery does come, the older inefficient types are citing to and the shop is further encumbered with old-style tools. 


Nor is the question of securing a more rigid and efficient tool such a simple question as at first appears. Few machine-tool manufacturers are making an earnest attempt to place upon the market tools strong enough to meet the more severe requirements of today. Why? First, because comparatively few have made tests of sufficient scientific worth to determine where the points of greatest weakness really are and how to strengthen them properly. Second — there is the money tied up in old patterns, old stock in the factory bins, in ma- chines going through the process of manufacturing, and finally in finished machine tools carried in the sales rooms. Changes of a radical character would prove a serious matter under such conditions. And, again, the demand of the manufacturer for better and heavier tools has not been urgent enough to force the machine-tool builder into the tremendous trouble that a thorough redesigning of the older types would surely cause. Therefore the latest product of a machine- tool manufacturer is not necessarily adapted to the methods of production that I am advocating. 


Greater driving power is usually the first requirement. Accurate tests have shown that modern lathes, for instance, should have fully double the driving power usually contemplated in their design. This is a point that must be considered carefully. Of course a proper increase in driving power of a lathe, for example, means wider cones, heavier bearings, and stronger heads. Immediately there follows the question of the rigidity of the bed. It is at once apparent that this is a very important point, and yet too little attention has been paid to the design of bed best suited for withstanding the strains and stresses due to the use of new high-speed cutting tools. Solidity is very necessary. The consideration of the need of strength and rigidity should certainly be applied to the tail stock. Slide rests and tool holders should be simple and strong. The tool must be held rigidly under all conditions. The tool posts should be set down lower than is customary in everyday practice. Under modem conditions much greater feeding power is needed. 


But however certain we may be that defects in machine tools have a direct effect upon the rate of production and the cost of the product, existing conditions may prevent purchase of new tools. Inasmuch as I have been through the mill several times with nm-down concerns, I appreciate fully the fact that most manufacturers are obliged, through sheer financial stress, to ignore any scheme, no matter how promising, that involves at the outset a thorough replacement of the existing machinery with the most modern types, even though it can be demonstrated that the latter are 50 per cent more efficient. 


The practical question that confronts many a manager is: "What on earth can I accomplish with my present old' rattle traps' of machine tools? I couldn't buy gold dollars for 98 cents if I had to pay cash, much less spend thousands for replacing my present machinery. I must first make good with what I have. After we are on firm ground we'll talk about stronger and better machine tools." 

True! Very true! A viewpoint very often overlooked by the manager, or by the man who has this work in charge but doesn't have to produce the dollars to "keep the old ship afloat." This latter situation, which is a stern actuality with many a man who is eager to improve conditions, is all compelling and must give shape to the preliminary methods of procedure. This I shall try to keep in mind. 


Granting, however, the hard fact that many concerns are obliged first to dig out the problem, using their existing facilities, it is of all the greater importance that two reports relative to machine tools be made out: — 

First, a report showing what heavier, stiffer, and more efficient types of machines should be substituted for existing types when the proper time comes. 

Second, a full report upon each and every machine tool in the shop, showing its points of weakness and its limitations in cutting speeds, feeds, and depth of cuts ; how it can be strengthened ; a description of the kind of work that should be done on it ; a record of best times on jobs ; a full statement of the best machine tool to substitute for it, and a clear-cut comparison of possible production by the use of the latter machines. 


I warn you again that unless this be done systematically at the start, it probably never will be done ; then as time goes on you will find yourself burdened with many a newly purchased machine tool just as weak and inefficient as the older one it replaces. 


In considering the problems of increasing production in any particular shop, we find therefore that they become problems of devising methods and making tests upon the supposition that existing machines and facilities must be used in regular production — that, however advantageous the latter types of tools, the important question of lowering costs must be considered on the basis of developing to the uttermost the efficiency of the present machinery. We must there- fore keep in mind these points in the building up of our system. The great importance of gathering all our data systematically and of using them scientifically cannot be too strongly insisted upon. 


PEOFIT MAKING IN SHOP AND EACTORY MANAGEMENT 

BY

CHARLES U. CARPENTER

NEW YORK 

THE ENGINEERING MAGAZINE 


1908 

Copyright, 1908 

By JOHN R. DUNLAP 

https://archive.org/stream/cu31924002748576/cu31924002748576_djvu.txt

CONTENTS. 


Chapter I. The Reorganization op a Run-Down Concern 


The Necessity for Analysis of Existing Conditions — ^Advantageous Posi- 

tion of a Well Organized Concern — The Manufacturer with his Eyes Closed — 

The Manufacturer with his Hands Tied — Organizing the Methods of Inves- 

tigation and Analysis — The Usual Defects of Organization, System and 

Methods in Manufacturing Plants — ^The Superintendent — ^The Foremen — 

Job Bosses and Workmen — Systems of Pay and their Effect — ^The Stock 

System — The Order and Tracing System — ^The Cost System — ^Machining 

Methods — Defects of the Sales Department — Defects of Executive Con- 

trol 9 


Chapter II. The Practical Working op the Committee System 


No Ready-Made System is a Panacea — ^Why New Systems so Often 

Fail — Co-operation of the Working Force is Essential — ^The Human Element 

and the Get-Together Spirit — Formation of the Committee System — ^The 

General Factory Committee — Its Personnel — Its Work — Its Meetings — 

Subsidiary CoHimittees — Job Bosses' Meetings — General Foremen's Meet- 

ings — ^The Workmen — Promotions 23 


Chapter III. Reports; Their Necessity and Their Uses 


The Necessity for Reports of Varied Kinds — ^What they should be and 

what they should Cover — A General Outline of the Essential Reports — ^The 

Monthly Analyzed Profit and Loss Sheet — ^The Sales Reports — ^The Factory 

Reports — ^The Cost Reports — ^The Points to be Shown and the Methods of 

Use 36 


Chapter IV. The Designing and Drafting Department 


Results to be Secured — Close Relations with the Tool Room — Require- 

ments of an EflScient Drafting Department — ^Meetings with the Com- 

mittees — Co-operation with Shop Foremen — Standardization in Design — 

Designing for Cheap Machining and Assembling — ^Making and Following 

of Drawings to be Invariable — Reports from Machining and Assembly 

Departments — ^The Use of the Coiimaittee System 42 


Chapter V. The Tool Room; the Heart op the Shop 


The Full Functions of the Tool Room — Systems of Tool Supply — 

Speed of Production in the Tool Room of Vital Import — ^Methods for 

Hastening Production — ^The Choice of the Foreman — Specialization of 

Labor — Standaxdization — Duplication of Standard Parts — Subdivision of 

Labor — ^The Small Shop — Speeding up Tool Production and Checking the 

Cost — Tool-Cost Cards — Examples — ^Method of Use — Tool-Room Commit- 

tee Membership 50 


Chapter VI. Minimizing the Time of Machine-Tool Operations  


The Determination of Standard Times — ^The Concentration of the Work- 

man's Time on Running his Machine — ^The Adoption of High-Speed Steel — 

Causes of Lost Time — The Starting Point in Minimizing Operation Costs — 

Investigation of Existing Machinery — Systematic Report upon Improve- 

ments in Old Machines and Recommendations for Replacements or New 

Purchase 64 


Chapteb VII. Possibilities Attending the Use of High-Speed Steel 

What Percentage of Increase may be Expected in the Output — ^The 

Abundant Provision of Cutting Tools — Standard Shapes for Tools — ^How 

Determined — Forging — Hardening — Form for Records — CooHng — Grind- 

ing — Use of Automatic Grinders 73 


Chapter VIII. The Determination or Standard Times por Machining 

Operations 


The Shop Conditions upon which Standard Times Depend — Tests of 

Times which should be Attained — ^How to Begin — Classification of Parts — 

The Expert Tester — ^His Qualifications — Practical Speeds in Lathe Work — 

In Planer Work — In Drilling — ^Tables — How to Use the Tables — ^The Com- 

mittee at Work — Requirements for Maximum Production by the Work- 

man 83 


Chapter IX. Standard Times for Handling the Work 


The Elements which must be Considered — Causes of Lost Time in Hand- 

ling—Injuries to Stock or Parts in Handling — ^The Use of Standard Boxes — 

Standard Places for Stock and Parts — Records of Handling Times — 

Forms — Setting-up Time— Times for Work on the Machines — ^Time for 

Removing Work from the Machines — ^The Use of Committee Action 94 


Chapter X. Standard Times for Assembling 


Special Difficulties to be Found in this Subject — ^Methods of Procedure 

which Succeed — Examples of Results Secured — ^An Instructive Case 

Described — ^Foremen's Co-operation Essential — How it can be Enlisted. . . . 101 


Chapter XI. Stimulating Production by the Wage System 


The Attitude of the Workman — ^Mischief Caused by Cutting of Rates — 

The True Theory of Costs — ^The Wage Problem in Introducing Standard 

Times — ^How to Get the Workman to Stand for Them — Systems of Pay — 

Day Work — Piece Work — Premium Plan — ^The Differential Plan — ^The 

Bonus Plan — Special Modifications of the Bonus Plan Recommended 109 


Chapter XII. Stock and Cost Systems as a Factor in Profit Making 


The Prime Requisites of a Cost System — Wha,t it should Accomplish — 

The Three Fundamental Problems at a Stock System — A Simple and Suc- 

cessful System Described — ^The Forms and Cards and their Mode of Use — 

Storage Platforms and" what they AccompUsh — Stock-Tracing and Cost 

Sheets — ^Forms — ^How the Data are Used 116 


Chapter XIII. The Upbuilding of a Selling Organization 


The Various Methods of Selling Manufactured Goods Defined — ^What is to 

be Considered in Developing a Selling Force — ^Training of Salesmen — Its 

Possibilities Proved — Development of a Selling System — Salesmen's Demon- 

stration Meetings — A Typical Programme — ^Modes of Stimulating Interest — 

Salesmen' Training Department — Selection of an Instructor— Prepara- 

tion of a Manual — Reports and their Importance — ^Forms — Lists — Adver- 

tising ._ 124 


Chapter XIV. Effective Organization in the Executive Department 

Difficulties Peculiar to the Executive Division — The Personal Element — 

The Use of the Report System — Reports from the Selling Division — ^Forms 

— Factory Reports — ^Forms — ^Executive Reports — ^Forms — The Methods 

Illustrated by an Example and a Typical Programme — ^The Results 

Secured 138 


About Carpenter

https://en.wikipedia.org/wiki/Charles_U._Carpenter


Charles Underwood Carpenter (Indiana, January 1872 – January 15, 1928[1]) was an American business manager, management author, and inventor, known as "one of the earliest advocates of the committee system in factory management."

Carpenter got his degree from Princeton University in 1893, and started his career in industry.

Profit Making in Factory Production through Modern Management Methods - 1908

 PROFIT MAKING IN SHOP AND FACTORY  MANAGEMENT 


Chapter I. 

The Factory  Reorganization Utilizing Modern Management Methods


Any manufacturer feeling the existence of unsatisfactory and unprofitable conditions must make up his mind that the real reasons for them must be discovered and the causes removed at the earlist; for should the management, in its conduct of the business, not discover its weaknesses, this same management may be sure that some thoroughly organized competitor will drive the condition to their startled attention when more severe seasons of trade come upon us. 

Necessity for Analysis. 

To solve the problems confronting him, a man must bring to them an absolutely unbiased mind and a determination to analyze the situation thoroughly  to form an accurate judgment as to the underlying reasons. You, the manufacturer, may be sure that unless your factory, selling, and executive organizations can stand this test of your coldest and most searching examination — your analytical test — with any change from expanding conditions of trade, you will find the foundation of your business slipping from under it, slowly perhaps, but surely. 


Advantageous Position of a Well Organized Concern. 


We hear much today of the advantages that one competitor secures over another through the "secret rebate," special "shipping privileges," unfair "rate classifications," "secret agreements," etc. 

In a manufacturing business these advantages count for little against a company with an effective organization of the working force, stimulated by a desire to work not only for self but also for the good of the concern, aided by up-to-date mechanical methods and modem tools especially adapted to the quick, accurate, and economical manufacture of the parts to be produced; supported' by compre- hensive, though simple, systems that enable the management to keep an accurate check upon the cost of production, and also enable them to determine the proper course to pursue in order to secure still greater economies — a system of manufacture that enables the management to feel certain that the most economical methods of production are being planned and pursued. 

Add to this an efficient selling force, properly trained by modern methods, and an economical plan of putting the manufactured goods upon the market, and the firm possessing such advantages is in an impregnable position. 


The Manufacturer "With His Eyes Closed." 


In this day, a firm which would hold its own, must adopt the / most modern methods in organization, method, and system. Reputtation gained in the earlier days of a firm's existence is a valuable asset when backed up by modem methods, but amounts to little when it is coupled with obsolete ways of doing busiaess. A business that does not  progress will slide backward in the market. . The manufacturer can always feel certain that if he is not progressing some one of his competitors surely is. This he may learn to his sorrow. The old maxim "a stern chase is a long one" applies with peculiar force to business conditions. Once your competitor has built his tools for economical production, improved his product, organized his forces, and secured the proper start on the market, his sales and profits multiply and yours decrease. And the longer you delay adopting similar methods, the more the difficulties increase. 


There are still many manufacturers who are not satisfied to give their unqualified approval to modern methods in shop and selling organization. The idea of "organization" is not compatible with their idea of economical management. To these the idea of "system" is indissolubly linked with "red tape." " System" to them means additions to their clerical force, and additions to their clerical force means additional dollars spent upon "non-producers." They will refuse to admit the advisability of systems sufficient to care for their heavy factory interests, and yet they have sufficient intelligence to keep up their general accounting system. In brief, they do not note the tremendous leaks in their factories because they have not sufficient experience or data to enable them to know, with any degree of exactness, whether or not they are getting proper and economical results from either foremen, men, or machinery. A moment's thought must make such as these realize the possibilities of the existence of such leaks, and they may be absolutely certain that where such possibilities exist, unchecked and unsystematized, there also exist the losses. 


The Manufacturer "With His Hands Tied." 

There are, however, many manufacturers on the other hand who realize that something is wrong, seriously wrong, and who would be glad to adopt modern methods if they but knew what they were and how to apply them. But to many a man who is intent on improving conditions, but who necessarily faces ignorance, prejudice, false pride, and stubbornness on the part of those in his organization who should help him. To such, however, as recognize the conditions and are willing to attack the problem, methods can be suggested, the value of which has been proven over and over in actual experience under the most distressing conditions. Careful investigations, coupled with a thorough campaign of action along organized lines, will bring the reward. 


The Reward. 

The reward for such investigation, coupled with vigorous, intelligent, and tactful action, is so great as to justify the required expenditure. That it will take time, and in most cases a long time, is very true ; but that is all the more reason for beginning and continuing courageously along steady lines of progress, and in such a manner that any backward step would not be be possible. The most difficult and discouraging problem to contend with, next to the difficulty of wheeling the old men into line, is that of progressing along new lines, devising and putting into effect new methods and new processes and tools, and at the same time not interfering with the regular required output. However, if the manager is sufficiently impressed by stern necessity to lay out plans for improvement, every one upon whom he must depend must be impressed with the idea that every day must show some 'progress, however slight, on the part of every one connected with the plans. 


Organizing the Method of Investigation and Analysis. 


The manufacturer, and such advisers as are qualified and trustworthy,  must make up their minds to analyze coldly each and every machine, man and situation. The problem may be attacked as outlined hereinafter. 


Let us consider first the usual defects in organization, system, and methods, in their order, and attempt to discover the "sticking points" in each division. They may be classified as follows : — 


1. — Defects of factory organization, dealing with the superintendent, the foremen, the job bosses, and the workmen, and the usual methods of management. 


2. — Defects of systems and methods of manufacturing. 


3. — Defects of sales organization and executive control. 


The separations made here are important ones and should be considered as thoroughly in the case of the concern with fifty men as in the case of the one with five thousand. 


If you are interested, take these divisions item by item and make a faithful memorandum of the defects under each heading that you alone know of. If you have such a knowledge of the business as you should have you will be surprised at the number of your notations. Then when you come to the headings of those processes with which you are not familiar, secure the advice of competent persons in each line and observe the extent and character of your notes. 


I. Defects of Factory Organization. 


The Superintendent. 


The method of management usually adopted is that of placing all the responsibility on the shoulders of one superintendent and failing to surround and strengthen him with a small body of the most efficient foremen, who might prove to be advisers of great value to him. In adopting such a method, the management fails to recognize the great benefit to be derived from securing the best advice of a small group of the best qualified men upon most important subjects, and from giving its foremen an opportunity to increase their knowledge of the business and so to grow to be of greater worth to the concern. The stimulus to the ambition of the foremen because of the opportunity so to show their worth is thus lost. Instead of these men being moved by the hearty desire to co-operate with the firm and with each other " for the good of the company," they are usually impelled by feelings of jealousy and impair the efficiency of themselves and the entire organization by their backbiting and faultfinding. 


And yet with any method of organization there must be a head and a strong one. A " cheap'-' superintendent is dear at any price. A strong and capable man in this position is usually worth any reasonable amoimt necessary to secure or retain him. A large manufacturer once said : " My $20,000 superintendent is the cheapest man I have." In reply to the expected "Why?" he said: "He's my ' dividend maker.' I tried 'em at $3,000, $5,000, $10,000, only to keep on losing. Finally, I made up my mind I wouldn't pay less than $20,000 — got my man, and he's bringing my dividends. Cheap at $20,000." 


The Foremen. 


The most important men in the shop. You may have the best qualified superintendent, but if you have inefficient foremen, you have poor management; you may have the best machinery — but with inefficient foremen, poor results; the best systems — complication; the best desires toward your workmen — your poor foremen bring upon you labor troubles galore. 

When one stops to consider that these are the men who come into daily touch with your workmen — that they practically control the shop life and shop destinies of your men on machines and bench — that to them falls the responsibility of getting the best results from the workmen, and upon their knowledge you must depend when it comes to the question of getting the proper and best results from the machinery you have bought — is it not absolutely true that they are the most important men in the shop, and that their methods, their intelligence, their experience, are questions most vital to you and your business? 


Usual Methods of Appointment and Development. — And yet what are the facts in many cases? The foreman is often a former machine hand promoted to this position because of superior intelligence, diligence, and desire to please. This man, who should have a wide and thorough experience in modern machine practice, is often simply a graduate of your own shop, with experience limited to your routine practice. 


The Proper Type. — The foreman should have a thorough knowledge of the best mechanical processes and the types of machines best suited for the work he handles. He should have also a wide knowledge of the tools, such as jigs, milling fixtures, dies, etc., best adapted to his work, and of methods of using them so as to procure the greatest economy in production; and, last but not least, the ability to handle men and get the best from them. Am I setting too high a standard for the foreman? I say No ! positively No ! These are the men who can "make or break" the concern. As is the foreman, so is the department. In nine cases out of ten, he is your "StickingPoint," or is responsible for it, be it poor workmanship, high costs, tardy production, or trouble with your workmen. This is as true of the small shop as of the large one. 

Therefore, select him with care, watch him and help him, educate him, and, above all, give him the stimulus of "his chance" and watch him grow, if he is the right kind. 

True it is that in the most modem shops the tendency now is to depend less and less upon the foremen on the important questions of speed of machines, types of tools, setting of standard time, and proper prices on jobs. The best practice in the up-to-date shop is to institute speed bosses, rate-making departments, and tool and tool-designing departments, entirely independent of the foremen. In fact, as will be brought out later, such plans, properly instituted and carried out, will accomplish wonders; but this course is rendered necessary because of the weakness of the ordinary foremen. But in most shops it is hardly possible to consider such elaborate, though extremely valuable plans amongst the first steps. Depend upon your foremen you must. Even though the greater plan of organization with speed bosses, rate-making departments, etc., may be determined upon, this consideration of the foremen's efficiency is equally necessary. In fact, the broader plan will utterly fail unless it is supported by the intelligent efforts of the heads of departments. 


The Management's Representatives. — Never forget that the foremen are the management's direct representatives to the workmen. The men form their opinion of the company from their opinion of their foremen. Their daily life and career are subject to his control, his whims and vagaries ; their promotions and increases in pay depend upon his characteristics and knowledge. They more often have reason to depend upon his practice of favoritism than upon his sense of fairness. The character and ability of the foremen affect the workmen more directly than any other three factors in the shop organization and management, and as a consequence have a direct effect upon their output and disposition toward the company. 


Job Bosses and Workmen. 


In any shop organization, however small, the question of the proper division of the working force, so that the proper amount of supervision can be given to each man or group of men, must receive careful attention. A foreman cannot properly oversee his entire department without assistance and still give his attention to the larger and more important details of his work. The usual method of securing this result is to appoint the more efficient members of the working force "job bosses" with some limited degree of authority over a small group of men. These men perform their share of the work, receiving a slight increase in their pay. 


The importance of carefully selecting these men is at once apparent. They are usually the next in line for advancement to assistant foremanship. From these men come your heads of departments. And yet how many managers or shop superintendents possess accurate information concerning the character and ability of their job bosses? They usually promptly pass over to the foremen the responsibility for making these selections, and very often they in turn just as promptly pass the coveted position to some favored friend without much regard to the matter of his ability compared to that of the rest of the group affected — or, to drive the thought harder home — without regard to the ability and intelligence of the rest of the candidates for promotion. Advancement in wage and authority is as important to the $1.50 per day workman as it is to the superintendent. It is the neglect of just such points as these that cause workmen to feel that merit and hard work count for little, and that extra effort brings no reward in the face of an unfair foreman's selection of his friends and favorites for the only progress that is possible to them. 


System of Pay and its Effect Upon Workmen. 


Of equal importance in its direct effect upon men is the question of the "system of pay" and the method of handling it. Little will be said at this point regarding these matters. However, in considering the defects directly affecting the workmen and seriously affecting the cost of production in many forms of business, the first prize (for total inefficiency) may usually be given blindly to the pay system without much danger of going amiss. 

The average system, usually piece work, started by men little versed in modern methods and based upon data usually secured by the foreman by methods " strictly their own" — and as often totally incorrect — supplies a first-class millstone to burden any concern. 

Little faith can usually be placed in the average foreman's estimate of a "fair price" for a job. Lacking proper knowledge himself, he will, however, unhesitatingly and with a great display of confidence, place a price upon any piece of work. Then follows the old story of, first, excessive earnings by workmen; second, dissatisfaction on the part of the employer, and consequent reductions in price; and, third, the invariable result of discontented workmen, who find that their only protection from reductions in price lies in. the strict adherence to a certain limited rate of earnings and hence of production. The foremen continue blithely to set the prices, the employer suffers unconsciously through excessive costs and limited output, and the workman works away discontented and determined to even up matters for unfair treatment. These conditions are still very prevalent. 

It is astonishing to note the manner in which otherwise sensible men will put into effect and enforce methods and policies vitally affecting the workman's daily life, without regard to the "human element" that enters into his makeup and that the manager should know must of necessity be reckoned with. 

Much has been said about the tendency of the modem workman to limit his output and not put forth his best efforts to improve either himself or the company's product. This complaint, however, generally comes from the manufactiurer who does not consider it worth while to give close attention to such details as are mentioned briefly here. Seldom is it "heard from the manager who wisely "puts himself in the other fellow's place," and then builds up his plans along lines that he realizes would mean encouragement and inspiration to him were he in that other fellow's place. 

Any man who has sufficiently clear vision to recognize such faults existing in his business must make up his mind to start right in at the bottom and build up. No points can be neglected. The faults in organization and methods mentioned in this brief outline, if existing, must be eradicated before any permanent or really effective improvement can result. 


II. Defects of Systems and Methods of Manufacturing. 


In this chapter, the intention is  to  point out the most serious defects of the ordinary systems, as the succeeding chapters will deal with the defects and suggested methods of betterment quite fully. The need of system is, of course, becoming more widely recognized each year. But in many cases the manufacturer stops just short of full success. Many times he also fails to realize the full purport of his system and to reap the full, and, in fact, the greatest benefit possible from it. 


System of  the shop processes of production, such as machining, assembling, etc. 


Proper results in the shop processes of production come from systems in production methods. 


The lack of accurate information relative to the amount of work that can and should be turned out from a first-class tool is astounding. In many shops it is only another case where those methods which vitally affect the cost of production are "up to the foremen," and the foremen, lacking knowledge and experience, cheerfully run their departments year in and year out, satisfied if they turn out sufficient volume to keep the "superintendent" off their trail. 

Machining Methods. 

In my own shops before they were reorganized, I have seen cases where one department was operating the machinery at such cutting speeds and with such depths of cut as to show a loss of 21 per cent when compared with another department directly beside it but under another foreman. And, at that, both departments were far below the standard of efficiency they have now attained, and the end has not yet been reached. 

In this matter understand me clearly. The average foreman wants to do well and to make a good showing. But he cannot but lack the desired (and indeed necessary) training and experience to secure proper results. The only proper method of handling these men is to train them. It can be done. It has been done with fine results. Necessarily, then, this vital information as to what should be produced from any one machine is usually lacking in foremen and superintendents.

I recently installed in certain factories several large boring mills and heavy planers built by two of the highest grades of manufacturers. In order to test the amount of knowledge possessed by the manufacturers of these machines, they were called upon for advice as to the best results that could be secured from them when working under differing conditions. Simple questions were asked as to the speed and depth of cut possible in order to secure the best results. These builders of the tools could not give a definite answer that would be of any material assistance to any one needing light. They knew that their machine tools ran as fast and "would turn out as much work, etc.," as any in the market, but when it came to the question of shapes of tools, depth of cuts, results upon differing grades of metal, results from the use of water and composition on the tool, etc., they floundered hopelessly. The lack of knowledge of the best results obtainable is not by any means confined to the older type of shops. There is many a factory today which to the eye presents a modem appearance, with its new buildings, well ventilated and cleanly, its fine equipment in machinery and tools, and its show of bustle and hustle, which yet needs the " doctor's care" badly. The shop, whether new or old in appearance, operating under the older methods of obsolete of obsolescent wage and shop systems, hampered by lack of accurate knowledge of best obtainable results in up-to-date processes of production, by lack of progressiveness and lack of " pulling for the good of the company" spirit in the working organization, is far behind in the race for commercial supremacy. 

More details regarding the improvement of machining methods are covered in a full chapter.


The Stock System. 


To the manufacturer who is not thoroughly awakened to modern possibilities, the stock system is simply a means of keeping track of his stock. It may never occur to him that it is possible to develop it easily so that he can cut down his necessary working capital to a minimum and reduce his interest account to the lowest point possible, or that, by a little development and attention on the part of several intelligent men, monthly inventories correct within 1 and 2 per cent can be easily secured and made the basis for an exceedingly valuable factory profit-and-loss sheet, so that factory conditions can be accurately noted monthly. 

The Order and Tracing System. 

The order and tracing system are often considered "necessary evils," and yet the great success of many a concern depends upon the promptness in filling orders and keeping delivery promises, and the tracing system is responsible for this. 

The tracing system as an aid in keeping down stock investment through keeping the regular stock constantly moving is also often a new idea. 

The Cost System. 

The possibility of ascertaining the cost of the article is often the only thought in the manufacturer's mind when the "cost system" is mentioned, and is accordingly its only function that is developed. In fact, however, the valuable analyses of costs, operation by operation, to be secured from an efficient cost system, supply the manager with invaluable data from which to work in reducing costs. Nor does their effectiveness stop here. If it is decided to start a campaign to increase the efficiency of the factory force and to eliminate the inefficient men, then the individual records of the man will be secured from the cost records. In large bodies of workmen, a steady and intelligent campaign along these lines will work wonders. 

While to some this last point may appear to be an unnecessary refinement, it must be admitted by all that a cost system must provide a method of cost analysis which will unerringly reveal the points of high and excessive costs throughout every stage of manufacture. The failure to accomplish this means the failure of the chief function of any cost system, namely, making possible the greatest economy in manufacture. 

Linked up closely with the cost system is the "system of pay" or the wage system already touched upon. This will be handled fully later, but must be mentioned now because of its great importance. It, and the "method of organization," form the two pillars upon which rest the whole framework of a successful concern. Any weakness here is felt throughout the entire structure. 


III. Defects of Sales Department and Executive. 


The Sales Department. 

Thorough and careful consideration of sales-department methods is considered essential in this discussion. A full study of any business is incomplete if the sales-department methods are neglected. For the "production of orders" is a most essential link to the chain. 

The possibilities of scientific development in this branch of the ordinary business are so great that they must be carefully studied. To this statement I often hear the manager say: "Scientific development of the selling end of the business! Why! a salesman is a salesman. The selling of the goods is an art in itself. A matter of individualism. Salesmen are born, not made. Training of salesmen! Bosh!" 


The managers who make such statements are usually of the type that will employ a new salesman, let him " dig around the shop a bit," give him a catalogue and start him out. A mere " taking of orders on price alone," not a finished salesman. For the gulf of difference between a man who takes orders because he quotes lower prices than his competitor, and the salesman who sells the goods at a higher price than his competitor because of his skill and knowledge of his business, is a very wide and deep one. That there is a " psychology of salesmanshp" I would be the last one to deny. But innate selling ablity, unless backed up by proper knowledge, will not win. Add to natural selling ability a thorough training in the "talking points" of the product, the defects (and good points) of the competitors, the best methods of meeting arguments and objections, gained from the experience of all the best men in the selling organization, the most successful means of demonstrating the merits of the goods to the prospective customer — and you have a strong salesman. 

Train your men collectively, thoroughly organize them along scientific lines, and then back up your training by simple yet adequate systems whereby you may know that the territories are being completely covered, your prospective customers are being handled properly, profitable prices being secured and competition being met, and you will have an invincible selling organization. 

Instead of this condition; one often sees a group of salesmen, jealous and distrustful of each other, lacking in the desire to work together for the good of the company, without a thorough knowledge of the company's goods or their competitors' product, and very chary about sharing what knowledge they do possess either with each other or with the poor newcomer. Usually the firm itself is almost entirely responsible for such conditions. 

The possibilities that lie in the development of proper methods are astounding. Actual experience to be described in later chapters has proven it beyond the peradventure of a doubt. 


The Executive. 


The weaknesses outlined in the preceding pages will surely be felt in the executive division whether that consists of one man or twenty. With the possibility of securing only such insufficient data as can be obtained with lack of organization, methods, and systems, such as has been outlined, what can the executive do but struggle along in. the dark and in doubt, trusting that his untrained salesmen can sell his product for such a price that a reasonable profit will be shown after his factory, without proper organization, system, and training, has produced? In passing, let me state again that there is many an executive today who, not realizing the inefficient condition of both branches of the organization, wonders what there is wrong with a business that apparently is in good condition as far as surface conditions are concerned. To such I say analyze the business to the uttermost. Compare it with a modem concern with an organization built upon lines that inspire the workers in it to give their best knowledge and ability to further its progress, with methods that ensure the best results in cost and volume, and systems that will not only tell the story of progress but also indicate the " Sticking Points" — and then begin to build along proper lines. And when the work is once begun, never let up; fight it out to a finish, It will pay. 


              End of the chapter


PEOFIT MAKING IN SHOP AND EACTORY MANAGEMENT 

BY

CHARLES U. CARPENTER

NEW YORK 

THE ENGINEERING MAGAZINE 


1908 

Copyright, 1908 

By JOHN R. DUNLAP 

https://archive.org/stream/cu31924002748576/cu31924002748576_djvu.txt

CONTENTS. 


Chapter I. The Reorganization op a Run-Down Concern 


The Necessity for Analysis of Existing Conditions — ^Advantageous Posi- 

tion of a Well Organized Concern — The Manufacturer with his Eyes Closed — 

The Manufacturer with his Hands Tied — Organizing the Methods of Inves- 

tigation and Analysis — The Usual Defects of Organization, System and 

Methods in Manufacturing Plants — ^The Superintendent — ^The Foremen — 

Job Bosses and Workmen — Systems of Pay and their Effect — ^The Stock 

System — The Order and Tracing System — ^The Cost System — ^Machining 

Methods — Defects of the Sales Department — Defects of Executive Con- 

trol 9 


Chapter II. The Practical Working op the Committee System 


No Ready-Made System is a Panacea — ^Why New Systems so Often 

Fail — Co-operation of the Working Force is Essential — ^The Human Element 

and the Get-Together Spirit — Formation of the Committee System — ^The 

General Factory Committee — Its Personnel — Its Work — Its Meetings — 

Subsidiary CoHimittees — Job Bosses' Meetings — General Foremen's Meet- 

ings — ^The Workmen — Promotions 23 


Chapter III. Reports; Their Necessity and Their Uses 


The Necessity for Reports of Varied Kinds — ^What they should be and 

what they should Cover — A General Outline of the Essential Reports — ^The 

Monthly Analyzed Profit and Loss Sheet — ^The Sales Reports — ^The Factory 

Reports — ^The Cost Reports — ^The Points to be Shown and the Methods of 

Use 36 


Chapter IV. The Designing and Drafting Department 


Results to be Secured — Close Relations with the Tool Room — Require- 

ments of an EflScient Drafting Department — ^Meetings with the Com- 

mittees — Co-operation with Shop Foremen — Standardization in Design — 

Designing for Cheap Machining and Assembling — ^Making and Following 

of Drawings to be Invariable — Reports from Machining and Assembly 

Departments — ^The Use of the Coiimaittee System 42 


Chapter V. The Tool Room; the Heart op the Shop 


The Full Functions of the Tool Room — Systems of Tool Supply — 

Speed of Production in the Tool Room of Vital Import — ^Methods for 

Hastening Production — ^The Choice of the Foreman — Specialization of 

Labor — Standaxdization — Duplication of Standard Parts — Subdivision of 

Labor — ^The Small Shop — Speeding up Tool Production and Checking the 

Cost — Tool-Cost Cards — Examples — ^Method of Use — Tool-Room Commit- 

tee Membership 50 


Chapter VI. Minimizing the Time of Machine-Tool Operations  


The Determination of Standard Times — ^The Concentration of the Work- 

man's Time on Running his Machine — ^The Adoption of High-Speed Steel — 

Causes of Lost Time — The Starting Point in Minimizing Operation Costs — 

Investigation of Existing Machinery — Systematic Report upon Improve- 

ments in Old Machines and Recommendations for Replacements or New 

Purchase 64 


Chapteb VII. Possibilities Attending the Use of High-Speed Steel 

What Percentage of Increase may be Expected in the Output — ^The 

Abundant Provision of Cutting Tools — Standard Shapes for Tools — ^How 

Determined — Forging — Hardening — Form for Records — CooHng — Grind- 

ing — Use of Automatic Grinders 73 


Chapter VIII. The Determination or Standard Times por Machining 

Operations 


The Shop Conditions upon which Standard Times Depend — Tests of 

Times which should be Attained — ^How to Begin — Classification of Parts — 

The Expert Tester — ^His Qualifications — Practical Speeds in Lathe Work — 

In Planer Work — In Drilling — ^Tables — How to Use the Tables — ^The Com- 

mittee at Work — Requirements for Maximum Production by the Work- 

man 83 


Chapter IX. Standard Times for Handling the Work 


The Elements which must be Considered — Causes of Lost Time in Hand- 

ling—Injuries to Stock or Parts in Handling — ^The Use of Standard Boxes — 

Standard Places for Stock and Parts — Records of Handling Times — 

Forms — Setting-up Time— Times for Work on the Machines — ^Time for 

Removing Work from the Machines — ^The Use of Committee Action 94 


Chapter X. Standard Times for Assembling 


Special Difficulties to be Found in this Subject — ^Methods of Procedure 

which Succeed — Examples of Results Secured — ^An Instructive Case 

Described — ^Foremen's Co-operation Essential — How it can be Enlisted. . . . 101 


Chapter XI. Stimulating Production by the Wage System 


The Attitude of the Workman — ^Mischief Caused by Cutting of Rates — 

The True Theory of Costs — ^The Wage Problem in Introducing Standard 

Times — ^How to Get the Workman to Stand for Them — Systems of Pay — 

Day Work — Piece Work — Premium Plan — ^The Differential Plan — ^The 

Bonus Plan — Special Modifications of the Bonus Plan Recommended 109 


Chapter XII. Stock and Cost Systems as a Factor in Profit Making 


The Prime Requisites of a Cost System — Wha,t it should Accomplish — 

The Three Fundamental Problems at a Stock System — A Simple and Suc- 

cessful System Described — ^The Forms and Cards and their Mode of Use — 

Storage Platforms and" what they AccompUsh — Stock-Tracing and Cost 

Sheets — ^Forms — ^How the Data are Used 116 


Chapter XIII. The Upbuilding of a Selling Organization 


The Various Methods of Selling Manufactured Goods Defined — ^What is to 

be Considered in Developing a Selling Force — ^Training of Salesmen — Its 

Possibilities Proved — Development of a Selling System — Salesmen's Demon- 

stration Meetings — A Typical Programme — ^Modes of Stimulating Interest — 

Salesmen' Training Department — Selection of an Instructor— Prepara- 

tion of a Manual — Reports and their Importance — ^Forms — Lists — Adver- 

tising ._ 124 


Chapter XIV. Effective Organization in the Executive Department 

Difficulties Peculiar to the Executive Division — The Personal Element — 

The Use of the Report System — Reports from the Selling Division — ^Forms 

— Factory Reports — ^Forms — ^Executive Reports — ^Forms — The Methods 

Illustrated by an Example and a Typical Programme — ^The Results 

Secured 138 


About Carpenter

https://en.wikipedia.org/wiki/Charles_U._Carpenter


Charles Underwood Carpenter (Indiana, January 1872 – January 15, 1928[1]) was an American business manager, management author, and inventor, known as "one of the earliest advocates of the committee system in factory management."

Carpenter got his degree from Princeton University in 1893, and started his career in industry.













September 18, 2024

Neglect and Decline of Manufacturing Management Subject Resulted in Decline of Manufacturing Sector in USA

 

BBA, MBA education had more focus on marketing and finance areas. There was education in scientific management also. But in Harvard, there was systematic campaign to malign scientific management and F.W. Taylor's contribution. In the departments focusing on manufacturing and production management, a trend emerged whereby manufacturing and production were substituted by operations management of service businesses. Slowly the textbooks became production and operations management and then Operations Management. The attention to manufacturing still declined further. There is a body, AIIE which became the main body supporting industrial engineering. This body supported Engineering Management also. Even this body neglected engineering and diverted attention to non-engineering areas like hospitals etc.  The net result is decline in research and innovation in manufacturing management in USA.

Some Japanese persons were present when F.W. Taylor made his presentation on Scientific Management. They instantly recognized its utility and they developed it further in Japan in their own way taking the help of US persons like Gilbreth. While the Japanese manufacturing prospered, US manufacturing declined due to their neglect and motivated criticism of Taylor and his contribution to productivity improvement in manufacturing.


The domain of production and operations management and the role of Elwood Buffa in its delineation

Kalyan Singhal, Jaya Singhal, Martin K. Starr

https://doi.org/10.1016/j.jom.2006.06.004   

Abstract

Production and operations management (POM), as we know it today, was established in the 1960s in response to various drivers. Elwood Spencer Buffa first published his textbook, Modern Production Management, in 1961. He had degrees in business and engineering and had worked as an industrial engineer. He was also part of the UCLA–RAND academic complex whose operations researchers coined the term management science and conceived the idea of The Institute of Management Sciences. Buffa coined the term operations management and consolidated knowledge from various streams of production management, including operations research and industrial engineering, into a coherent managerial framework.


Modern business education had started to emerge around 1959 after reports from the Carnegie Corporation and the Ford Foundation recommended improving research and analytical approaches. Many business schools created courses in POM. At the time, no single book covered what we now call production and operations management. The POM faculty at most business schools, including Columbia's Graduate School of Business, adopted Buffa's book enthusiastically when they introduced courses in “production management”. Buffa  covered supply chain management, design for manufacturing, quality management, service operations, and computer applications and the automated factory. The POM community pursued these issues more actively 2 or 3 decades later.


https://onlinelibrary.wiley.com/doi/10.1016/j.jom.2006.06.004

Related articles

https://onlinelibrary.wiley.com/doi/abs/10.1111/j.1937-5956.2006.tb00238.x


Article to be developed further.

Manufacturing process design is not adequately described in Operations Management  textbooks. Developing an article. 

Developing the article: Manufacturing Process Design.

Please share useful articles or papers. Give reference. I want to use and include in the bibliography.

https://nraomtr.blogspot.com/2024/09/manufacturing-process-design-work-flow.html

#ManufacturingProcessDesign  #OperationsManagement   #IndustrialEngineering  #Manufacturing







Manufacturing Management - Introduction


Planning, organizing and controlling manufacture of goods is manufacturing management. Chase et al. define operations management as the design, operation, and improvement of the systems that create and deliver the firm's primary products and services. Operations management is a discipline that includes production of goods and services.

Once the company decides to manufacture and sell a product, the specialized responsibility of the manufacturing management starts. But the decision to manufacture a product is based on feasibility analysis. During this analysis also manufacturing management issues are involved. Therefore, the persons doing strategic analysis or corporate planning analysis include persons from manufacturing management discipline with manufacturing management knowledge and bring into the analysis or decision making process the manufacturing view point.

Manufacturing is carried out through processes. A process is any activity or group of activities that takes one or more inputs, transforms them, and provides one or more outputs. The output could be for an external customer for sale or for an internal customer to use for further processing. In some cases it can be for consumption in the same process or by the consumption by the producer himself. Manufacturing processes convert materials into goods that have a physical form. The transformation processes change the materials on one or more of the following dimensions:

1. Physical properties
2. Shape
3. Fixed dimension
4. Surface finish
5. Joining parts and materials.

The outputs from manufacturing processes can stored and transported in anticipation of future demand (Krajewski et al. 2007).

Important Developments in Manufacturing Management



Developments in manufacturing management include certain technical developments that made manufacturing systems more productive and flexible.

Shop Management - F.W. Taylor


Shop floor management guidelines provided by F.W. Taylor were landmarks in the field of manufacturing management. Taylor further development Scientific management philosophy. Taylor also brought out the importance of scientific studies in manufacturing processes improvement or design. His studies on machining were considered a very important research contribution. Taylor also introduced time study based best practice identification and training all operators in the best practice. He advocated that manufacturing managers have the responsibility of developing manufacturing methods and training operators in best methods.

Frank Gilbreth developed study of motions of operators to develop efficient operator movements either to do manual work or to operate machines. He and Lilian Gilbreth also introduced the concept of fatigue and proposed ways to prevent the negative consequences of fatigue in operators as well as in manufacturing systems.

Henry Ford introduced moving assembly lines that revolutionized the production systems. Henry Gantt developed charts that helped scheduling production activities.

Harry Emerson wrote a book on principles of efficiency and it became part of industrial engineering and scientific management literature. Focus on efficiency in systems in general and especially manufacturing systems sharpened.

F.W. Harris developed theory of batch quantities in production and purchase. Walter Shewart developed procedures for using statistical thinking in process control. He created methods for determining when to change machine setups based on the measurements of samples taken at random intervals.

Hawthorne studies became another landmark development in manufacturing management. They brought out the importance of psychological variables in improving or decreasing productivity of operators. Unfortunately, the proponents of this line of thought have not integrated their conclusions with the ideas of scientific management appropriately. They chose to attack themes of scientific management. Manufacturing management might have had a different state today, if scientific management movement that had engineering foundations and human relations school of thought that had psychology as its foundation were appropriately integrated by human relations school.

Operations Research


Development of operations research (OR) helped manufacturing managers to understand and optimize their systems better. Study of operations research became a part of studies of manufacturing managers. Use of computers was started in recording store related transactions and data and it was extended to shop floor transaction data. The use was further extended to calculation of batch quantities and preparation of loading sheets and schedules. MRP and MRP II came into existence and they got extended into ERP systems.

The domain of production and operations management and the role of Elwood Buffa in its delineation
Kalyan Singhal, Jaya Singhal, Martin K. Starr
https://doi.org/10.1016/j.jom.2006.06.004   


Production and operations management (POM), as we know it today, was established in the 1960s in response to various drivers. Elwood Spencer Buffa first published his textbook, Modern Production Management, in 1961. Buffa coined the term operations management and consolidated knowledge from various streams of production management, including operations research and industrial engineering, into a coherent managerial framework.

Modern business education had started to emerge around 1959 after reports from the Carnegie Corporation and the Ford Foundation recommended improving research and analytical approaches. Many business schools created courses in POM. At the time, no single book covered what we now call production and operations management. The POM faculty at most business schools, including Columbia's Graduate School of Business, adopted Buffa's book enthusiastically when they introduced courses in “production management”. Buffa covered supply chain management, design for manufacturing, quality management, service operations, and computer applications and the automated factory. The POM community pursued these issues more actively 2 or 3 decades later.

https://onlinelibrary.wiley.com/doi/10.1016/j.jom.2006.06.004

https://openlibrary.org/authors/OL1193811A/Elwood_Spencer_Buffa

Elwood Buffa's pioneering contributions to production and operations management
Authors: Sushil Gupta and Martin K. Starr

From: Production and Operations Management,  Summer 2006 (Vol. 15, Issue 2)





1. Introduction

The first three editions of his textbook, Modern Production Management (Buffa 1961a, 1965, 1969), played a major role in the evolution of an integrated and coherent discipline that has come to be known as production and operations management (P/OM). Although P/OM has existed for centuries and the work of Smith (1937, originally published in 1776) and is widely regarded as its formal beginning, Buffa's book marked the founding of this discipline. It immediately became the dominant book for introductory P/OM courses all over the world.  While Modern Production Management created an identity for our discipline in 1961, the P/OM community still remained fragmented into several interest groups and societies until 1989, when the Production and Operations Management Society (POMS) was founded. Later, the European Operations Management Association (EuROMA) was formed in 1993.

2. Teaching and Textbooks

 Although Buffa's books covered a wide range of areas, such as general business, management science, production and operations management, and strategy, all of them evolved from his interest in production and operations management.

While the series of books written by Buffa were becoming standard texts for introductory P/OM courses, several other books were published in the early 1960s that introduced the field of P/OM to students at an advanced level (Fetter and Dalleck 1961; Hanssmann 1961; Miller and Starr 1962). Buffa also published an advanced level book, Production and Inventory Systems: Planning and Control in 1968, and wrote its second edition with William Taubert (Buffa and Taubert 1972), and the third edition with Jeffrey Miller (Buffa and Miller 1977). These advanced level books, written by several P/OM thought leaders at that time, were used as texts for a second course in production and operations management. 

Japanese Contribution to Production Management


In 1970s, scholars in USA recognized that Japanese had used their manufacturing management philosophies, strategies and techniques as a strategic capability to win market shares in global markets. A new era of manufacturing strategy thought developed in manufacturing management. Automation increased in factories. With this multi-skilling of operators came into picture as now operators have more time and can operate more machines. As group layout became more popular, an operator was required to operate different machines which were in series. Total quality management, total productive maintenance, total cost management became the strategies. JIT or lean systems became the best practice production systems. While improvement everywhere reached its zenith, the important idea that it is improvement in bottleneck that has the most value was highlighted by Goldratt in the name of 'Theory of Constraints.'

Many new technologies came into existence and were adopted into manufacturing processes. The existing ideas regarding technology adoption did not emphasize the suboptimal use of technology. The full power of technology was not being put to use by many. Theory of BPR brought this into focus and helped systems become more productive by utilizing the power and potential of the new technologies more. Ability to look at bigger and bigger systems using OR models and system dynamics models and the ability to access data anywhere using internet based data communication systems made coordination across distributed national and global facilities. This led to the development of theory of supply chain wherein information can be made visible to anybody and optimization can be done from the point of origin or raw materials to its dumping point. Manufacturing facilities are now a part of supply chains wherein information is available to both suppliers and potential customers in real time and purchasing is done through electronic orders. In a century, manufacturing management theory and practice developed immensely.


Industry 4.0 - Japanese Attempt to Master Implementing New Technologies and Equipment


Machine Work Study - Machine Improvement in Toyota Production System (TPS)







Chase, Richard, B., F. Robert Jacobs, Nicholas J. Aquilano , Operations Management, 11th Edition, McGraw-Hill, New York, 2006.
Krajewski, Lee et al., Operations Management: Processes and Value Chains, 8th Edition, Prentice Hall, Upper Saddle River, 2007.

________________________________________________________________________

Early Books on Manufacturing Management




Learning from the first Operations Management textbook

Christopher A. Voss

//doi.org/10.1016/j.jom.2006.05.013


De Re Metallica by Georgius Agricola was published in 1556. It is arguably the first Operations Management textbook. In it the author describes the management and technologies of the mining and metallurgical industry of the period. There is a  translation by Herbert and Lou Hoover. Many areas which we see as contemporary, such as ethical and environmental issues, are explicitly addressed in the book.  The book describes how the operations should be organized and managed, the role of the foreman, and the education and training required.  The most enduring lesson from this remarkable book is the importance of systematic capture and dissemination of knowledge in Operations Management.

Introduction
A few years ago, I published a paper reviewing the history of Operations Management from Taylor to Toyota (Voss, 1995). Like many in the field, the work was based on the underlying assumption that Operations Management started with Frederick W. Taylor. However, as many have pointed out, it is possible to trace the field much further back.

De Re Metallica by Georgius Agricola - published in 1556.
Translation by Herbert and Lou Hoover.




Shop Management - Themes


1. Definition of Management 

2. Difference in Production Quantity between a first class man and an average man

3. Developing and Employing First Class People in an Organization

4. Confronting Soldiering - Slow Pace of Work

5. Halsey Plan - F.W. Taylor's Comments

6. Task Management

7. Investment for Increasing Productivity or Efficiency

8. Importance of people - organization

9. Modern Engineering and Modern Shop Management

10. Task Management - Starting and Ending Times

11. Task Work - Some More Thoughts

12. Usefulness of Gantt's system

13. Time Study - Part 1- F.W. Taylor in Shop Management

14. Bicylcle Ball Inspection Case Study

15. Need for Functional Foremanship or Functional Organisation of Foremen

16. Functional Foremanship

17. Production Planning and Control

18. Role of Top Management in Managing Change to High Productive Shop

19. Train Operators in High Productivity One by One and Then in Small Batches

20. Organizing a Small Workshop for High Productivity

21. Introducing Functional Foremanship




Profit Making in Shop and Factory Management
Charles U. Carpenter, 1908
http://www.archive.org/stream/cu31924002748576#page/n1/mode/2up

Factory Organization and Administration
Hugo Dimer, First Professor of Industrial Engineering, Pennsylavania State College
First edition: 1910
Third edition digital copy
http://www.archive.org/stream/factoryorganiza00diemgoog#page/n10/mode/2up



Factory and Office Administration
Lee Galloway, 1918
http://www.archive.org/stream/factoryofficeadm00galliala#page/n3/mode/2up

Factory Management Wastes: And How to Prevent Them
James F. Whiteford, 1919
http://www.archive.org/stream/factorymanagemen00whit#page/n7/mode/2up

Plant Management
Dexter S. Kimball, 1919
http://www.archive.org/stream/cu31924031222627#page/n7/mode/2up

__________________________________________________________________________

1958
https://books.google.com/books?id=J5pZAAAAMAAJ

1962
https://books.google.com/books?id=OgocWwOBxs4C

Introduction to Manufacturing Management
Ivan R. Vernon
American Society of Tool and Manufacturing Engineers, 1969 - Technology & Engineering - 301 pages
Clarifies the managerial and operational responsibilities of manufacturing.
https://books.google.co.in/books/about/Introduction_to_Manufacturing_Management.html?id=z9JTAAAAMAAJ

1974
https://books.google.com/books?id=RZRZAAAAMAAJ  

1987
https://books.google.com/books?id=juJTAAAAMAAJ

1993
Manufacturing Organization and Management
Harold T. Amrine et al.
Pearson Education India, 1993 - 640 pages

See page 109 for the chapter Design of Manufacturing Processes



1995




2000
Encyclopedia of Production and Manufacturing Management

Paul M. Swamidass
Springer Science & Business Media, 30 Jun 2000 - Business & Economics - 979 pages
The Encyclopedia of Production and Manufacturing Management is an encyclopedia that has been developed to serve this field as the fundamental reference work. Over the past twenty years, the field of production and operations management has grown more rapidly than ever and consequently its boundaries have been stretched in all directions. For example, in the last two decades, production and manufacturing management absorbed in rapid succession several new production management concepts: manufacturing strategy, focused factory, just-in-time manufacturing, concurrent engineering, total quality management, supply chain management, flexible manufacturing systems, lean production, and mass customization, to name a few. This explosive growth makes the need for this volume abundantly clear.
Preview

2006
Strategic Manufacturing Management: Strategies to Achieve Managerial Competitiveness

Thomas J. Sowell
Xlibris Corporation, 28 Feb 2006 - Business & Economics - 163 pages
The economic interdependence amongdeveloping and established industrializednations, and the disintegration of barriersto the flow of capital, information andtechnology across national borders facilitatesinternational market integration andglobalization. These market conditionsforce manufacturing companies to seriouslyconsider the strategies they need to implementif they are to develop competitive advantages. Very often the strategies that are executedwill result in a sustained competitiveadvantage through which a firm becomesleaner, more flexible, and more focused onproviding cost-effective goods and services tosophisticated customers. This book providesmanufacturing business strategies to assistcompanies to meet those requirements.
Preview

2013
Industrial Production Management in Flexible Manufacturing Systems

Dima, Ioan Constantin
IGI Global, 31 Jan 2013 - Business & Economics - 512 pages
Industrial Production Management in Flexible Manufacturing Systems addresses the present discussions surrounding flexible production systems based on automation, robotics and cybernetics as they continue to replace the traditional production systems. The book also covers issues related to the use of multi-servicing in the operational management of the industrial production and its scheduling systems.
Preview



2017





Advances in Production Management Systems. Initiatives for a Sustainable World: IFIP WG 5.7 International Conference, APMS 2016, Iguassu Falls, Brazil, September 3-7, 2016, Revised Selected Papers

Irenilza Nääs, Oduvaldo Vendrametto, João Mendes Reis, Rodrigo Franco Gonçalves, Márcia Terra Silva, Gregor von Cieminski, Dimitris Kiritsis
Springer, 15-Mar-2017 - Computers - 962 pages


This book constitutes the refereed post-conference proceedings of the International IFIP WG 5.7 Conference on Advances in Production Management Systems, APMS 2016, held in Iguassu Falls, Brazil, in September 2016.

The 117 revised full papers were carefully reviewed and selected from 164 submissions. They are organized in the following topical sections: computational intelligence in production management; intelligent manufacturing systems; knowledge-based PLM; modelling of business and operational processes; virtual, digital and smart factory; flexible, sustainable supply chains; large-scale supply chains; sustainable manufacturing; quality in production management; collaborative systems; innovation and collaborative networks; agrifood supply chains; production economics; lean manufacturing; cyber-physical technology deployments in smart manufacturing systems; smart manufacturing system characterization; knowledge management in production systems; service-oriented architecture for smart manufacturing systems; advances in cleaner production; sustainable production management; and operations management in engineer-to-order manufacturing. 


2018
https://books.google.com/books?id=zbSKDwAAQBAJ




Global Manufacturing Management
From Excellent Plants Toward Network Optimization
© 2021

Editors:
Thomas Friedli, Gisela Lanza, Dominik Remling
Features the St. Gallen Network Management approach, enhancing it with key practice-relevant facets
Highlights the scarcely investigated performance perspective in the field of international manufacturing networks
Combines outstanding world-class research with real-world evidence, including case studies

https://link.springer.com/book/10.1007/978-3-030-72740-6


2024
10 articles
https://books.google.co.in/books?id=HQkcEQAAQBAJ

Gavriel Salvendy
Professor Emeritus
salvendy at purdue.edu


Article originally posted in
knol   nrao 3309

Updated  19.9.2024,   15 November 2019,  22 October 2017, 13 October 2014