continuous process improvement: the lessons of history badm 701 dr. ron lembke
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Continuous Process Improvement: The Lessons of History
BADM 701
Dr. Ron Lembke
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Cotton Gin at Work
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Eli Whitney Introduced interchangeable
parts in large musket contract for U.S. Army
Interchangeable parts the true secret of Ford’s success
Made possible by advances in measurement and tool steel
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Tool Steel Advances
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Beginning of Standards
Before standardized parts, need Screws
1860s Machine Tool industry: Silicon Valley of its day
All screws custom made by tool & die shops according to what they thought best
William Sellers: 1864 “On a Uniform System of Screw Threads”
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Sellers vs. Whitworth
Sellers objectively better Easier: simple angle vs. difficult; rounded top vs. straight 3 cutters & 2 lathes vs. 1 cutter & 1 lathe
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Not Just What you Know
Machine tool makers didn’t want to be commoditized like gun makers
The standard people expect to win usually does.
Navy Board found it superior, asked Singer Sewing Machine, Baldwin Locomotive which would win (already adopted).
Pennsylvania RR adopted (Sellers on the Board)
British tanks & trucks couldn’t be repaired in WWII because Britain adopted Whitworth
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Frederick W. Taylor
Scientific Management Searching for the “One Best Way” to
do a process Find ways to improve work
environment and work processes Quantify, measure & track
everything:
Time required to haul wheelbarrow:
B p aL
0 51 0 004827
127. . .distance hauled
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Factory Life
Henry Noll“Schmidt”
Taylor’s Factory
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Frank and Lillian Gilbreth Systematically study a work
environment and find the best way to achieve a particular task
With Taylor, pioneered “industrial engineering” -- time and motion studies
“Cheaper by the Dozen”
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Motion Capture Lights illuminate key motion
joints For Computer Generation,
convert to 3D
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Barry Zito
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Chronocyclegraph light-1914
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Bricklayer
Hourly output up from 125 to 350
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Typesetter
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Drill Press
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The Entire Work Environment
Color coded slots Groove for grabbing pencil
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ErgonomicsToday
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Ergonomics Then
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Continuous Process Improvement
Eli Whitney and Interchangeable Parts
William Sellers and the rise of standards
Frederick Winslow Taylor and Scientific Management
Frank & Lillian Gilbreth and time and motion study