Mass production
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Mass production (also called flow production, repetitive flow production, or series production) is the production of large amounts of standardized products on production lines. It was popularized by Henry Ford in the early 20th Century, notably in his Ford Model T. Mass production typically uses moving tracks or conveyor belts to move partially complete products to workers, who perform simple repetitive tasks to permit very high rates of production per worker, allowing the high-volume manufacture of inexpensive finished goods. Mass production is capital intensive, as it uses a high proportion of machinery in relation to workers. With fewer labour costs and a faster rate of production, capital is increased while expenditure is decreased. However the machinery that is needed to set up a mass production line is so expensive that there must be some assurance that the product is to be successful so the company can get a return on its investment. Machinery for mass production such as robots and machine presses have high installation costs as well. Thus, mass production is idealy suited to serve large, relatively homogenous populations of consumers, whose demand would satisfy the long production runs required by this method of manufacturing. As such, it is not surprising that, given a number of other factors, mass production first became prevalent in the United States.
One of the descriptions of mass production is that the craftsmanship is in the workbench itself, not the training of the worker; rather than having a skilled worker measure every dimension of each part of the product against the plans or the other parts as it is being formed, there are jigs and gauge blocks that are ready at hand to ensure that the part is made to fit this set-up. It has already been checked that the finished part will be to specifications to fit all the other finished parts - and it will be made quicker, with no time spent on finishing the parts to fit one another. This is the specialized capital required for mass production; each workbench is different and each set of tools at each workbench limited to those necessary to make one part. As each of these parts is uniformly and consistently constructed, interchangeability of components is thus another hallmark of mass produced goods.
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[edit] Use of assembly lines in mass production
Mass production systems are usually organized into assembly lines. The assemblies pass by on a conveyor, or if they are heavy, hung from an overhead monorail.
In a factory for a complex product, rather than one assembly line, there may be many auxiliary assembly lines feeding sub-assemblies (i.e. car engines or seats) to a backbone "main" assembly line. A diagram of a typical mass-production factory looks more like the skeleton of a fish than a single line.
This is also used in food manufacturing to produce foods continuously.
[edit] Advantages and disadvantages
The economies of mass production come from several sources. The primary cause is a reduction of nonproductive effort of all types. In craft production, the craftsman must bustle about a shop, getting parts and assembling them. He must locate and use many tools many times for varying tasks. In mass production, each worker repeats one or a few related tasks that use the same tool to perform identical or near-identical operations on a stream of products. The exact tool and parts are always at hand, having been moved down the assembly line consecutively. The worker spends little or no time retrieving and/or preparing materials and tools, and so the time taken to manufacture a product using mass production is shorter than when using traditional methods.
The probability of human error and variation is also reduced, as tasks are predominantly carried out by machinery. A reduction in labour costs, as well as an increased rate of production, enables a company to produce a larger quantity of one product at a lower cost than using traditional, non-linear methods.
However, mass production is inflexible because it is difficult to alter a design or production process after a production line is implemented. Also, all products produced on one production line will be identical or very similar, and introducing variety to satisfy individual tastes is not easy. However, some variety can be achieved by applying different finishes and decorations at the end of the production line if necessary.
[edit] Vertical integration
Vertical integration is a business practice that involves gaining complete control over a product's production, from raw materials to final assembly.
In the age of mass production, this caused shipping and trade problems in that shipping systems were unable to transport huge volumes of finished automobiles (in Henry Ford's case) without causing damage, and also government policies imposed trade barriers on finished units.
Womack, Jones, Roos; The Machine That Changed The World, Rawson & Associates, New York. Published by Simon & Schuster, 1990.
[edit] History
Ford was a comparatively late developer of mass production, since the idea was first developed in Venice several hundred years earlier, where ships were mass-produced using pre-manufactured parts, and assembly lines.
The Venice Arsenal apparently produced nearly one ship every day, in what was effectively the world's first factory that, at its height, employed 16,000 people.
Mass production in the publishing industry has been commmonplace since Johannes Gutenberg's Bible was published using a printing press in the mid-1400s.
During the Industrial Revolution simple mass production techniques were used at the Portsmouth Block Mills to manufacture ships' pulley blocks for the British Navy during the Napoleonic Wars. It was also used in the manufacture of clocks and watches, and in the manufacture of small arms.
During the American Civil War, the Springfield Armory started to mass produce guns, using interchangeable parts on a large scale. For this reason, the term Armory practice is occasionally used to refer to mass production.
Soon after the war, the American System of Watch Manufacturing showed that these techniques could be successfully applied even when very high precision was required. Later, in the 1890s, dollar watches traded off lower precision for much lower manufacturing costs.
While the preceding American system of manufacturing relied on water and steam power, mass production factories were electrified and used sophisticated machinery. Adoption of these techniques coincided with US growth take-off.
French political thinker and historian, Alexis de Tocqueville identified one of the key reasons mass production was able to succeed so quickly in America, namely that of the homogeneous consumer base. De Tocqueville wrote in his Democracy in America (1835) that "The absence in the United States of those vast accumulations of wealth which favor the expenditures of large sums on articles of mere luxury... impact to the productions of American industry a character distinct from that of other countries. [Production is geared toward] articles suited to the wants of the whole people".
