Ford and flexible manufacturing

Henry Ford had managed by going to the gemba to inspect the value creation process. The goal for Ford is to have three quarters of their 21 North American automotive plants able to perform flexible manufacturing by Robert McNamara and the Whiz Kids were the exemplars.

Moreover, Flexible manufacturing has had a major increase in parts stock levels. The damage to Ford was disastrous bearing witness to a year market share low: However, in order to optimize the assembly line, a stable workforce was needed that could be trained and then relied upon to fulfill their assigned tasks on a daily basis.

100 Years of the Moving Assembly Line

There are four sub-assembly areas involving, respectively, pistons, heads, fuel pumps and the kitting of small parts for attachment to the engine assemblies during the final operator-intensive phase of operations.

Finally, rethink brand strategy to get rid of hopeless makes that can never make money — Mercury, Jaguar, Lincoln too.

100 Years of the Moving Assembly Line

On the first of those points Payne is emphatic: General Motors calls their flexible manufacturing "C. Fundamentally rethink the product development system.

Conveyor transport The line itself is a mix of purely automated cells and semiautomated operations involving human operators, with the former concentrated at the front end and the latter for the final sequence of operations.

Ford surrounded himself with experts from various fields, such as brewing, canning and steel making, and each contributed his expertise to a solution for mass auto manufacturing.

We took this to mean that at least one American company was applying lean principles and with good results. ByFord will increase its global flexible manufacturing to produce on average four different models at each plant around the world to allow for greater adaptability based on varying customer demand.

His mind naturally focused on the value creation process rather than assets or organizations. Corps pieces of equipment such as robotics, painting technologies, and welding systems must work in simultaneously and synchronously. So he changed the management metrics, purged the poorest managers according to the metrics, and experimented with selling cars on the web.

One of the vehicles that has its access facilitated in such a way is a pedal-powered tricycle.


The savings could be tremendous. Who knows whether this is doable in the time still available but it is the lean way forward. In an effort to regain brand loyalty Ford has embarked on an ambitious automotive development process known as flexible manufacturing.

The full system was in a harmonization with the rhythm of the assembly line.

Ford and Flexible Manufacturing

Ford CEO Bill Ford was forced to make quick changes to appease the fickle consumer or face severe monetary consequences. The automotive assembly process, perfected by Henry Ford, was based on the simple principle that "customers can order a Model T in any color they wanted as long as it was black.

One of the most distinctive is probably the way that it approaches the issue of on-line buffer stores. With high investment barriers to entry, a remarkable era of stability was put place, lasting nearly forty years until the transplant Japanese factories succeeded in the U.

In Januarythe rope was replaced by an endless chain.

Flexible Manufacturing System - FMS

The image below is the revised Manufacturing Umbrella. Flexible manufacturing is a game changer for Ford of Canada. Employees have completed extensive training in flexible assembly techniques, utilizing the latest computer technology.

Additionally, Ford is expanding its capabilities in 3D printingwhich creates production-representative 3D parts layer by layer for testable prototypes. In the late s, as Dan JonesDan Roos, and I wrote The Machine That Changed the World, we were able to document that Ford had applied a number of lean techniques in its assembly operations and was making dramatic progress in manufacturing productivity.

Man hours of final assembly dropped from more than 12 hours under the stationary assembly system to fewer than three. To improve efficiencies, OAC is one of seven flexible Ford facilities in North America to employ the same cell flexible body assembly system; a cell is a self-contained work station that enables a common assembly sequence regardless of the type of vehicle.

The technology, known as Ford Freeform Fabrication Technology, or F3Twill lower costs and speed delivery times for prototype stamping molds — within three business days versus two to six months for prototypes made using conventional methods.

Moreover, Flexible manufacturing has had a major increase in parts stock levels. New Goals for Advanced, Flexible Manufacturing As today marks the th anniversary of the moving assembly line invented by Ford Motor Company under the leadership of Henry Ford, the company is building on its legacy of innovation by expanding advanced manufacturing capabilities and introducing groundbreaking technologies that could revolutionize mass production for decades to come.

The Lean Way Forward at Ford. I’ve been reflecting on the latest retreat by the Ford Motor Company as part of its “Way Forward” campaign.

Ford of Canada sees benefits in flexible manufacturing

While reflecting, I have found it useful to think about the history of lean thinking at Ford, going back nearly years. Feb 19,  · In JanuaryFord initiated Ford program, which was aim to develop and implement a new manufacturing system called the Ford Production System (FPS).

Ford and Flexible Manufacturing This Research Paper Ford and Flexible Manufacturing and other 64,+ term papers, college essay examples and free essays are available now on Autor: review • February 13, • Research Paper • 1, Words (5 Pages) • Views4/4(1).

Powertrain Manufacturing Ford College Graduate. Through the FCG program, Molli is proud to have earned the opportunity to work on an engine for the model year. John Savona Director of Manufacturing for Assembly. John knows that veterans’ training and discipline can be a huge asset at Ford.

Flexible manufacturing is a game changer for Ford of Canada. Through the use of reprogrammable and quick change tooling, OAC can build multiple models on unique platforms, enabling the plant to change the mix, volume and options of products more quickly in response to consumer demand.

A flexible manufacturing system (FMS) is a method for producing goods that is readily adaptable to changes in the product being manufactured, both in type and quantity.

Ford and flexible manufacturing
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Ford and Flexible Manufacturing