A Comparative Study of Lean and Mass Production System: Toyota and Ford

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SUB: LEAN MANAGEMENT AND TOTAL PRODUCTIVE MAINTENANCE

TERM PAPER

TOPIC: - A COMPARATIVE STUDY OF LEAN AND MASS PRODUCTION SYSTEM: TOYOTA AND FORD Date of Submission: 13th Sep’10
By

GROUP-11
Yashraj D. Pawar -09258
Chaintanya Sharavanth C. - 09211
Harshita M. - 09217

Batch - XVII

VIGNANA JYOTHI INSTITUTE OF MANAGEMENT
Bachupally, Hyderabad, A.P – 500072, India

SUMMARY:
This paper deals with the production systems of two major leaders in the automobile market. Mass production is briefly touched up on and its advantages and disadvantages are discussed. Lean production is the emerging trend, which talks about minimizing waste and increasing production. We have also thrown light on when to use lean and mass production in production process .Our study majorly concentrates on Ford Co. and Toyota Co. which follows mass and lean production systems respectively, a detailed study has been done on their production processes.

Contents
1. OBJECTIVES4
2. MASS PRODUCTION5
2.1 USE OF ASSEMBLY LINES IN MASS PRODUCTION6
2.2 WHEN TO GO FOR MASS PRODUCTION:6
2.3 ADVANTAGES6
2.4 DISADVANTAGES7
2.5 HOW DID MASS PRODUCTION EVOLVE7
2.6 THE LIMITS OF FORD’S SYSTEM9
3. LEAN PRODUCTION10
3.1 CHARACTERISTICS OF LEAN PRODUCTION11
3.2 BASIC ELEMENTS OF LEAN MANUFACTURING13
3.3 BENEFITS OF LEAN PRODUCTION14
3.4 SEVEN PRINCIPLES OF TOYOTA PRODUCTION SYSTEM (TPS)15
3.5 THE FOCUS OF TOYOTA PRODUCTION SYSTEM16
3.6 LEAN MANUFACTURING AT TOYOTA17
3.7 FOCUS ON FLEXIBILITY19
4. COMPARISON BETWEEN MASS AND LEAN PRODUCTION20
5. Conclusion21
6. Bibilography21

1. OBJECTIVES
To understand lean and mass production in detail.
To understand Implications of lean and mass production in production process. To compare Ford and Toyota with respect to production processes.

2. MASS PRODUCTION
Mass production (also called flow production, repetitive flow production, series production, or serial production) is the production of large amounts of standardized products, including and especially on assembly lines. The concepts of mass production are applied to various kinds of products, from fluids and particulates handled in bulk (such as food, fuel, chemicals, and mined minerals) to discrete solid parts (such as fasteners) to assemblies of such parts (such as household appliances and automobiles). Mass production of assemblies typically uses electric-motor-powered moving tracks or conveyor belts to move partially complete products to workers, who perform simple repetitive tasks Mass production of fluid and particulate matter typically involves pipes with pumps or augers to transfer partially complete product between vessels. Mass production is capital intensive and energy intensive, as it uses a high proportion of machinery and energy in relation to workers. It is also usually automated to the highest extent possible. With fewer labour costs and a faster rate of production, capital and energy are increased while total expenditure per unit of product is decreased. However, the machinery that is needed to set up a mass production line (such as robots and machine presses) is so expensive that there must be some assurance that the product is to be successful to attain profits. One of the descriptions of mass production is that the craftsmanship is in the workbench itself, not the training of the worker; for example, 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 more quickly, 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...
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