Introduction to Production and
Manufacturing Systems
Gary M. Gaukler
5/29/2016
Texas A&M Industrial Engineering
1
What Is Manufacturing?
• Varying definitions of scope
– Our focus is on manufacturing systems
• Technically complex manufacturing processes
• Machining characteristics, assembly instructions...
– Necessary to make the product
• Technically complex manufacturing system
operations and coordination
• Facility layout, capacity planning, production control...
– Necessary to make money making the product
5/29/2016
Texas A&M Industrial Engineering
2
Why Is Manufacturing Hard?
• Customer demands have increased
– Traditional: “The customer can have any color as long
as it’s black.” - Henry Ford
– Modern: Customers expect large product variety,
reasonable price, superior quality, comprehensive
service, and responsive delivery
• Competition has increased
– Low labor cost countries like China, Taiwan, Eastern
European states
5/29/2016
Texas A&M Industrial Engineering
3
Evolution of Manufacturing
• Completely custom - craftsman (pre 1800)
• English system (1800s)
– Introduction of general purpose machines that could
be used for a variety of products.
• American system (1850s)
– Emphasized precision and interchangeability.
Changed from a "best fit" to a "greatest clearance
without loss of functionality" focus.
• Scientific management (1900s)
– Prespecified worker motions - Moved the control
totally into the hands of management.
5/29/2016
Texas A&M Industrial Engineering
4
Evolution of Manufacturing
• Process improvement (SPC) (1950s)
– The identical procedure will produce different results
on the same machine at different times. It
emphasized outliers rather that mean performance.
• Numerical control (1970s)
– Combining the versatility of general purpose
machines with the precision and control of specialpurpose machines.
• Computer integrated manufacturing (1980s)
• Logistics/Supply-chain management (1990s)
5/29/2016
Texas A&M Industrial Engineering
5
Eli Whitney
 Born 1765; died 1825
 In 1798, received government
contract to make 10,000 muskets
 Showed that machine tools could
make standardized parts to exact
specifications
 Musket parts could be used in any
musket
Frederick W. Taylor
 Born 1856; died 1915
 Known as ‘father of scientific
management’
 In 1881, as chief engineer for
Midvale Steel, studied how tasks
were done
 Began first motion and time studies
 Created efficiency principles
Taylor’s Principles
Management Should Take More
Responsibility for:
 Matching employees to right job
 Providing the proper training
 Providing proper work methods and tools
 Establishing legitimate incentives for
work to be accomplished
Henry Ford
 Born 1863; died 1947
 In 1903, created Ford Motor
Company
 In 1913, first used moving assembly
line to make Model T
 Unfinished product moved by
conveyor past work station
 Paid workers very well for 1911
($5/day!)