Mass production
Mass production, also known as flow production, series production or continuous production, is the production of substantial amounts of standardized products in a constant flow, including and especially on assembly lines. Together with job production and batch production, it is one of the three main production methods.[1]
This article is about large-scale production. For the creation of matter, see mass generation. For other uses, see Mass Production (disambiguation).
The term mass production was popularized by a 1926 article in the Encyclopædia Britannica supplement that was written based on correspondence with Ford Motor Company. The New York Times used the term in the title of an article that appeared before the publication of the Britannica article.[2]
The idea of mass production is applied to many kinds of products: from fluids and particulates handled in bulk (food, fuel, chemicals and mined minerals), to clothing, textiles, parts and assemblies of parts (household appliances and automobiles).
Some mass production techniques, such as standardized sizes and production lines, predate the Industrial Revolution by many centuries; however, it was not until the introduction of machine tools and techniques to produce interchangeable parts were developed in the mid-19th century that modern mass production was possible.[2]
Overview[edit]
Mass production involves making many copies of products, very quickly, using assembly line techniques to send partially complete products to workers who each work on an individual step, rather than having a worker work on a whole product from start to finish. The emergence of mass production allowed supply to outstrip demand in many markets, forcing companies to seek new ways to become more competitive. Mass production ties into the idea of overconsumption and the idea that we as humans consume too much.
Mass production of fluid matter typically involves piping with centrifugal pumps or screw conveyors (augers) to transfer raw materials or partially complete products between vessels. Fluid flow processes such as oil refining and bulk materials such as wood chips and pulp are automated using a system of process control which uses various instruments to measure variables such as temperature, pressure, volumetric and level, providing feedback.
Bulk materials such as coal, ores, grains and wood chips are handled by belt, chain, slat, pneumatic or screw conveyors, bucket elevators and mobile equipment such as front-end loaders. Materials on pallets are handled with forklifts. Also used for handling heavy items like reels of paper, steel or machinery are electric overhead cranes, sometimes called bridge cranes because they span large factory bays.
Mass production is capital-intensive and energy-intensive, for it uses a high proportion of machinery and energy in relation to workers. It is also usually automated 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 in order to attain profits there must be some assurance that the product will be successful.
One of the descriptions of mass production is that "the skill is built into the tool", which means that the worker using the tool may not need the skill. For example, in the 19th or early 20th century, this could be expressed as "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 were jigs ready at hand to ensure that the part was made to fit this set-up. It had already been checked that the finished part would be to specifications to fit all the other finished parts—and it would be made more quickly, with no time spent on finishing the parts to fit one another. Later, once computerized control came about (for example, CNC), jigs were obviated, but it remained true that the skill (or knowledge) was built into the tool (or process, or documentation) rather than residing in the worker's head. This is the specialized capital required for mass production; each workbench and set of tools (or each CNC cell, or each fractionating column) is different (fine-tuned to its task).
Vertical integration[edit]
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.[42]
Ford built the Ford River Rouge Complex with the idea of making the company's own iron and steel in the same large factory site where parts and car assembly took place. River Rouge also generated its own electricity.
Upstream vertical integration, such as to raw materials, is away from leading technology toward mature, low-return industries. Most companies chose to focus on their core business rather than vertical integration. This included buying parts from outside suppliers, who could often produce them as cheaply or cheaper.
Standard Oil, the major oil company in the 19th century, was vertically integrated partly because there was no demand for unrefined crude oil, but kerosene and some other products were in great demand. The other reason was that Standard Oil monopolized the oil industry. The major oil companies were, and many still are, vertically integrated, from production to refining and with their own retail stations, although some sold off their retail operations. Some oil companies also have chemical divisions.
Lumber and paper companies at one time owned most of their timber lands and sold some finished products such as corrugated boxes. The tendency has been to divest of timber lands to raise cash and to avoid property taxes.
Advantages and disadvantages[edit]
The economies of mass production come from several sources. The primary cause is a reduction of non-productive 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; error in operating such machinery has more far-reaching consequences. 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. The starter cost for the machinery can be expensive so the producer must be sure it sells or the producers will lose a lot of money.
The Ford Model T produced tremendous affordable output but was not very good at responding to demand for variety, customization, or design changes. As a consequence Ford eventually lost market share to General Motors, who introduced annual model changes, more accessories and a choice of colors.[2]
With each passing decade, engineers have found ways to increase the flexibility of mass production systems, driving down the lead times on new product development and allowing greater customization and variety of products.
Compared with other production methods, mass production can create new occupational hazards for workers. This is partly due to the need for workers to operate heavy machinery while also working close together with many other workers. Preventative safety measures, such as fire drills, as well as special training is therefore necessary to minimise the occurrence of industrial accidents.
Socioeconomic impacts[edit]
In the 1830s, French political thinker and historian Alexis de Tocqueville identified one of the key characteristics of America that would later make it so amenable to the development of mass production: 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' industries. [Production is geared toward] articles suited to the wants of the whole people".
Mass production improved productivity, which was a contributing factor to economic growth and the decline in work week hours, alongside other factors such as transportation infrastructures (canals, railroads and highways) and agricultural mechanization. These factors caused the typical work week to decline from 70 hours in the early 19th century to 60 hours late in the century, then to 50 hours in the early 20th century and finally to 40 hours in the mid-1930s.
Mass production permitted great increases in total production. Using a European crafts system into the late 19th century it was difficult to meet demand for products such as sewing machines and animal powered mechanical harvesters.[2] By the late 1920s many previously scarce goods were in good supply. One economist has argued that this constituted "overproduction" and contributed to high unemployment during the Great Depression.[43] Say's law denies the possibility of general overproduction and for this reason classical economists deny that it had any role in the Great Depression.
Mass production allowed the evolution of consumerism by lowering the unit cost of many goods used.
Mass production has been linked to the Fast Fashion Industry, often leaving the consumer with lower quality garments for a lower cost. Most fast-fashion clothing is mass-produced, which means it is typically made of cheap fabrics, such as polyester, and constructed poorly in order to keep short turnaround times to meet the demands of consumers and shifting trends.
