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Mass production, also known as flow 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. 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 Ford Motor Company (commonly known as Ford) is an American multinational automobile manufacturer headquartered in Dearborn, Michigan, United States. It was founded by Henry Ford and incorporated on June 16, 1903. The company sells automobi ...
. ''The New York Times'' used the term in the title of an article that appeared before publication of the ''Britannica'' article. The concepts of mass production are applied to various kinds of products: from fluids and particulates handled in bulk ( food,
fuel A fuel is any material that can be made to react with other substances so that it releases energy as thermal energy or to be used for work. The concept was originally applied solely to those materials capable of releasing chemical energy b ...
, chemicals and mined
minerals In geology and mineralogy, a mineral or mineral species is, broadly speaking, a solid chemical compound with a fairly well-defined chemical composition and a specific crystal structure that occurs naturally in pure form.John P. Rafferty, ed ...
), to parts and assemblies of parts (
household appliances A major appliance, also known as a large domestic appliance or large electric appliance or simply a large appliance, large domestic, or large electric, is a non-portable or semi-portable machine used for routine housekeeping tasks such as cookin ...
and
automobiles A car or automobile is a motor vehicle with wheels. Most definitions of ''cars'' say that they run primarily on roads, seat one to eight people, have four wheels, and mainly transport people instead of goods. The year 1886 is regarded ...
). Some mass production techniques, such as standardized sizes and production lines, predate the
Industrial Revolution The Industrial Revolution was the transition to new manufacturing processes in Great Britain, continental Europe, and the United States, that occurred during the period from around 1760 to about 1820–1840. This transition included going f ...
by many centuries; however, it was not until the introduction of
machine tool A machine tool is a machine for handling or machining metal or other rigid materials, usually by cutting, boring, grinding, shearing, or other forms of deformations. Machine tools employ some sort of tool that does the cutting or shaping. Al ...
s and techniques to produce interchangeable parts were developed in the mid-19th century that modern mass production was possible.


Overview

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. Mass production of fluid matter typically involves pipes 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 A screw and a bolt (see '' Differentiation between bolt and screw'' below) are similar types of fastener typically made of metal and characterized by a helical ridge, called a ''male thread'' (external thread). Screws and bolts are used to ...
conveyors,
bucket elevator A bucket elevator, also called a grain leg, is a mechanism for hauling flowable bulk materials (most often grain or fertilizer) vertically. It consists of: # Buckets to contain the material; # A belt to carry the buckets and transmit the pull; ...
s 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
robot A robot is a machine—especially one programmable by a computer—capable of carrying out a complex series of actions automatically. A robot can be guided by an external control device, or the control may be embedded within. Robots may be ...
s and
machine press A forming press, commonly shortened to press, is a machine tool that changes the shape of a work-piece by the application of pressure. The operator of a forming press is known as a press-tool setter, often shortened to tool-setter. Presses ...
es) is so expensive that in order to attain profits there must be some assurance that the product is to be successful to. 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).


History


Pre-industrial

Standardized parts and sizes and factory production techniques were developed in pre-industrial times; before the invention of
machine tool A machine tool is a machine for handling or machining metal or other rigid materials, usually by cutting, boring, grinding, shearing, or other forms of deformations. Machine tools employ some sort of tool that does the cutting or shaping. Al ...
s the manufacture of precision parts, especially metal ones, was highly labour-intensive. Crossbows made with bronze parts were produced in
China China, officially the People's Republic of China (PRC), is a country in East Asia. It is the world's List of countries and dependencies by population, most populous country, with a Population of China, population exceeding 1.4 billion, slig ...
during the
Warring States period The Warring States period () was an era in History of China#Ancient China, ancient Chinese history characterized by warfare, as well as bureaucratic and military reforms and consolidation. It followed the Spring and Autumn period and concluded ...
. The Qin Emperor unified China at least in part by equipping large armies with these weapons, which were equipped with a sophisticated trigger mechanism made of interchangeable parts. The
Terracotta Army The Terracotta Army is a collection of terracotta sculptures depicting the armies of Qin Shi Huang, the first emperor of China. It is a form of funerary art buried with the emperor in 210–209 BCE with the purpose of protecting the emperor ...
guarding the Emperor's necropolis is also believed to have been created through the use of standardized molds on an assembly line. In
ancient Carthage Carthage () was a settlement in modern Tunisia that later became a city-state and then an empire. Founded by the Phoenicians in the ninth century BC, Carthage reached its height in the fourth century BC as one of the largest metropolises in ...
, ships of war were mass-produced on a large scale at a moderate cost, allowing them to efficiently maintain their control of the
Mediterranean The Mediterranean Sea is a sea connected to the Atlantic Ocean, surrounded by the Mediterranean Basin and almost completely enclosed by land: on the north by Western and Southern Europe and Anatolia, on the south by North Africa, and on ...
. Many centuries later, the
Republic of Venice The Republic of Venice ( vec, Repùblega de Venèsia) or Venetian Republic ( vec, Repùblega Vèneta, links=no), traditionally known as La Serenissima ( en, Most Serene Republic of Venice, italics=yes; vec, Serenìsima Repùblega de Venèsia ...
would follow Carthage in producing ships with prefabricated parts on an assembly line: the Venetian Arsenal produced nearly one ship every day in what was effectively the world's first
factory A factory, manufacturing plant or a production plant is an industrial facility, often a complex consisting of several buildings filled with machinery, where workers manufacture items or operate machines which process each item into another. ...
, which at its height employed 16,000 people. The invention of
movable type Movable type (US English; moveable type in British English) is the system and technology of printing and typography that uses movable components to reproduce the elements of a document (usually individual alphanumeric characters or punctuation m ...
has allowed for documents such as books to be mass produced. The first movable type system was invented in China by Bi Sheng, during the reign of the
Song Dynasty The Song dynasty (; ; 960–1279) was an imperial dynasty of China that began in 960 and lasted until 1279. The dynasty was founded by Emperor Taizu of Song following his usurpation of the throne of the Later Zhou. The Song conquered the res ...
, where it was used to, among other things, issue paper money. The oldest extant book produced using metal type is the '' Jikji'', printed in Korea in the year 1377. Johannes Gutenberg, through his invention of the
printing press A printing press is a mechanical device for applying pressure to an inked surface resting upon a print medium (such as paper or cloth), thereby transferring the ink. It marked a dramatic improvement on earlier printing methods in which the ...
and production of the Gutenberg Bible, introduced movable type to Europe. Through this introduction, mass production in the European publishing industry was made commonplace, leading to a democratization of knowledge, increased literacy and education, and the beginnings of modern
science Science is a systematic endeavor that builds and organizes knowledge in the form of testable explanations and predictions about the universe. Science may be as old as the human species, and some of the earliest archeological evidence ...
. Jean-Baptiste de Gribeauval, a French artillery engineer, introduced the standardization of cannon design in the mid-18th century. He developed a 6-inch (150 mm) field howitzer whose gun barrel, carriage assembly and ammunition specifications were made uniform for all French cannons. The standardized interchangeable parts of these cannons down to the nuts, bolts and screws made their mass production and repair easier than before.


Industrial

In the
Industrial Revolution The Industrial Revolution was the transition to new manufacturing processes in Great Britain, continental Europe, and the United States, that occurred during the period from around 1760 to about 1820–1840. This transition included going f ...
, simple mass production techniques were used at the Portsmouth Block Mills in England to make ships' pulley blocks for the
Royal Navy The Royal Navy (RN) is the United Kingdom's naval warfare force. Although warships were used by English and Scottish kings from the early medieval period, the first major maritime engagements were fought in the Hundred Years' War against Fr ...
in the
Napoleonic Wars The Napoleonic Wars (1803–1815) were a series of major global conflicts pitting the French Empire and its allies, led by Napoleon I, against a fluctuating array of European states formed into various coalitions. It produced a period of Fre ...
. It was achieved in 1803 by Marc Isambard Brunel in cooperation with
Henry Maudslay Henry Maudslay ( pronunciation and spelling) (22 August 1771 – 14 February 1831) was an English machine tool innovator, tool and die maker, and inventor. He is considered a founding father of machine tool technology. His inventions were ...
under the management of Sir Samuel Bentham. The first unmistakable examples of manufacturing operations carefully designed to reduce production costs by specialized labour and the use of machines appeared in the 18th century in England. The Navy was in a state of expansion that required 100,000 pulley blocks to be manufactured a year. Bentham had already achieved remarkable efficiency at the docks by introducing power-driven machinery and reorganising the dockyard system. Brunel, a pioneering engineer, and Maudslay, a pioneer of machine tool technology who had developed the first industrially practical screw-cutting lathe in 1800 which standardized screw thread sizes for the first time which in turn allowed the application of interchangeable parts, collaborated on plans to manufacture block-making machinery. By 1805, the dockyard had been fully updated with the revolutionary, purpose-built machinery at a time when products were still built individually with different components. A total of 45 machines were required to perform 22 processes on the blocks, which could be made into one of three possible sizes. The machines were almost entirely made of metal thus improving their accuracy and durability. The machines would make markings and indentations on the blocks to ensure alignment throughout the process. One of the many advantages of this new method was the increase in labour productivity due to the less labour-intensive requirements of managing the machinery. Richard Beamish, assistant to Brunel's son and engineer,
Isambard Kingdom Brunel Isambard Kingdom Brunel (; 9 April 1806 – 15 September 1859) was a British civil engineer who is considered "one of the most ingenious and prolific figures in engineering history," "one of the 19th-century engineering giants," and "on ...
, wrote:
So that ten men, by the aid of this machinery, can accomplish with uniformity, celerity and ease, what formerly required the uncertain labour of one hundred and ten.
By 1808, annual production from the 45 machines had reached 130,000 blocks and some of the equipment was still in operation as late as the mid-twentieth century."The Portsmouth blockmaking machinery"
. makingthemodernworld.org
Mass production techniques were also used to rather limited extent to make clocks and watches, and to make small arms, though parts were usually non-interchangeable. Though produced on a very small scale,
Crimean War The Crimean War, , was fought from October 1853 to February 1856 between Russia and an ultimately victorious alliance of the Ottoman Empire, France, the United Kingdom and Piedmont-Sardinia. Geopolitical causes of the war included the ...
gunboat engines designed and assembled by John Penn of Greenwich are recorded as the first instance of the application of mass production techniques (though not necessarily the assembly-line method) to marine engineering. In filling an Admiralty order for 90 sets to his high-pressure and high-revolution horizontal trunk engine design, Penn produced them all in 90 days. He also used Whitworth Standard threads throughout. Prerequisites for the wide use of mass production were interchangeable parts, machine tools and power, especially in the form of
electricity Electricity is the set of physical phenomena associated with the presence and motion of matter that has a property of electric charge. Electricity is related to magnetism, both being part of the phenomenon of electromagnetism, as describe ...
. Some of the organizational management concepts needed to create 20th-century mass production, such as scientific management, had been pioneered by other engineers (most of whom are not famous, but Frederick Winslow Taylor is one of the well-known ones), whose work would later be synthesized into fields such as
industrial engineering Industrial engineering is an engineering profession that is concerned with the optimization of complex processes, systems, or organizations by developing, improving and implementing integrated systems of people, money, knowledge, information an ...
,
manufacturing engineering Manufacturing engineering or production engineering is a branch of professional engineering that shares many common concepts and ideas with other fields of engineering such as mechanical, chemical, electrical, and industrial engineering. Manufa ...
,
operations research Operations research ( en-GB, operational research) (U.S. Air Force Specialty Code: Operations Analysis), often shortened to the initialism OR, is a discipline that deals with the development and application of analytical methods to improve decis ...
, and
management consultancy Management consulting is the practice of providing consulting services to organizations to improve their performance or in any way to assist in achieving organizational objectives. Organizations may draw upon the services of management consultant ...
. Although after leaving the Henry Ford Company which was rebranded as Cadillac and later was awarded the Dewar Trophy in 1908 for creating interchangeable mass-produced precision engine parts,
Henry Ford Henry Ford (July 30, 1863 – April 7, 1947) was an American industrialist, business magnate, founder of the Ford Motor Company, and chief developer of the assembly line technique of mass production. By creating the first automobile that ...
downplayed the role of Taylorism in the development of mass production at his company. However, Ford management performed time studies and experiments to mechanize their factory processes, focusing on minimizing worker movements. The difference is that while Taylor focused mostly on efficiency of the worker, Ford also substituted for labor by using machines, thoughtfully arranged, wherever possible. In 1807, Eli Terry was hired to produce 4,000 wooden movement clocks in the Porter Contract. At this time, the annual yield for wooden clocks did not exceed a few dozen on average. Terry developed a milling machine in 1795, in which he perfected Interchangeable parts. In 1807, Terry developed a spindle cutting machine, which could produce multiple parts at the same time. Terry hired Silas Hoadley and Seth Thomas to work the Assembly line at the facilities. The Porter Contract was the first contract which called for mass production of clock movements in history. In 1815, Terry began mass-producing the first shelf clock. Chauncey Jerome, an apprentice of Eli Terry mass-produced up to 20,000 brass clocks annually in 1840 when he invented the cheap 30-hour OG clock. The United States Department of War sponsored the development of interchangeable parts for guns produced at the arsenals at Springfield, Massachusetts and Harpers Ferry, Virginia (now West Virginia) in the early decades of the 19th century, finally achieving reliable interchangeability by about 1850. This period coincided with the development of machine tools, with the armories designing and building many of their own. Some of the methods employed were a system of gauges for checking dimensions of the various parts and jigs and fixtures for guiding the machine tools and properly holding and aligning the work pieces. This system came to be known as ''armory practice'' or the '' American system of manufacturing'', which spread throughout New England aided by skilled mechanics from the armories who were instrumental in transferring the technology to the sewing machines manufacturers and other industries such as machine tools, harvesting machines and bicycles. Singer Manufacturing Co., at one time the largest sewing machine manufacturer, did not achieve interchangeable parts until the late 1880s, around the same time Cyrus McCormick adopted modern manufacturing practices in making harvesting machines. During
World War II World War II or the Second World War, often abbreviated as WWII or WW2, was a world war that lasted from 1939 to 1945. It involved the World War II by country, vast majority of the world's countries—including all of the great power ...
, The United States mass-produced many vehicles and weapons, such as ships (i.e. Liberty Ships,
Higgins boats The landing craft, vehicle, personnel (LCVP) or Higgins boat was a landing craft used extensively by the Allied forces in amphibious landings in World War II. Typically constructed from plywood, this shallow-draft, barge-like boat could ferry ...
), aircraft (i.e. North American P-51 Mustang, Consolidated B-24 Liberator, Boeing B-29 Superfortress), jeeps (i.e. Willys MB), trucks, tanks (i.e.
M4 Sherman } The M4 Sherman, officially Medium Tank, M4, was the most widely used medium tank by the United States and Western Allies in World War II. The M4 Sherman proved to be reliable, relatively cheap to produce, and available in great numbers. It ...
) and
M2 Browning The M2 machine gun or Browning .50 caliber machine gun (informally, "Ma Deuce") is a heavy machine gun that was designed towards the end of World War I by John Browning. Its design is similar to Browning's earlier M1919 Browning machine gun, ...
and
M1919 Browning machine gun The M1919 Browning is a .30 caliber medium machine gun that was widely used during the 20th century, especially during World War II, the Korean War, and the Vietnam War. The M1919 saw service as a light infantry, coaxial, mounted, aircraft, ...
s. Many vehicles, transported by ships have been shipped in parts and later assembled on-site. For the ongoing energy transition, many wind turbine components and solar panels are being mass-produced. Wind turbines and solar panels are being used in respectively
wind farm A wind farm or wind park, also called a wind power station or wind power plant, is a group of wind turbines in the same location used to produce electricity. Wind farms vary in size from a small number of turbines to several hundred wind turb ...
s and solar farms. In addition, in the ongoing climate change mitigation, large-scale carbon sequestration (through
reforestation Reforestation (occasionally, reafforestation) is the natural or intentional restocking of existing forests and woodlands ( forestation) that have been depleted, usually through deforestation, but also after clearcutting. Management A de ...
, blue carbon restoration, etc) has been proposed. Some projects (such as the
Trillion Tree Campaign The Trillion Tree Campaign is a project which aims to plant one trillion trees worldwide. It seeks to repopulate the world's trees and combat climate change as a nature-based solution. The project was launched at PlantAhead 2018 in Monaco by P ...
) involve planting a very large amount of trees. In order to speed up such efforts, fast propagation of trees may be useful. Some automated machines have been produced to allow for fast (vegetative) plant propagation.Also, for some plants that help to sequester carbon (such as
seagrass Seagrasses are the only flowering plants which grow in marine environments. There are about 60 species of fully marine seagrasses which belong to four families ( Posidoniaceae, Zosteraceae, Hydrocharitaceae and Cymodoceaceae), all in the ...
), techniques have been developed to help speed up the process . Mass production benefited from the development of materials such as inexpensive steel, high strength steel and plastics. Machining of metals was greatly enhanced with high-speed steel and later very hard materials such as tungsten carbide for cutting edges. Fabrication using steel components was aided by the development of
electric welding Electric resistance welding (ERW) is a welding process where metal parts in contact are permanently joined by heating them with an electric current, melting the metal at the joint. Electric resistance welding is widely used, for example, in manuf ...
and stamped steel parts, both which appeared in industry in about 1890. Plastics such as
polyethylene Polyethylene or polythene (abbreviated PE; IUPAC name polyethene or poly(methylene)) is the most commonly produced plastic. It is a polymer, primarily used for packaging ( plastic bags, plastic films, geomembranes and containers including b ...
,
polystyrene Polystyrene (PS) is a synthetic polymer made from monomers of the Aromatic hydrocarbon, aromatic hydrocarbon styrene. Polystyrene can be solid or foamed. General-purpose polystyrene is clear, hard, and brittle. It is an inexpensive resin pe ...
and polyvinyl chloride (PVC) can be easily formed into shapes by
extrusion Extrusion is a process used to create objects of a fixed cross-sectional profile by pushing material through a die of the desired cross-section. Its two main advantages over other manufacturing processes are its ability to create very complex c ...
, blow molding or injection molding, resulting in very low cost manufacture of consumer products, plastic piping, containers and parts. An influential article that helped to frame and popularize the 20th century's definition of mass production appeared in a 1926 ''Encyclopædia Britannica'' supplement. The article was written based on correspondence with Ford Motor Company and is sometimes credited as the first use of the term.


Factory electrification

Electrification Electrification is the process of powering by electricity and, in many contexts, the introduction of such power by changing over from an earlier power source. The broad meaning of the term, such as in the history of technology, economic histo ...
of factories began very gradually in the 1890s after the introduction of a practical DC motor by Frank J. Sprague and accelerated after the AC motor was developed by
Galileo Ferraris Galileo Ferraris (31 October 1847 – 7 February 1897) was an Italian university professor, physicist and electrical engineer, one of the pioneers of AC power system and inventor of the induction motor although he never patented his work. Many ...
,
Nikola Tesla Nikola Tesla ( ; ,"Tesla"
''Random House Webster's Unabridged Dictionary''.
; 1856 – 7 January 1943 ...
and Westinghouse,
Mikhail Dolivo-Dobrovolsky Mikhail Osipovich Dolivo-Dobrovolsky (russian: Михаи́л О́сипович Доли́во-Доброво́льский; german: Michail von Dolivo-Dobrowolsky or ''Michail Ossipowitsch Doliwo-Dobrowolski''; – ) was a Russian Empire ...
and others. Electrification of factories was fastest between 1900 and 1930, aided by the establishment of electric utilities with central stations and the lowering of electricity prices from 1914 to 1917. Electric motors were several times more efficient than small steam engines because central station generation were more efficient than small steam engines and because
line shaft A line shaft is a power-driven rotating shaft for power transmission that was used extensively from the Industrial Revolution until the early 20th century. Prior to the widespread use of electric motors small enough to be connected directly t ...
s and belts had high friction losses. Electric motors also allowed more flexibility in manufacturing and required less maintenance than line shafts and belts. Many factories saw a 30% increase in output simply from changing over to electric motors. Electrification enabled modern mass production, as with Thomas Edison's iron ore processing plant (about 1893) that could process 20,000 tons of ore per day with two shifts, each of five men. At that time it was still common to handle bulk materials with shovels, wheelbarrows and small narrow-gauge rail cars, and for comparison, a canal digger in previous decades typically handled five tons per 12-hour day. The biggest impact of early mass production was in manufacturing everyday items, such as at the Ball Brothers Glass Manufacturing Company, which electrified its mason jar plant in Muncie, Indiana, U.S., around 1900. The new automated process used glass-blowing machines to replace 210 craftsman glass blowers and helpers. A small electric truck was used to handle 150 dozen bottles at a time where previously a hand truck would carry six dozen. Electric mixers replaced men with shovels handling sand and other ingredients that were fed into the glass furnace. An electric overhead crane replaced 36 day laborers for moving heavy loads across the factory. According to
Henry Ford Henry Ford (July 30, 1863 – April 7, 1947) was an American industrialist, business magnate, founder of the Ford Motor Company, and chief developer of the assembly line technique of mass production. By creating the first automobile that ...
:
The provision of a whole new system of electric generation emancipated industry from the leather belt and
line shaft A line shaft is a power-driven rotating shaft for power transmission that was used extensively from the Industrial Revolution until the early 20th century. Prior to the widespread use of electric motors small enough to be connected directly t ...
, for it eventually became possible to provide each tool with its own electric motor. This may seem only a detail of minor importance. In fact, modern industry could not be carried out with the belt and line shaft for a number of reasons. The motor enabled machinery to be arranged in the order of the work, and that alone has probably doubled the efficiency of industry, for it has cut out a tremendous amount of useless handling and hauling. The belt and
line shaft A line shaft is a power-driven rotating shaft for power transmission that was used extensively from the Industrial Revolution until the early 20th century. Prior to the widespread use of electric motors small enough to be connected directly t ...
were also tremendously wasteful – so wasteful indeed that no factory could be really large, for even the longest line shaft was small according to modern requirements. Also high speed tools were impossible under the old conditions – neither the pulleys nor the belts could stand modern speeds. Without high speed tools and the finer steels which they brought about, there could be nothing of what we call modern industry.
Mass production was popularized in the late 1910s and 1920s by Henry Ford's
Ford Motor Company Ford Motor Company (commonly known as Ford) is an American multinational automobile manufacturer headquartered in Dearborn, Michigan, United States. It was founded by Henry Ford and incorporated on June 16, 1903. The company sells automobi ...
, which introduced electric motors to the then-well-known technique of chain or sequential production. Ford also bought or designed and built special purpose machine tools and fixtures such as multiple spindle drill presses that could drill every hole on one side of an engine block in one operation and a multiple head milling machine that could simultaneously machine 15 engine blocks held on a single fixture. All of these machine tools were arranged systematically in the production flow and some had special carriages for rolling heavy items into machining position. Production of the Ford Model T used 32,000 machine tools.


Buildings

The process of prefabrication, wherein parts are created separately from the finished product, is at the core of all mass-produced construction. Early examples include movable structures reportedly utilized by Akbar the Great, and the
chattel house Chattel house is a Barbadian term for a small moveable wooden house that working class people would occupy. The term goes back to the plantation days when the home owners would buy houses designed to move from one property to another. The word " c ...
s built by emancipated slaves on
Barbados Barbados is an island country in the Lesser Antilles of the West Indies, in the Caribbean region of the Americas, and the most easterly of the Caribbean Islands. It occupies an area of and has a population of about 287,000 (2019 estima ...
. The Nissen hut, first used by the British during
World War I World War I (28 July 1914 11 November 1918), often abbreviated as WWI, was List of wars and anthropogenic disasters by death toll, one of the deadliest global conflicts in history. Belligerents included much of Europe, the Russian Empire, ...
, married prefabrication and mass production in a way that suited the needs of the military. The simple structures, which cost little and could be erected in just a couple of hours, were highly successful: over 100,000 Nissen huts were produced during World War I alone, and they would go on to serve in other conflicts and inspire a number of similar designs. Following World War II, in the United States, William Levitt pioneered the building of standardized
tract house Tract housing is a type of housing development in which multiple similar houses are built on a tract (area) of land that is subdivided into smaller lots. Tract housing developments are found in suburb developments that were modeled on the "Levit ...
s in 56 different locations around the country. These communities were dubbed Levittowns, and they were able to be constructed quickly and cheaply through the leveraging of
economies of scale In microeconomics, economies of scale are the cost advantages that enterprises obtain due to their scale of operation, and are typically measured by the amount of output produced per unit of time. A decrease in cost per unit of output enables ...
, as well as the specialization of construction tasks in a process akin to an assembly line. This era also saw the invention of the mobile home, a small prefabricated house that can be transported cheaply on a truck bed. In the modern industrialization of construction, mass production is often used for prefabrication of house components.


The use of assembly lines

Mass production systems for items made of numerous parts are usually organized into assembly lines. The assemblies pass by on a conveyor, or if they are heavy, hung from an overhead crane or 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.


Vertical integration

Vertical integration In microeconomics, management and international political economy, vertical integration is a term that describes the arrangement in which the supply chain of a company is integrated and owned by that company. Usually each member of the suppl ...
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. 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 Standard Oil Company, Inc., was an American oil production, transportation, refining, and marketing company that operated from 1870 to 1911. At its height, Standard Oil was the largest petroleum company in the world, and its success made its co- ...
, 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

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 Craft production is manufacturing by hand, with or without the aid of tools. The term "craft production" describes manufacturing techniques that are used in handicraft trades. They were the common methods of manufacture in the pre-industrialize ...
, 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 Human error refers to something having been done that was " not intended by the actor; not desired by a set of rules or an external observer; or that led the task or system outside its acceptable limits".Senders, J.W. and Moray, N.P. (1991) Human ...
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 A design is a plan or specification for the construction of an object or system or for the implementation of an activity or process or the result of that plan or specification in the form of a prototype, product, or process. The verb ''to design' ...
or production process after a
production line A production line is a set of sequential operations established in a factory where components are assembled to make a finished article or where materials are put through a refining process to produce an end-product that is suitable for onward c ...
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. 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

In the 1830s, French political thinker and historian
Alexis de Tocqueville Alexis Charles Henri Clérel, comte de Tocqueville (; 29 July 180516 April 1859), colloquially known as Tocqueville (), was a French aristocrat, diplomat, political scientist, political philosopher and historian. He is best known for his wo ...
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 (; published in two volumes, the first in 1835 and the second in 1840) is a classic French text by Alexis de Tocqueville. Its title literally translates to ''On Democracy in America'', but official English translations are usually simply entitl ...
'' (1835) that "The absence in the United States of those vast accumulations of
wealth Wealth is the abundance of valuable financial assets or physical possessions which can be converted into a form that can be used for transactions. This includes the core meaning as held in the originating Old English word , which is from an I ...
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. roduction is geared towardarticles 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 Harvester may refer to: Agriculture and forestry * Combine harvester, a machine commonly used to harvest grain crops * Forage harvester, a machine used to harvest forage * Harvester (forestry), a type of heavy vehicle employed in cut-to-length log ...
. 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 The Great Depression (19291939) was an economic shock that impacted most countries across the world. It was a period of economic depression that became evident after a major fall in stock prices in the United States. The economic contagio ...
. 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 Evolution is change in the heritable characteristics of biological populations over successive generations. These characteristics are the expressions of genes, which are passed on from parent to offspring during reproduction. Variation ...
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 Polyester is a category of polymers that contain the ester functional group in every repeat unit of their main chain. As a specific material, it most commonly refers to a type called polyethylene terephthalate (PET). Polyesters include natura ...
, and constructed poorly in order to keep short turnaround times to meet the demands of consumers and shifting trends.


See also

* Batch production *
Craft production Craft production is manufacturing by hand, with or without the aid of tools. The term "craft production" describes manufacturing techniques that are used in handicraft trades. They were the common methods of manufacture in the pre-industrialize ...
*
Continuous production Continuous production is a flow production method used to manufacture, produce, or process materials without interruption. Continuous production is called a continuous process or a continuous flow process because the materials, either dry bulk ...
* Culture industry * Fast-moving consumer goods * Fordism * Ford Model T * Great Divergence *
Industrial engineering Industrial engineering is an engineering profession that is concerned with the optimization of complex processes, systems, or organizations by developing, improving and implementing integrated systems of people, money, knowledge, information an ...
* Industrialisation *
Industrial Revolution The Industrial Revolution was the transition to new manufacturing processes in Great Britain, continental Europe, and the United States, that occurred during the period from around 1760 to about 1820–1840. This transition included going f ...
* Instant manufacturing * Job production * Just-in-time * Lean manufacturing * Licensed production *
Manufacturing Manufacturing is the creation or production of goods with the help of equipment, labor, machines, tools, and chemical or biological processing or formulation. It is the essence of secondary sector of the economy. The term may refer to ...
*
Mass market The term "mass market" refers to a market for goods produced on a large scale for a significant number of end consumers. The mass market differs from the niche market in that the former focuses on consumers with a wide variety of backgrounds wi ...
* Mechanization *
Modular construction systems Modular construction is a construction technique which involves the prefabrication of 2D panels or 3D volumetric structures in off-site factories and transportation to construction sites for assembly. This process has the potential to be superior ...
: identical components are easier to mass-produce * Operations management *
Outline of industrial organization The following outline is provided as an overview of and topical guide to industrial organization: Industrial organization – describes the behavior of firms in the marketplace with regard to production, pricing, employment and other decisi ...
* Pilot plant * Cost-of-production theory of value * Scientific management *
Second Industrial Revolution The Second Industrial Revolution, also known as the Technological Revolution, was a phase of rapid scientific discovery, standardization, mass production and industrialization from the late 19th century into the early 20th century. The ...
* Technological revolution * Technological unemployment


References


Further reading

* * Borth, Christy. ''Masters of Mass Production'', Bobbs-Merrill Company, Indianapolis, IN, 1945. * Herman, Arthur. ''Freedom's Forge: How American Business Produced Victory in World War II'', Random House, New York, NY, 2012. .


External links

* * {{DEFAULTSORT:Mass Production History of science and technology in the United States Industrial processes Business economics Types of production Economic development