THE FORD PRODUCTION

SYSTEM (FPS)
GROUP 6: EMP OCTOBER 2018
PRESENTED BY: GROUP 6: EMP 2018 OCT BATCH
HEEMANSHI (25), UMANG (54), SANDEEP (45), PRASHANT (35), AKSHAY S. (06) & AVINASH (15)
FORD -History

Introduced 3D
Ford
Began Mass Introduced visualization
production
Operation in Production Assembly tools like
System (FPS)
1903 System in Line in 1913 CAD, CAM
1990’s
1907 in the 1970’s
FORD -Recognition
 Ford received Shingo Prize for excellence in
manufacturing in 2002, termed as Nobel Prize of
Manufacturing

 Three plant were in the list viz Ford Assembly

Plant, Chicago III, Ford Engine Plant, Romeo,
Michigan and Ford Engine Plant, Chihuahua,
Mexico

 Award was given in Operational Excellence in

recognition of Lean manufacturing Process thus
improving the quality of automobile it produced
 CRAFT PRODUCTION SYSTEM (CPS)
 All cars have same basic Chassis and
Engine
 Design was different based on customer
preference
 It incur high manufacturing cost which
did not reduce even if production
volume increases
 Based on Fixed Assembly Stand – One
fitter (Assembler) fitted whole car before
moving to next car
 Assembler perform same set of activities
repetitively at his Fixed Assembly Stand
 Workers procured the necessary part
 Later workstation were supplied with
parts to reduce time
 MASS PRODUCTION SYSTEM (MPS)
 Model T launched in 1908 as an affordable car
 Parts were standardised and fixing was much
easier
 Standardised “Gauging System” was introduced
 Pre-hardened Metal was used – Hardening
without loss of shape
 It reduces twisting of plate during impression
printing
 Developed design that reduces number of parts
 4-Cylinder Engine block combined to have single
complete casting
 Each assembler has to perform a single task
Model T Assembly - https://youtu.be/cTZ3rJHHSik
 MOVING ASSEMBLY LINE
 Started at Highland park
 Bringing car assembly line to stationary workers
 Reduces cycle time from 2.3 minutes to 1.19
minutes
 Assembly time of Model T improved from 12 hrs 30
min to 5 hrs 50 min
 Reduced Inventory to great extent
 In Jan 1914 designed “Endless –Chain – Driven”
conveyor
 In April 1914 designed “Man- High” Line with all
parts and belts at waist level
 Production doubled every year from 1913 to 1923

Model T Assembly - https://youtu.be/cTZ3rJHHSik

 FORD PRODUCTION SYSTEM (FPS) Vision of FPS
is a lean,
 Implemented Lean manufacturing initiative called as FORD flexible and
disciplined
2000 having focus on 11 critical areas common
 Do away any task that does not add value production
System
 JIT : Helped in keeping minimum Inventory and workforce thus defined by a
set of
increasing productivity principles
 Employees were empowered to take decisions. Training and and
processes
reward system introduced …that….exc
eed
 Employees were given extensive training and appropriate
customer
reward system was introduced expectation
in quality,
 FPS involved supplier in production planning and they were cost and
kept informed about demand time

 Result Oriented Performance measurement and Controlling

System
11 CRITICAL AREAS

Ford Total Safety and Health

Environment Productive Assessment
Work Groups
management Management Review Process
(FTPM) (SHARP)

Synchronus
Training Leadership Quality Material Flow
(SMF)

In-Station Process Manufacturing Industrial Material

Control (ISPC) Engineering Flow
Key Elements of FPS
•All FPS Plants are required to be ISO 14001
Environmental management Certifies

Safety and Health Assessment •Used to employ most advanced safety

Review System (SHARP) standard at Ford Plants

Ford Total Productive •Management of equipment. Aims to

Maintenance (FTPM) prevents defects and breakdown

•For continuous flow of material and

Synchronous Material Flow (SMF) products in an orderly fashion
•Inline Vehicle Sequencing (ILVS)
•Through ISPS line operator ensures that
In-station Process Control (ISPS) there is no defect on product passing
through their work cells

•Just in Time :Producing exactly the units

JIT required in the quantity required at the time
Lean Manufacturing System

Building Blocks of LMS

Major Tenets
• Quick Changeover
• Worksplace Organisation System
• Value Stream System
• Standardised Operation
• Kanban
• Total Productive Manufacturing
• Cellular Manufacturing
Supporting Strategies
• TAKT Time
• One Piece Flow
• Quality at Source
• Employee Involvement
• Continuous Improvement
• Equipment Replacement

Changeover of Michigan Plant

https://youtu.be/E4OgG7TDRE4
LEAN MANUFACTURING IN PRACTICE
 Ford Halewood Plant In Uk produced the Jaguar X-Type
Model started with an investment of $300mn by replacing
old production lines to completely new lines.

 Robots controlled 95% of the body construction of the car

 Unique feature of the plant was that all critical production

facilities were located at one place (Press shop, Body
construction, Trim ,Paint shop and Final lines for Synchronised
material flow(SMF)  The employees got two and a half year of training to
prepare themselves for production with 9 week of intensive
training just before production

 Product coaches were chosen for better process

implementation and to lead a work group of 6 employees
instead of 20 employees as per previous practice

 Ford entered the full service supplier contract with Supplier

Park to assemble and manufacture parts in this park

 Subassembly by supplier only 12 hours before the demand

PRODUCTION SYSTEM POST FORD 2000
 In 2003 all plants had adopted FPS System
 Achieved Savings of $500 mn per year
 Standardised workstations
 In 2004 New Truck Plant at Dearborn, North America to produce
famous F150 truck
 Used Inline Vehicle Sequencing techniques (ILVS) to know
exactly when to ship component to the plant
 Advanced logistic system made unload component time 15
minutes
 Body Shop – Split into 16 standardised cells
 Each cells having particular task
 Future Way forward
 Investing in 3 D Printing
 With Innovation only 300 components are
needed to create 16 cells
 These different cells are put together to make “Technologies such as 3D printing,
up entire body shop robotics and virtual manufacturing may
 More than 80% of tools and facilities will be live in research but have real-world
reused applications for tomorrow and beyond,”

 The computer and robots are reprogrammed
to suit the new requirement
 Advanced inspection mechanism were used to
ensure that product passed all quality test
Paul Mascarenas, chief technical officer
and vice president, Ford Research and
Innovation.

Ford Fiesta in 86 Seconds

https://www.youtube.com/watch?v=ErSZmor1qok
THANK YOU
Q& A
Video Link

 Model T Assembly - https://youtu.be/cTZ3rJHHSik

 Ford Fiesta in 86 Seconds
https://www.youtube.com/watch?v=ErSZmor1qok
 Changeover of Michigan Plant https://youtu.be/E4OgG7TDRE4
 100 Years of Ford Innovation :
https://corporate.ford.com/articles/history/100-years-moving-assembly-
line.html