Inside Tesla’s Robotic Factory

July 25, 2013

teslaWired Magazine (July 16, 2013) provides a tour of the 5 million-square-foot Tesla Motors factory in Fremont, California to see how CEO Elon Musk is rethinking how cars are built.  Tesla Motors has kicked off production of the gorgeous Model S into overdrive, cranking out some 400 cars a week on one of the world’s most advanced automotive production lines.

A major automaker in Detroit or Japan can churn out 400 cars a day, and in fact the Tesla Motors plant had a capacity of 6,000 cars a week when Toyota and General Motors ran this factory in the 1980s and 1990s. But Tesla’s numbers are impressive when you consider the Silicon Valley automaker started less than a decade ago with a few engineers and mechanics shoving piecemeal components into a rolling chassis made by Lotus.

Tesla got the factory for a song from Toyota in 2010, spent about a year or so setting up tooling and started producing the Model S sedan in mid-2012. The automaker brings in raw materials by the truckload, including the massive rolls of aluminum we see in the 5 minute video that are bent, pressed, and formed to create the car. Those lightweight components are assembled by swarm of 160 red robots.

The bare body is shipped off for prepping and paint before joining the assembly line under the power of autonomous robots. The shell is ushered through the line as Tesla’s 3,000 workers work alongside their robotic counterparts to install the battery, motor, interior, and miles of cabling and components that help create the electric sports sedan.

This post provided courtesy of Jay and Barry’s OM Blog at www.heizerrenderom.wordpress.comProfessors Jay Heizer and Barry Render are authors of Operations Management , the world’s top selling textbook in its field, published by Pearson.

Social Media on the Factory Floor

July 23, 2013

by

social mediaAccording to a recent survey by the Manufacturing Leadership Council, 13% of manufacturing executives plan to digitize their design/production processes, and social media tools represent an important component. By 2023, that percentage will rise to more than half. “What’s the goal of increased social media-based interactions, ” asks Cisco News Network? Manufacturers want to tap into valuable customer opinions, preferences and desires. They also want to encourage collaborations between employees, partners and suppliers in order to create better end products.

For example, Frito Lay offers one illustration of a manufacturer going directly to its core constituency for critical product feedback. The company collaborated with customers via social media to define and select the most appealing flavor ideas. Such combinations of crowdsourcing—a form of distributive problem-solving—and taste buds represents a novel, and completely different, approach to the use of social media in manufacturing.

At the other end of the spectrum, a range of more industrial companies are beginning to employ social media-driven, collaborative tools for their workforce.  Airbus offers partners and dealers a range of interactive procurement portals. These platform-based resources enable suppliers to describe their capabilities to Airbus buyers in addition to exchanging requirements and proposals online during the bid process.

Such social media trends extend even further. Industrial Mold and Machine in Twinsburg, Ohio makes custom molds for plastic bottle manufacturers. The company empowers its workers by providing an iPad-accessible Social Media platform for production-line quality control, design access and problem-solving.

It appears that more and more manufacturers will use collaborative Social Media technology to advance their operations through multiple, diverse collaborations.

This post provided courtesy of Jay and Barry’s OM Blog at www.heizerrenderom.wordpress.comProfessors Jay Heizer and Barry Render are authors of Operations Management , the world’s top selling textbook in its field, published by Pearson.

Designing a Spot for the iPhone in Your Car

July 21, 2013

Jeep designers got inspiration for this in-door net when they peeked in car windows and saw a bottle secured with a bungee cord

Jeep designers got inspiration for this in-door net when they peeked in car windows and saw a bottle secured with a bungee cord.

Here  is a Wall Street Journal article (July 18, 2013) you may find interesting. In it, we find that Chris Shinouskis, whose title is “Engineering Specialist for Storage” at GM, is one of a handful of designers who carve out compartments to hold the ever-growing array of items people bring into their cars.

Adding storage can be a hard-fought battle, especially as cars today come crammed with high-tech safety, information and entertainment systems, all of which require space-hogging wiring and hardware. But buyers are demanding it–65% of new-car buyers said interior storage is “very” or “extremely important”– as they spend more time on the road and bring their tablets to stay plugged in.

Complicating the storage challenge is the fact that it can take 4 years to develop or completely redesign a model, while the technology world moves much faster. For example, Apple offered 4 generations of its iPad tablet in under 3 years. Matt Rutman, a Ford  storage specialist, was adamant that the new SUV needed a place, right above the shifter, for mobile-phone storage and charging. “I was told it wasn’t possible,” says  Rutman. “So I went back to my own computer and figured it out myself.” His solution involved redoing the ventilation system behind the dash, and moving up the video screen and controls.

The glove compartment, in particular, often becomes catchall for junk, so Chrysler has just designed a glove box in its new Dodge Dart deep enough to fit a small laptop or tablet. To make it fit, Chrysler had to mount the heating and cooling unit vertically, instead of the normal horizontal fit. With the importance of drinks and cell phones, the 2014 Chevy Malibu offers two cup holders and two cellphone cradles, one each for the driver and the passenger.

This post provided courtesy of Jay and Barry’s OM Blog at www.heizerrenderom.wordpress.comProfessors Jay Heizer and Barry Render are authors of Operations Management , the world’s top selling textbook in its field, published by Pearson.