manufacturing – Life In A Word

Parts Party

I’ve always been fascinated – mesmerized even – by the mechanics of assembly line manufacturing. A product takes form from a single part, then moves down the line to where another part is added. Then another part, another, and another, until at long last the completed product presents itself at the very end for packaging. Assembly lines are becoming more and more automated, which begs the question: When will humans be removed from the process altogether?

On a recent trip to Detroit with my brothers, we were lucky enough to snag tickets to a tour of the Ford River Rouge Complex, where the F-150 truck (gas engine) is mass-produced. Ford has over 65 manufacturing plants worldwide but I think “The Rouge” is the only one you can tour. And boy is it worth it. You walk away with a lot more admiration for a fully-built F-150 than when you first set foot in the building.

The tour begins on the bridge at the lower left

Ford doesn’t allow you to take photos inside The Rouge (and they keep a close eye on visitors) else I’d include a few here. The tour starts with a couple of promotional videos in comfortable theaters, followed by an elevator trip to the top of the visitors center for a look down at the vast campus. Then things get serious. You put away your phones, listen to the rules and regulations about behaving inside the factory, and off you go.

Here are the eye-popping numbers. The F-150 travels the length of a four-mile assembly line as it grows from parts to finished product. That line includes over two hundred stops to add parts (which aren’t really stops because the truck is always being pulled along). A fully-functioning F-150 rolls off The Rouge assembly line every 52 seconds, which translates to a remarkable 650 new vehicles per ten-hour working shift. And finally, the whole process is far from automated. 6,000 workers assemble the vehicles, each a specialist in the given part, calibration, or inspection the truck demands.

Of course, an F-150 has far more than two hundred parts. Some of those assembly line stops are for the installation of major components. The entire dashboard, for example, or most of the engine are installed in a single stop. But you also have workers who do nothing more than take a rubber mallet and pound on rear taillight covers. Think about it. Can you imagine hammering on taillight covers 650 times a day? It’s mindless, it’s repetitive, and you have to wonder about the toll it takes on the human body.

Assembly line work can be more fun and less repetitive than building cars. My family and I visited the Kellogg’s (cereal) factory in Battle Creek, Michigan in the early 1970s. The smell of cooked corn flakes might’ve turned a kid’s nose but the tour was the next best thing to Willy Wonka’s. You’d don a Kellogg’s paper hat and read the colorful brochure story about how “this little kernel went to Kellogg’s… first it was milled… then it was flavored…”. Then you’d walk the assembly line of breakfast cereal, from cooking all the way to box filling. The best part was at the very end, where you’d get free samples of all your Kellogg’s favorites, and postcards so you could brag about the place to your friends. Alas, like many manufacturing facilities, safety and espionage concerns brought an end to the Kellogg’s tours in the mid-1980s.

At least I could watch assembly lines on TV after that. How It’s Made was my kind of show. The Canadian documentary spent years creating virtual factory tours so viewers could see the ins and outs of manufacturing processes. In a single episode you’d watch the dizzying mechanics behind the creation of everything from candies to clothing to cars. How It’s Made kind of gave you access where access wasn’t allowed.

Speaking of no access, the electric-engine version of the Ford F-150 – the “Lightning” – is produced in a plant where no tours are permitted (back to the espionage thing). Instead, you watch a short video of the process after you’ve completed The Rouge tour. How are the two F-150 assembly lines different? Several thousand humans. The Lightning production is almost entirely automated, with robotic machines hovering over the vehicles as they come together. Our tour guide said the assembly line is eerily quiet, since a robot doesn’t require a banging mallet to add on a taillight cover.

For all my fascination with assembly lines and automation, I wonder whether “loss of humanity” is really the way to go. All those jobs at The Rouge would disappear. Machines would be one step closer to taking over the world. Suddenly “handmade” sounds better than ever.

Some content sourced from the Michigan Blue article, “Visiting the Kellogg’s Factory”, and Wikipedia, “the free encyclopedia”.

Mechanical Wonders

A Wall Street Journal headline stopped me in my tracks today. In Guangzhou, China, you can now buy a car from a vending machine. Starting with a smartphone app, you book a test drive before you arrive. Once at the “dealership”, facial recognition software kicks the machine into gear, delivering your car-of-choice from an eight-story automated garage. If you’re happy with the test drive, you negotiate the purchase through the app – no haggling salesperson to be seen – and off you drive with a new car. I’d fly to China and take a test drive just to see the automated garage vend a car. That’s some cool technology.

Vending is more sophisticated these days than the plain-Jane cigarette and candy machines of old, of course. Airports dispense cell phones and other pricey electronics to travelers from vending machines. Food-truck-like boxes dispense made-to-order pizzas. A mall in Beverly Hills vends Beluga caviar from self-serve refrigerators ($500 a pop). Las Vegas’s “The Lobster Zone” is like one of those machines where you joystick the claw to your toy of choice, only here you’re plucking live lobsters from a tank. Finally, the cupcake company Sprinkles makes serious bank with its street-side “cupcake ATM’s”.

Speaking of bank, I used to collect mechanical banks when I was a kid. That sounds like a strange (nerdy?) admission – collecting toy banks – but that’s what kids did in the 1970’s. They collected things. Mechanical banks wouldn’t appeal to today’s youth for a couple of reasons. One, they’re battery-operated or “wind-up”, so you can’t control them with a phone or an app. Two, they work on the assumption you’re saving up nickels, dimes, and quarters for future purchases. Today’s kids seem less likely to save that way (if at all), and their purchases are with bills or electronic cash. Mechanical banks prefer coins.

My collection of banks – which disappeared years ago – is a good example of the limitations of what and how a kid could purchase back then. Almost all my banks came from the Johnson Smith Company, a manufacturer out of Chicago (“Since 1914!”) Johnson Smith sold endless novelty and gag gift items: x-ray goggles, whoopee cushions, joy buzzers, and those really annoying “chattering teeth”. They also sold mechanical banks; not the beautiful collector’s editions of old, but plastic, battery-operated cheapies, probably manufactured in China. Johnson Smith was the closest thing a kid in my day had to Amazon.

Because I lived in Los Angeles and Johnson Smith sold their mechanical banks in Chicago, the U.S. Postal Service was a lifeline; the critical link between my quiet suburban neighborhood and the Midwest’s biggest city. When I saved enough money, I’d stuff my bills and coins into an envelope, hand-address it, add several postage stamps (Mom helped with the calculation), and walk it out to the mailbox at the end of our driveway. Four to six weeks later, a small brown box would arrive from Chicago, addressed to me and containing my latest mechanical wonder.

Think about that for a second. Not only was I putting cash into a flimsy white envelope to be processed through the endless shipping and handling of USPS, but I was also leaving my hard-earned money out by the street, alerting the world to its presence with the little red mailbox flag. That same transaction today – with “1-click ordering” – takes a single keystroke or voice command and shows up on my doorstep in two days or less.

The irony of collecting mechanical banks is that you’re spending your hard-earned pennies on the very thing designed to keep you from spending them. Truth be told, my banks weren’t about saving money at all. Instead, they were entertainment in the form of plastic-and-battery-operated mechanics, watching coins go here-and-there before finally disappearing from sight.

I never lost my fascination for mechanics. I remember grade-school field trips to commercial bakeries, going behind-the-scenes to see how big vats of dough methodically evolved into sliced, packaged loaves of bread. My kids and I used to watch the Food Network’s “Unwrapped”, a half-hour tour through the sophisticated mechanics behind a product’s evolution, from individual ingredients, through various stages of assembly (and several conveyor belts), finally to the finish line: a brightly-wrapped ready-to-eat consumable.

Mechanical banks may be long gone, but even in today’s age of electronics I say we’re still fascinated by mechanics itself. It’s the reason we buy cars from vending machines or cupcakes from ATM’s. And it’s the reason I still haul my pocket change down to the bank, just to see the teller dump the lot into the coin-counting machine; the noisy, mechanical wonder that sorts, counts, and spits out a receipt just before gobbling up every last penny.