My Life and Work
It is particularly easy for any man who never knows it all to go forward
to a higher position with us. Some men will work hard but they do not
possess the capacity to think and especially to think quickly. Such men
get as far as their ability deserves. A man may, by his industry,
deserve advancement, but it cannot be possibly given him unless he also
has a certain element of leadership. This is not a dream world we are
living in. I think that every man in the shaking-down process of our
factory eventually lands about where he belongs.
We are never satisfied with the way that everything is done in any part
of the organization; we always think it ought to be done better and that
eventually it will be done better. The spirit of crowding forces the man
who has the qualities for a higher place eventually to get it. He
perhaps would not get the place if at any time the organization--which
is a word I do not like to use--became fixed, so that there would be
routine steps and dead men's shoes. But we have so few titles that a man
who ought to be doing something better than he is doing, very soon gets
to doing it--he is not restrained by the fact that there is no position
ahead of him "open"--for there are no "positions." We have no
cut-and-dried places--our best men make their places. This is easy
enough to do, for there is always work, and when you think of getting
the work done instead of finding a title to fit a man who wants to be
promoted, then there is no difficulty about promotion. The promotion
itself is not formal; the man simply finds himself doing something other
than what he was doing and getting more money.
All of our people have thus come up from the bottom. The head of the
factory started as a machinist. The man in charge of the big River Rouge
plant began as a patternmaker. Another man overseeing one of the
principal departments started as a sweeper. There is not a single man
anywhere in the factory who did not simply come in off the street.
Everything that we have developed has been done by men who have
qualified themselves with us. We fortunately did not inherit any
traditions and we are not founding any. If we have a tradition it is
this:
Everything can always be done better than it is being done.
That pressing always to do work better and faster solves nearly every
factory problem. A department gets its standing on its rate of
production. The rate of production and the cost of production are
distinct elements. The foremen and superintendents would only be wasting
time were they to keep a check on the costs in their departments. There
are certain costs--such as the rate of wages, the overhead, the price of
materials, and the like, which they could not in any way control, so
they do not bother about them. What they can control is the rate of
production in their own departments. The rating of a department is
gained by dividing the number of parts produced by the number of hands
working. Every foreman checks his own department daily--he carries the
figures always with him. The superintendent has a tabulation of all the
scores; if there is something wrong in a department the output score
shows it at once, the superintendent makes inquiries and the foreman
looks alive. A considerable part of the incentive to better methods is
directly traceable to this simple rule-of-thumb method of rating
production. The foreman need not be a cost accountant--he is no better a
foreman for being one. His charges are the machines and the human beings
in his department. When they are working at their best he has performed
his service. The rate of his production is his guide. There is no reason
for him to scatter his energies over collateral subjects.
This rating system simply forces a foreman to forget personalities--to
forget everything other than the work in hand. If he should select the
people he likes instead of the people who can best do the work, his
department record will quickly show up that fact.
There is no difficulty in picking out men. They pick themselves out
because--although one hears a great deal about the lack of opportunity
for advancement--the average workman is more interested in a steady job
than he is in advancement. Scarcely more than five per cent, of those
who work for wages, while they have the desire to receive more money,
have also the willingness to accept the additional responsibility and
the additional work which goes with the higher places. Only about
twenty-five per cent. are even willing to be straw bosses, and most of
them take that position because it carries with it more pay than working
on a machine. Men of a more mechanical turn of mind, but with no desire
for responsibility, go into the tool-making departments where they
receive considerably more pay than in production proper. But the vast
majority of men want to stay put. They want to be led. They want to have
everything done for them and to have no responsibility. Therefore, in
spite of the great mass of men, the difficulty is not to discover men to
advance, but men who are willing to be advanced.
The accepted theory is that all people are anxious for advancement, and
a great many pretty plans have been built up from that. I can only say
that we do not find that to be the case. The Americans in our employ do
want to go ahead, but they by no means do always want to go clear
through to the top. The foreigners, generally speaking, are content to
stay as straw bosses. Why all of this is, I do not know. I am giving the
facts.
As I have said, everyone in the place reserves an open mind as to the
way in which every job is being done. If there is any fixed theory--any
fixed rule--it is that no job is being done well enough. The whole
factory management is always open to suggestion, and we have an informal
suggestion system by which any workman can communicate any idea that
comes to him and get action on it.
The saving of a cent per piece may be distinctly worth while. A saving
of one cent on a part at our present rate of production represents
twelve thousand dollars a year. One cent saved on each part would amount
to millions a year. Therefore, in comparing savings, the calculations
are carried out to the thousandth part of a cent. If the new way
suggested shows a saving and the cost of making the change will pay for
itself within a reasonable time--say within three months--the change is
made practically as of course. These changes are by no means limited to
improvements which will increase production or decrease cost. A great
many--perhaps most of them--are in the line of making the work easier.
We do not want any hard, man-killing work about the place, and there is
now very little of it. And usually it so works out that adopting the way
which is easier on the men also decreases the cost. There is most
intimate connection between decency and good business. We also
investigate down to the last decimal whether it is cheaper to make or to
buy a part.
The suggestions come from everywhere. The Polish workmen seem to be the
cleverest of all of the foreigners in making them. One, who could not
speak English, indicated that if the tool in his machine were set at a
different angle it might wear longer. As it was it lasted only four or
five cuts. He was right, and a lot of money was saved in grinding.
Another Pole, running a drill press, rigged up a little fixture to save
handling the part after drilling. That was adopted generally and a
considerable saving resulted. The men often try out little attachments
of their own because, concentrating on one thing, they can, if they have
a mind that way, usually devise some improvement. The cleanliness of a
man's machine also--although cleaning a machine is no part of his
duty--is usually an indication of his intelligence.
Here are some of the suggestions: A proposal that castings be taken from
the foundry to the machine shop on an overhead conveyor saved seventy
men in the transport division. There used to be seventeen men--and this
was when production was smaller--taking the burrs off gears, and it was
a hard, nasty job. A man roughly sketched a special machine. His idea
was worked out and the machine built. Now four men have several times
the output of the seventeen men--and have no hard work at all to do.
Changing from a solid to a welded rod in one part of the chassis
effected an immediate saving of about one half million a year on a
smaller than the present-day production. Making certain tubes out of
flat sheets instead of drawing them in the usual way effected another
enormous saving.
The old method of making a certain gear comprised four operations and 12
per cent. of the steel went into scrap. We use most of our scrap and
eventually we will use it all, but that is no reason for not cutting
down on scrap--the mere fact that all waste is not a dead loss is no
excuse for permitting waste. One of the workmen devised a very simple
new method for making this gear in which the scrap was only one per
cent. Again, the camshaft has to have heat treatment in order to make
the surface hard; the cam shafts always came out of the heat-treat oven
somewhat warped, and even back in 1918, we employed 37 men just to
straighten the shafts. Several of our men experimented for about a year
and finally worked out a new form of oven in which the shafts could not
warp. In 1921, with the production much larger than in 1918, we employed
only eight men in the whole operation.
And then there is the pressing to take away the necessity for skill in
any job done by any one. The old-time tool hardener was an expert. He
had to judge the heating temperatures. It was a hit-or-miss operation.
The wonder is that he hit so often. The heat treatment in the hardening
of steel is highly important--providing one knows exactly the right heat
to apply. That cannot be known by rule-of-thumb. It has to be measured.
We introduced a system by which the man at the furnace has nothing at
all to do with the heat. He does not see the pyrometer--the instrument
which registers the temperature. Coloured electric lights give him his
signals.
None of our machines is ever built haphazardly. The idea is investigated
in detail before a move is made. Sometimes wooden models are constructed
or again the parts are drawn to full size on a blackboard. We are not
bound by precedent but we leave nothing to luck, and we have yet to
build a machine that will not do the work for which it was designed.
About ninety per cent. of all experiments have been successful.
Whatever expertness in fabrication that has developed has been due to
men. I think that if men are unhampered and they know that they are
serving, they will always put all of mind and will into even the most
trivial of tasks.
CHAPTER VII
THE TERROR OF THE MACHINE
Repetitive labour--the doing of one thing over and over again and always
in the same way--is a terrifying prospect to a certain kind of mind. It
is terrifying to me. I could not possibly do the same thing day in and
day out, but to other minds, perhaps I might say to the majority of
minds, repetitive operations hold no terrors. In fact, to some types of
mind thought is absolutely appalling. To them the ideal job is one where
the creative instinct need not be expressed. The jobs where it is
necessary to put in mind as well as muscle have very few takers--we
always need men who like a job because it is difficult. The average
worker, I am sorry to say, wants a job in which he does not have to put
forth much physical exertion--above all, he wants a job in which he does
not have to think. Those who have what might be called the creative type
of mind and who thoroughly abhor monotony are apt to imagine that all
other minds are similarly restless and therefore to extend quite