Lines, Cards and Castings: teacher key

How Cars Are Made, grade 10 edition, written for 10th grade. How Ford's moving line, Toyota's kanban cards, giant castings, welds and thin layers of paint turn metal into a car. Each method solves a different problem.

Read the book. Print this page for the key.

Questions and answers

1. When did the moving assembly line begin operation?
   • 1867
   • 7 October 1913 (answer)
   • 1961
2. What did Ohno see as the model for the factory?
   • A loom
   • A pulley system
   • A supermarket (answer)
3. What does a kanban signal tell the supplier?
   • To produce and deliver a new shipment (answer)
   • To stop all work
   • To paint the part
4. What goes wrong if a spot weld gets too much energy?
   • It makes a hole instead of a weld (answer)
   • It becomes stronger
   • It needs a vacuum
5. Why does gigacasting trade fewer parts for more risk?
   • A single flaw can compromise the whole piece (answer)
   • It uses more pieces
   • It has a lower scrap rate

Words

• kanban: tracking cards
• jidoka: self-stopping automation
• Gigacasting: giant-part casting
• electrodes: current carriers
• inventory: stock on hand