Engineering the Factory: teacher key

How Cars Are Made, grade 11 edition, written for 11th grade. The teams, systems and methods behind the modern car plant: interchangeable parts, Fordism, Toyota's waste rules, stamping, welding, paint chemistry and recycling.

Read the book. Print this page for the key.

Questions and answers

1. Where and when did Ford's moving assembly line first run?
   • At Highland Park, Michigan, in October 1913 (answer)
   • At Chicago in 1867
   • At Toyota in 1948
2. How many kinds of muda does the Toyota system address?
   • Three
   • Eight (answer)
   • Fifteen
3. Why did Ford's line cause a paint bottleneck?
   • Only japan black would dry fast enough (answer)
   • Paint was too expensive
   • Workers disliked color
4. What does the primer layer do?
   • It makes the surface smooth and even (answer)
   • It gives the car its color
   • It dries the paint
5. Why does a spot weld fail if it gets too much energy?
   • It melts excess metal, ejects it and makes a hole (answer)
   • It never gets hot enough
   • The electrodes move like scissors

Words

• interchangeable: swappable
• muda: waste
• hemming: folding edges
• hydroforming: shaping with fluid