(iv) Total manufacturing flexibility was achieved by:
– breaking the traditional large factory plant into smaller, semi-autonomous
and specialized workshops; and
– making all machines self-contained, independently powered and motorized
by electric motors (referred to as “electric robots” by Bata)
(v) Changes in product styles and types were achieved quickly (in a few hours) by
rearrangingmachine sequences and layouts, by pulling outmachines temporarily
(“decoupling the line”) and by designing most adjustments and customization
into the early stages of the production process;
(vi) A close personal “ownership” relationship between workers and “their” machines:
not only was there no distrust of the machinery but there was also no
neglect – only pride of ownership, emotional involvement and total care;
(vii) All operators were able to stop production line conveyors at will; all waste in
production was minimized (everything had to be ready just in time for the next
step); all machines were designed to serve “the process,” not just individual
operations;
(viii) Dedication to automation: one of Bata machines “did everything but talk and
sing” (the note-scribbling overseas visitors were never able to copy it; a machine
called the “Union press” produced a full pair of shoes in a single movement);
(ix) A perfect, semi-automated, rotational system of preventive maintenance of all
machinery (including overhauls and updates), carried out without ever stopping
production.