The Principles of Scientific Management by Frederick Winslow Taylor
introduction of scientific management. Their shops had been run for many
14761 words | Chapter 5
years under a good superintendent and with excellent foremen and
workmen, on piece work. The whole establishment was, without doubt, in
better physical condition than the average machine-shop in this country.
The superintendent was distinctly displeased when told that through the
adoption of task management the output, with the same number of men and
machines, could be more than doubled. He said that he believed that any
such statement was mere boasting, absolutely false, and instead of
inspiring him with confidence, he was disgusted that any one should make
such an impudent claim. He, however, readily assented to the proposition
that he should select any one of the machines whose output he considered
as representing the average of the shop, and that we should then
demonstrate on this machine that through scientific methods its output
could be more than doubled.
The machine selected by him fairly represented the work of the shop. It
had been run for ten or twelve years past by a first-class mechanic who
was more than equal in his ability to the average workmen in the
establishment. In a shop of this sort in which similar machines are
made over and over again, the work is necessarily greatly subdivided, so
that no one man works upon more than a comparatively small number of
parts during the year. A careful record was therefore made, in the
presence of both parties, of the time actually taken in finishing each
of the parts which this man worked upon. The total time required by him
to finish each piece, as well as the exact speeds and feeds which he
took, were noted and a record was kept of the time which he took in
setting the work in the machine and removing it. After obtaining in this
way a statement of what represented a fair average of the work done in
the shop, we applied to this one machine the principles of scientific
management.
By means of four quite elaborate slide-rules, which have been especially
made for the purpose of determining the all-round capacity of
metal-cutting machines, a careful analysis was made of every element of
this machine in its relation to the work in hand. Its Pulling power at
its various speeds, its feeding capacity, and its proper speeds were
determined by means of the slide-rules, and changes were then made in
the countershaft and driving pulleys so as to run it at its proper
speed. Tools, made of high-speed steel, and of the proper shapes, were
properly dressed, treated, and ground. (It should be understood,
however, that in this case the high-speed steel which had heretofore
been in general use in the shop was also used in our demonstration.) A
large special slide-rule was then made, by means of which the exact
speeds and feeds were indicated at which each kind of work could be done
in the shortest possible time in this particular lathe. After preparing
in this way so that the workman should work according to the new method,
one after another, pieces of work were finished in the lathe,
corresponding to the work which had been done in our preliminary trials,
and the gain in time made through running the machine according to
scientific principles ranged from two and one-half times the speed in
the slowest instance to nine times the speed in the highest.
The change from rule-of-thumb management to scientific management
involves, however, not only a study of what is the proper speed for
doing the work and a remodeling of the tools and the implements in the
shop, but also a complete change in the mental attitude of all the men
in the shop toward their work and toward their employers. The physical
improvements in the machines necessary to insure large gains, and the
motion, study followed by minute study with a stop-watch of the time in
which each workman should do his work, can be made comparatively
quickly. But the change in the mental attitude and in the habits of the
three hundred or more workmen can be brought about only slowly and
through a long series of object-lessons, which finally demonstrates to
each man the great advantage which he will gain by heartily cooperating
in his every-day work with the men in the management. Within three
years, however, in this shop, the output had been more than doubled per
man and per machine. The men had been carefully selected and in almost
all cases promoted from a lower to a higher order of work, and so
instructed by their teachers (the functional foremen) that they were
able to earn higher wages than ever before. The average increase in the
daily earnings of each man was about 35 per cent., while, at the same
time, the sum total of the wages paid for doing a given amount of work
was lower than before. This increase in the speed of doing the work, of
course, involved a substitution of the quickest hand methods for the old
independent rule-of-thumb methods, and an elaborate analysis of the hand
work done by each man. (By hand work is meant such work as depends upon
the manual dexterity and speed of a workman, and which is independent of
the work done by the machine.) The time saved by scientific hand work
was in many cases greater even than that saved in machine-work.
It seems important to fully explain the reason why, with the aid of a
slide-rule, and after having studied the art of cutting metals, it was
possible for the scientifically equipped man, who had never before seen
these particular jobs, and who had never worked on this machine, to do
work from two and one-half to nine times as fast as it had been done
before by a good mechanic who had spent his whole time for some ten to
twelve years in doing this very work upon this particular machine. In a
word, this was possible because the art of cutting metals involves a
true science of no small magnitude, a science, in fact, so intricate
that it is impossible for any machinist who is suited to running a lathe
year in and year out either to understand it or to work according to its
laws without the help of men who have made this their specialty. Men who
are un-familiar with machine-shop work are prone to look upon the
manufacture of each piece as a special problem, independent of any other
kind of machine-work. They are apt to think, for instance, that the
problems connected with making the parts of an engine require the
especial study, one may say almost the life study, of a set of
engine-making mechanics, and that these problems are entirely different
from those which would be met with in machining lathe or planer parts.
In fact, however, a study of those elements which are peculiar either to
engine parts or to lathe parts is trifling, compared with the great
study of the art, or science, of cutting metals, upon a knowledge of
which rests the ability to do really fast machine-work of all kinds.
The real problem is how to remove chips fast from a casting or a
forging, and how to make the piece smooth and true in the shortest time,
and it matters but little whether the piece being worked upon is part,
say, of a marine engine, a printing-press, or an automobile. For this
reason, the man with the slide rule, familiar with the science of
cutting metals, who had never before seen this particular work, was able
completely to distance the skilled mechanic who had made the parts of
this machine his specialty for years.
It is true that whenever intelligent and educated men find that the
responsibility for making progress in any of the mechanic arts rests
with them, instead of upon the workmen who are actually laboring at the
trade, that they almost invariably start on the road which leads to the
development of a science where, in the past, has existed mere
traditional or rule-of-thumb knowledge. When men, whose education has
given them the habit of generalizing and everywhere looking for laws,
find themselves confronted with a multitude of problems, such as exist
in every trade and which have a general similarity one to another, it is
inevitable that they should try to gather these problems into certain
logical groups, and then search for some general laws or rules to guide
them in their solution. As has been pointed out, however, the underlying
principles of the management of "initiative and incentive," that is, the
underlying philosophy of this management, necessarily leaves the
solution of all of these problems in the hands of each individual
workman, while the philosophy of scientific management places their
solution in the hands of the management. The workman's whole time is
each day taken in actually doing the work with his hands, so that, even
if he had the necessary education and habits of generalizing in his
thought, he lacks the time and the opportunity for developing these
laws, because the study of even a simple law involving say time study
requires the cooperation of two men, the one doing the work while the
other times him with a stop-watch. And even if the workman were to
develop laws where before existed only rule-of-thumb knowledge, his
personal interest would lead him almost inevitably to keep his
discoveries secret, so that he could, by means of this special
knowledge, personally do more work than other men and so obtain higher
wages.
Under scientific management, on the other hand, it becomes the duty and
also the pleasure of those who are engaged in the management not only to
develop laws to replace rule of thumb, but also to teach impartially all
of the workmen who are under them the quickest ways of working. The
useful results obtained from these laws are always so great that any
company can well afford to pay for the time and the experiments needed
to develop them. Thus under scientific management exact scientific
knowledge and methods are everywhere, sooner or later, sure to replace
rule of thumb, whereas under the old type of management working in
accordance with scientific laws is an impossibility. The development of
the art or science of cutting metals is an apt illustration of this
fact. In the fall of 1880, about the time that the writer started to
make the experiments above referred to, to determine what constitutes a
proper day's work for a laborer, he also obtained the permission of Mr.
William Sellers, the President of the Midvale Steel Company, to make a
series of experiments to determine what angles and shapes of tools were
the best for cutting steel, and also to try to determine the proper
cutting speed for steel. At the time that these experiments were started
it was his belief that they would not last longer than six months, and,
in fact, if it had been known that a longer period than this would be
required, the permission to spend a considerable sum of money in making
them would not have been forthcoming.
A 66-inch diameter vertical boring-mill was the first machine used in
making these experiments, and large locomotive tires, made out of hard
steel of uniform quality, were day after day cut up into chips in
gradually learning how to make, shape, and use the cutting tools so that
they would do faster work. At the end of six months sufficient
practical information had been obtained to far more than repay the cost
of materials and wages which had been expended in experimenting. And yet
the comparatively small number of experiments which had been made served
principally to make it clear that the actual knowledge attained was but
a small fraction of that which still remained to be developed, and which
was badly needed by us, in our daily attempt to direct and help the
machinists in their tasks.
Experiments in this field were carried on, with occasional interruption,
through a period of about 26 years, in the course of which ten different
experimental machines were especially fitted up to do this work. Between
30,000 and 50,000 experiments were carefully recorded, and many other
experiments were made, of which no record was kept. In studying these
laws more than 800,000 pounds of steel and iron was cut up into chips
with the experimental tools, and it is estimated that from $150,000 to
$200,000 was spent in the investigation.
Work of this character is intensely interesting to any one who has any
love for scientific research. For the purpose of this paper, however, it
should be fully appreciated that the motive power which kept these
experiments going through many years, and which supplied the money and
the opportunity for their accomplishment, was not an abstract search
after scientific knowledge, but was the very practical fact that we
lacked the exact information which was needed every day, in order to
help our machinists to do their work in the best way and in the quickest
time.
All of these experiments were made to enable us to answer correctly the
two questions which face every machinist each time that he does a piece
of work in a metal-cutting machine, such as a lathe, planer, drill
press, or milling machine. These two questions are:
In order to do the work in the quickest time, At what cutting speed
shall I run my machine? and
What feed shall I use?
They sound so simple that they would appear to call for merely the
trained judgment of any good mechanic. In fact, however, after working
26 years, it has been found that the answer in every case involves the
solution of an intricate mathematical problem, in which the effect of
twelve independent variables must be determined.
Each of the twelve following variables has an important effect upon the
answer. The figures which are given with each of the variables represent
the effect of this element upon the cutting speed.
For example, after the first variable (A) we quote,
"The proportion is as I in the case of semi-hardened steel or chilled
iron to 100 in the case of a very soft, low-carbon steel." The meaning
of this quotation is that soft steel can be cut 100 times as fast as the
hard steel or chilled iron. The ratios which are given, then, after each
of these elements, indicate the wide range of judgment which practically
every machinist has been called upon to exercise in the past in
determining the best speed at which to run the machine and the best feed
to use.
(A) The quality of the metal which is to be cut; i.e., its hardness
or other qualities which affect the cutting speed. The proportion is as
1 in the case of semi-hardened steel or chilled iron to 100 in the case
of very soft, low-carbon steel.
(B) The chemical composition of the steel from which the tool is
made, and the heat treatment of the tool. The proportion is as 1 in
tools made from tempered carbon steel to 7 in the best high-speed tools.
(C) The thickness of the shaving, or, the thickness of the spiral
strip or band of metal which is to be removed by the tool. The
proportion is as 1 with thickness of shaving 3/16 of an inch to 3 1/2
with thickness of shaving 1/64 of an inch.
(D) The shape or contour of the cutting edge of the tool. The
proportion is as 1 in a thread tool to 6 in a broad-nosed cutting tool.
(E) Whether a copious stream of water or other cooling medium is
used on the tool. The proportion is as 1 for tool running dry to 1.41
for tool cooled by a copious stream of water.
(F) The depth of the cut. The proportion is as 1 with 1/2 inch depth
of cut to 1.36 with 1/8 inch depth of cut.
(G) The duration of the cut, i.e., the time which a tool must last under
pressure of the shaving without being reground. The proportion is as 1
when tool is to be ground every 1 1/2 hours to 1.20 when tool is to be
ground every 20 minutes.
(H) The lip and clearance angles of the tool. The proportion is as 1
with lip angle of 68 degrees to 1.023 with lip angle of 61 degrees.
(J) The elasticity of the work and of the tool on account of
producing chatter. The proportion is as 1 with tool chattering to 1.15
with tool running smoothly.
(K) The diameter of the casting or forging which is being cut.
(L) The pressure of the chip or shaving upon the cutting surface of the
tool.
(M) The pulling power and the speed and feed changes of the machine.
It may seem preposterous to many people that it should have required a
period of 26 years to investigate the effect of these twelve variables
upon the cutting speed of metals. To those, however, who have had
personal experience as experimenters, it will be appreciated that the
great difficulty of the problem lies in the fact that it contains so
many variable elements. And in fact the great length of time consumed in
making each single experiment was caused by the difficulty of holding
eleven variables constant and uniform throughout the experiment, while
the effect of the twelfth variable was being investigated. Holding the
eleven variables constant was far more difficult than the investigation
of the twelfth element.
As, one after another, the effect upon the cutting speed of each of
these variables was investigated, in order that practical use could be
made of this knowledge, it was necessary to find a mathematical formula
which expressed in concise form the laws which had been obtained. As
examples of the twelve formulae which were developed, the three
following are given:
P = 45,000 D 14/15 F 3/4
V = 90/T 1/8
V = 11.9/ (F 0.665(48/3 D) 0.2373 + (2.4 / (18 + 24D))
After these laws had been investigated and the various formulae which
mathematically expressed them had been determined, there still remained
the difficult task of how to solve one of these complicated mathematical
problems quickly enough to make this knowledge available for every-day
use. If a good mathematician who had these formula before him were to
attempt to get the proper answer (i.e., to get the correct cutting speed
and feed by working in the ordinary way) it would take him from two to
six hours, say, to solve a single problem; far longer to solve the
mathematical problem than would be taken in most cases by the workmen in
doing the whole job in his machine. Thus a task of considerable
magnitude which faced us was that of finding a quick solution of this
problem, and as we made progress in its solution, the whole problem was
from time to time presented by the writer to one after another of the
noted mathematicians in this country. They were offered any reasonable
fee for a rapid, practical method to be used in its solution. Some of
these men merely glanced at it; others, for the sake of being courteous,
kept it before them for some two or three weeks. They all gave us
practically the same answer: that in many cases it was possible to,
solve mathematical problems which contained four variables, and in some
cases problems with five or six variables, but that it was manifestly
impossible to solve a problem containing twelve variables in any other
way than by the slow process of "trial and error."
A quick solution was, however, so much of a necessity in our every-day
work of running machine-shops, that in spite of the small encouragement
received from the mathematicians, we continued at irregular periods,
through a term of fifteen years, to give a large amount of time
searching for a simple solution. Four or five men at various periods
gave practically their whole time to this work, and finally, while we
were at the Bethlehem Steel Company, the slide-rule was developed which
is illustrated on Folder No. 11 of the paper "On the Art of Cutting
Metals," and is described in detail in the paper presented by Mr. Carl
G. Barth to the American Society of Mechanical Engineers, entitled
"Slide-rules for the Machine-shop, as a part of the Taylor System of
Management" (Vol. XXV of The Transactions of the American Society of
Mechanical Engineers). By means of this slide-rule, one of these
intricate problems can be solved in less than a half minute by any good
mechanics whether he understands anything about mathematics or not, thus
making available for every-day, practical use the years of experimenting
on the art of cutting metals. This is a good illustration of the fact
that some way can always be found of making practical, everyday use of
complicated scientific data, which appears to be beyond the experience
and the range of the technical training of ordinary practical men. These
slide-rules have been for years in constant daily use by machinists
having no knowledge of mathematics.
A glance at the intricate mathematical formula (see page 109) which
represent the laws of cutting metals should clearly show the reason why
it is impossible for any machinist, without the aid of these laws, and
who depends upon his personal experience, correctly to guess at the
answer to the two questions,
What speed shall I use?
What feed shall I use?
even though he may repeat the same piece of work many times.
To return to the case of the machinist who had been working for ten to
twelve years in machining the same pieces over and over again, there was
but a remote chance in any of the various kinds of work which this man
did that he should hit upon the one best method of doing each piece of
work out of the hundreds of possible methods which lay before him. In
considering this typical case, it must also be remembered that the
metal-cutting machines throughout our machine-shops have practically all
been speeded by their makers by guesswork, and without the knowledge
obtained through a study of the art of cutting metals. In the
machine-shops systematized by us we have found that there is not one
machine in a hundred which is speeded by its makers at anywhere near the
correct cutting speed. So that, in order to compete with the science of
cutting metals, the machinist, before he could use proper speeds, would
first have to put new pulleys on the countershaft of his machine, and
also make in most cases changes in the shapes and treatment of his
tools, etc. Many of these changes are matters entirely beyond his
control, even if he knows what ought to be done.
If the reason is clear to the reader why the rule-of-thumb knowledge
obtained by the machinist who is engaged on repeat work cannot possibly
compete with the true science of cutting metals, it should be even more
apparent why the high-class mechanic, who is called upon to do a great
variety of work from day to day, is even less able to compete with this
science. The high-class mechanic who does a different kind of work each
day, in order to do each job in the quickest time, would need, in
addition to a thorough knowledge of the art of cutting metals, a vast
knowledge and experience in the quickest way of doing each kind of hand
work. And the reader, by calling to mind the gain which was made by Mr.
Gilbreth through his motion and time study in laying bricks, will
appreciate the great possibilities for quicker methods of doing all
kinds of hand work which lie before every tradesman after he has the
help which comes from a scientific motion and time study of his work.
For nearly thirty years past, time-study men connected with the
management of machine-shops have been devoting their whole time to a
scientific motion study, followed by accurate time study, with a
stop-watch, of all of the elements connected with the machinist's work.
When, therefore, the teachers, who form one section of the management,
and who are cooperating with the working men, are in possession both of
the science of cutting metals and of the equally elaborate motion-study
and time-study science connected with this work, it is not difficult to
appreciate why even the highest class mechanic is unable to do his best
work without constant daily assistance from his teachers. And if this
fact has been made clear to the reader, one of the important objects in
writing this paper will have been realized.
It is hoped that the illustrations which have been given make it
apparent why scientific management must inevitably in all cases produce
overwhelmingly greater results, both for the company and its employees,
than can be obtained with the management of "initiative and incentive."
And it should also be clear that these results have been attained, not
through a marked superiority in the mechanism of one type of management
over the mechanism of another, but rather through the substitution of
one set of underlying principles for a totally different set of
principles, by the substitution of one philosophy for another philosophy
in industrial management.
To repeat them throughout all of these illustrations, it will be seen
that the useful results have hinged mainly upon (1) the substitution of
a science for the individual judgment of the workman; (2) the scientific
selection and development of the workman, after each man has been
studied, taught, and trained, and one may say experimented with, instead
of allowing the workmen to select themselves and develop in a haphazard
way; and (3) the intimate cooperation of the management with the
workmen, so that they together do the work in accordance with the
scientific laws which have been developed, instead of leaving the
solution of each problem in the hands of the individual workman. In
applying these new principles, in place of the old individual effort of
each workman, both sides share almost equally in the daily performance
of each task, the management doing that part of the work for which they
are best fitted, and the workmen the balance.
It is for the illustration of this philosophy that this paper has been
written, but some of the elements involved in its general principles
should be further discussed.
The development of a science sounds like a formidable undertaking, and
in fact anything like a thorough study of a science such as that of
cutting metals necessarily involves many years of work. The science of
cutting metals, however, represents in its complication, and in the time
required to develop it, almost an extreme case in the mechanic arts. Yet
even in this very intricate science, within a few months after starting,
enough knowledge had been obtained to much more than pay for the work of
experimenting. This holds true in the case of practically all scientific
development in the mechanic arts. The first laws developed for cutting
metals were crude, and contained only a partial knowledge of the truth,
yet this imperfect knowledge was vastly better than the utter lack of
exact information or the very imperfect rule of thumb which existed
before, and it enabled the workmen, with the help of the management, to
do far quicker and better work.
For example, a very short time was needed to discover one or two types
of tools which, though imperfect as compared with the shapes developed
years afterward, were superior to all other shapes and kinds in common
use. These tools were adopted as standard and made possible an immediate
increase in the speed of every machinist who used them. These types were
superseded in a comparatively short time by still other tools which
remained standard until they in their turn made way for later
improvements.*
[*Footnote: Time and again the experimenter in the mechanic arts will
find himself face to face with the problem as to whether he had better
make immediate practical use of the knowledge which he has attained, or
wait until some positive finality in his conclusions has been reached.
He recognizes clearly the fact that he has already made some definite
progress, but sees the possibility (even the probability) of still
further improvement. Each particular case must of course be
independently considered, but the general conclusion we have reached is
that in most instances it is wise to put one's conclusions as soon as
possible to the rigid test of practical use. The one indispensable
condition for such a test, however, is that the experimenter shall have
full opportunity, coupled with sufficient authority, to insure a
thorough and impartial trial. And this, owing to the almost universal
prejudice in favor of the old, and to the suspicion of the new, is
difficult to get.]
The science which exists in most of the mechanic arts is, however, far
simpler than the science of cutting metals. In almost all cases, in
fact, the laws or rules which are developed are so simple that the
average man would hardly dignify them with the name of a science. In
most trades, the science is developed through a comparatively simple
analysis and time study of the movements required by the workmen to do
some small part of his work, and this study is usually made by a man
equipped merely with a stop-watch and a properly ruled notebook.
Hundreds of these "time-study men" are now engaged in developing
elementary scientific knowledge where before existed only rule of thumb.
Even the motion study of Mr. Gilbreth in bricklaying (described on pages
77 to 84) involves a much more elaborate investigation than that which
occurs in most cases. The general steps to be taken in developing a
simple law of this class are as follows:
First. Find, say, 10 or 15 different men (preferably in as many separate
establishments and different parts of the country) who are especially
skilful in doing the particular work to be analyzed.
Second. Study the exact series of elementary operations or motions which
each of these men uses in doing the work which is being investigated, as
well as the implements each man uses.
Third. Study with a stop-watch the time required to make each of these
elementary movements and then select the quickest way of doing each
element of the work.
Fourth. Eliminate all false movements, slow movements, and useless
movements.
Fifth. After doing away with all unnecessary movements, collect into one
series the quickest and best movements as well as the best implements.
This one new method, involving that series of motions which can be made
quickest and best, is then substituted in place of the ten or fifteen
inferior series which were formerly in use. This best method becomes
standard, and remains standard, to be taught first to the teachers (or
functional foremen) and by them to every workman in the establishment
until it is superseded by a quicker and better series of movements. In
this simple way one element after another of the science is developed.
In the same way each type of implement used in a trade is studied. Under
the philosophy of the management of "initiative and incentive" each
work-man is called upon to use his own best judgment, so as to do the
work in the quickest time, and from this results in all cases a large
variety in the shapes and types of implements which are used for any
specific purpose. Scientific management requires, first, a careful
investigation of each of the many modifications of the same implement,
developed under rule of thumb; and second, after a time study has been
made of the speed attainable with each of these implements, that the
good points of several of them shall be united in a single standard
implement, which will enable the workman to work faster and with greater
ease than he could before. This one implement, then, is adopted as
standard in place of the many different kinds before in use, and it
remains standard for all workmen to use until superseded by an implement
which has been shown, through motion and time study, to be still better.
With this explanation it will be seen that the development of a science
to replace rule of thumb is in most cases by no means a formidable
under-taking, and that it can be accomplished by ordinary, every-day men
without any elaborate scientific training; but that, on the other hand,
the successful use of even the simplest improvement of this kind calls
for records, system, and cooperation where in the past existed only
individual effort.
There is another type of scientific investigation which has been
referred to several times in this paper, and which should receive
special attention, namely, the accurate study of the motives which
influence men. At first it may appear that this is a matter for
individual observation and judgment, and is not a proper subject for
exact scientific experiments. It is true that the laws which result from
experiments of this class, owing to the fact that the very complex
organism--the human being--is being experimented with, are subject to a
larger number of exceptions than is the case with laws relating to
material things. And yet laws of this kind, which apply to a large
majority of men, unquestionably exist, and when clearly defined are of
great value as a guide in dealing with men. In developing these laws,
accurate, carefully planned and executed experiments, extending through
a term of years, have been made, similar in a general way to the
experiments upon various other elements which have been referred to in
this paper. Perhaps the most important law belonging to this class, in
its relation to scientific management, is the effect which the task idea
has upon the efficiency of the workman. This, in fact, has become such
an important element of the mechanism of scientific management, that by
a great number of people scientific management has come to be known as
"task management."
There is absolutely nothing new in the task idea. Each one of us will
remember that in his own case this idea was applied with good results in
his school-boy days. No efficient teacher would think of giving a class
of students an indefinite lesson to learn. Each day a definite,
clear-cut task is set by the teacher before each scholar, stating that
he must learn just so much of the subject; and it is only by this means
that proper, systematic progress can be made by the students. The
average boy would go very slowly if, instead of being given a task, he
were told to do as much as he could. All of us are grown-up children,
and it is equally true that the average workman will work with the
greatest satisfaction, both to himself and to his employer, when he is
given each day a definite task which he is to perform in a given time,
and which constitutes a proper day's work for a good workman. This
furnishes the workman with a clear-cut standard, by which he can
throughout the day measure his own progress, and the accomplishment of
which affords him the greatest satisfaction.
The writer has described in other papers a series of experiments made
upon workmen, which have resulted in demonstrating the fact that it is
impossible, through any long period of time, to get work-men to work
much harder than the average men around them, unless they are assured a
large and a permanent increase in their pay. This series of experiments,
however, also proved that plenty of workmen can be found who are willing
to work at their best speed, provided they are given this liberal
increase in wages. The workman must, however, be fully assured that this
increase beyond the average is to be permanent. Our experiments have
shown that the exact percentage of increase required to make a workman
work at his highest speed depends upon the kind of work which the man is
doing.
It is absolutely necessary, then, when workmen are daily given a task
which calls for a high rate of speed on their part, that they should
also be insured the necessary high rate of pay whenever they are
successful. This involves not only fixing for each man his daily task,
but also paying him a large bonus, or premium, each time that he
succeeds in doing his task in the given time. It is difficult to
appreciate in full measure the help which the proper use of these two
elements is to the workman in elevating him to the highest standard of
efficiency and speed in his trade, and then keeping him there, unless
one has seen first the old plan and afterward the new tried upon the
same man. And in fact until one has seen similar accurate experiments
made upon various grades of workmen engaged in doing widely different
types of work. The remarkable and almost uniformly good results from the
correct application of the task and the bonus must be seen to be
appreciated.
These two elements, the task and the bonus (which, as has been pointed
out in previous papers, can be applied in several ways), constitute two
of the most important elements of the mechanism of scientific
management. They are especially important from the fact that they are,
as it were, a climax, demanding before they can be used almost all of
the other elements of the mechanism; such as a planning department,
accurate time study, standardization of methods and implements, a
routing system, the training of functional foremen or teachers, and in
many cases instruction cards slide-rules, etc. (Referred to later in
rather more detail on page 129.)
The necessity for systematically teaching workmen how to work to the
best advantage has been several times referred to. It seems desirable,
therefore, to explain in rather more detail how this teaching is done.
In the case of a machine-shop which is managed under the modern system,
detailed written instructions as to the best way of doing each piece of
work are prepared in advance, by men in the planning department. These
instructions represent the combined work of several men in the planning
room, each of whom has his own specialty, or function. One of them, for
instance, is a specialist on the proper speeds and cutting tools to be
used. He uses the slide-rules which have been above described as an aid,
to guide him in obtaining proper speeds, etc. Another man analyzes the
best and quickest motions to be made by the workman in setting the work
up in the machine and removing it, etc. Still a third, through the
time-study records which have been accumulated, makes out a timetable
giving the proper speed for doing each element of the work. The
directions of all of these men, however, are written on a single
instruction card, or sheet.
These men of necessity spend most of their time in the planning
department, because they must be close to the records and data which
they continually use in their work, and because this work requires the
use of a desk and freedom from interruption. Human nature is such,
however, that many of the workmen, if left to themselves, would pay but
little attention to their written instructions. It is necessary,
therefore, to provide teachers (called functional foremen) to see that
the workmen both understand and carry out these written instructions.
Under functional management, the old-fashioned single foreman is
superseded by eight different men, each one of whom has his own special
duties, and these men, acting as the agents for the planning department
(see paragraph 234 to 245 of the paper entitled "Shop Management"), are
the expert teachers, who are at all times in the shop, helping, and
directing the workmen. Being each one chosen for his knowledge and
personal skill in his specialty, they are able not only to tell the
workman what he should do, but in case of necessity they do the work
themselves in the presence of the workman, so as to show him not only
the best but also the quickest methods.
One of these teachers (called the inspector) sees to it that he
understands the drawings and instructions for doing the work. He teaches
him how to do work of the right quality; how to make it fine and exact
where it should be fine, and rough and quick where accuracy is not
required,--the one being just as important for success as the other. The
second teacher (the gang boss) shows him how to set up the job in his
machine, and teaches him to make all of his personal motions in the
quickest and best way. The third (the speed boss) sees that the machine
is run at the best speed and that the proper tool is used in the
particular way which will enable the machine to finish its product in
the shortest possible time. In addition to the assistance given by these
teachers, the workman receives orders and help from four other men; from
the "repair boss" as to the adjustment, cleanliness, and general care of
his machine, belting, etc.; from the "time clerk," as to everything
relating to his pay and to proper written reports and returns; from the
"route clerk," as to the order in which he does his work and as to the
movement of the work from one part of the shop to another; and, in case
a workman gets into any trouble with any of his various bosses, the
"disciplinarian" interviews him.
It must be understood, of course, that all workmen engaged on the same
kind of work do not require the same amount of individual teaching and
attention from the functional foremen. The men who are new at a given
operation naturally require far more teaching and watching than those
who have been a long time at the same kind of jobs.
Now, when through all of this teaching and this minute instruction the
work is apparently made so smooth and easy for the workman, the first
impression is that this all tends to make him a mere automaton, a wooden
man. As the workmen frequently say when they first come under this
system, "Why, I am not allowed to think or move without some one
interfering or doing it for me!" The same criticism and objection,
however, can be raised against all other modern subdivision of labor. It
does not follow, for example, that the modern surgeon is any more narrow
or wooden a man than the early settler of this country. The
frontiersman, however, had to be not only a surgeon, but also an
architect, house-builder, lumberman, farmer, soldier, and doctor, and he
had to settle his law cases with a gun. You would hardly say that the
life of the modern surgeon is any more narrowing, or that he is more of
a wooden man than the frontiersman. The many problems to be met and
solved by the surgeon are just as intricate and difficult and as
developing and broadening in their way as were those of the
frontiersman.
And it should be remembered that the training of the surgeon has been
almost identical in type with the teaching and training which is given
to the workman under scientific management. The surgeon, all through his
early years, is under the closest supervision of more experienced men,
who show him in the minutest way how each element of his work is best
done. They provide him with the finest implements, each one of which has
been the subject of special study and development, and then insist upon
his using each of these implements in the very best way. All of this
teaching, however, in no way narrows him. On the contrary he is quickly
given the very best knowledge of his predecessors; and, provided (as he
is, right from the start) with standard implements and methods which
represent the best knowledge of the world up to date, he is able to use
his own originality and ingenuity to make real additions to the world's
knowledge, instead of reinventing things which are old. In a similar way
the workman who is cooperating with his many teachers under scientific
management has an opportunity to develop which is at least as good as
and generally better than that which he had when the whole problem was
"up to him" and he did his work entirely unaided.
If it were true that the workman would develop into a larger and finer
man without all of this teaching, and without the help of the laws which
have been formulated for doing his particular job, then it would follow
that the young man who now comes to college to have the help of a
teacher in mathematics, physics, chemistry, Latin, Greek, etc., would do
better to study these things unaided and by himself. The only difference
in the two cases is that students come to their teachers, while from the
nature of the work done by the mechanic under scientific management, the
teachers must go to him. What really happens is that, with the aid of
the science which is invariably developed, and through the instructions
from his teachers, each workman of a given intellectual capacity is
enabled to do a much higher, more interesting, and finally more
developing and more profitable kind of work than he was before able to
do. The laborer who before was unable to do anything beyond, perhaps,
shoveling and wheeling dirt from place to place, or carrying the work
from one part of the shop to another, is in many cases taught to do the
more elementary machinist's work, accompanied by the agreeable
surroundings and the interesting variety and higher wages which go with
the machinist's trade. The cheap machinist or helper, who before was
able to run perhaps merely a drill press, is taught to do the more
intricate and higher priced lathe and planer work, while the highly
skilled and more intelligent machinists become functional foremen and
teachers. And so on, right up the line.
It may seem that with scientific management there is not the same
incentive for the workman to use his ingenuity in devising new and
better methods of doing the work, as well as in improving his
implements, that there is with the old type of management. It is true
that with scientific management the workman is not allowed to use
whatever implements and methods he sees fit in the daily practice of his
work. Every encouragement, however, should be given him to suggest
improvements, both in methods and in implements. And whenever a workman
proposes an improvement, it should be the policy of the management to
make a careful analysis of the new method, and if necessary conduct a
series of experiments to determine accurately the relative merit of the
new suggestion and of the old standard. And whenever the new method is
found to be markedly superior to the old, it should be adopted as the
standard for the whole establishment. The workman should be given the
full credit for the improvement, and should be paid a cash premium as a
reward for his ingenuity. In this way the true initiative of the workmen
is better attained under scientific management than under the old
individual plan.
The history of the development of scientific, management up to date,
however, calls for a word of warning. The mechanism of management must
not be mistaken for its essence, or underlying philosophy. Precisely the
same mechanism will in one case produce disastrous results and in
another the most beneficent. The same mechanism which will produce the
finest results when made to serve the underlying principles of
scientific management, will lead to failure and disaster if accompanied
by the wrong spirit in those who are using it. Hundreds of people have
already mistaken the mechanism of this system for its essence. Messrs.
Gantt, Barth and the writer have presented papers to, the American
Society of Mechanical Engineers on the subject of scientific management.
In these papers the mechanism which is used has been described at some
length. As elements of this mechanism may be cited:
Time study, with the implements and methods for properly making it.
Functional or divided foremanship and its superiority to the
old-fashioned single foreman.
The standardization of all tools and implements used in the trades, and
also of the acts or movements of workmen for each class of work.
The desirability of a planning room or department.
The "exception principle" in management.
The use of slide-rules and similar timesaving implements.
Instruction cards for the workman.
The task idea in management, accompanied by a large bonus for the
successful performance of the task.
The "differential rate."
Mnemonic systems for classifying manufactured products as well as
implements used in manufacturing.
A routing system.
Modern cost system, etc., etc.
These are, however, merely the elements or details of the mechanism of
management. Scientific management, in its essence, consists of a certain
philosophy, which results, as before stated, in a combination of the
four great underlying principles of management:*
[*Footnote: First. The development of a true science.
Second. The scientific selection of the workman.
Third. His scientific education and development.
Fourth. Intimate friendly cooperation between the management and the men.]
When, however the elements of this mechanism, such as time study,
functional foremanship etc., are used without being accompanied by the
true philosophy of management, the results are in many cases disastrous.
And, unfortunately, even when men who are thoroughly in sympathy with
the principles of scientific management undertake to change too rapidly
from the old type to the new, without heeding the warnings of those who
have had years of experience in making this change, they frequently meet
with serious troubles, and sometimes with strikes, followed by failure.
The writer, in his paper on "Shop Management," has called especial
attention to the risks which managers run in attempting to change
rapidly from the old to the new management in many cases, however, this
warning has not been heeded. The physical changes which are needed, the
actual time study which has to be made, the standardization of all
implements connected with the work, the necessity for individually
studying each machine and placing it in perfect order, all take time,
but the faster these elements of the work are studied and improved, the
better for the undertaking. On the other hand, the really great problem
involved in a change from the management of "initiative and incentive"
to scientific management consists in a complete revolution in the mental
attitude and the habits of all of those engaged in the management, as
well of the workmen. And this change can be brought about only gradually
and through the presentation of many object-lessons to the workman,
which, together with the teaching which he receives, thoroughly convince
him of the superiority of the new over the old way of doing the work.
This change in the mental attitude of the workman imperatively demands
time. It is impossible to hurry it beyond a certain speed. The writer
has over and over again warned those who contemplated making this change
that it was a matter, even in a simple establishment, of from two to
three years, and that in some cases it requires from four to five years.
The first few changes which affect the workmen should be made
exceedingly slowly, and only one workman at a time should be dealt with
at the start. Until this single man has been thoroughly convinced that a
great gain has come to him from the new method, no further change should
be made. Then one man after another should be tactfully changed over.
After passing the point at which from one.-fourth to one-third of the
men in the employ of the company have been changed from the old to the
new, very rapid progress can be made, because at about this time there
is, generally, a complete revolution in the public opinion of the whole
establishment and practically all of the workmen who are working under
the old system become desirous to share in the benefits which they see
have been received by those working under the new plan.
Inasmuch as the writer has personally retired from the business of
introducing this system of management (that is, from all work done in
return for any money compensation), he does not hesitate again to
emphasize the fact that those companies are indeed fortunate who can
secure the services of experts who have had the necessary practical
experience in introducing scientific management, and who have made a
special study of its principles. It is not enough that a man should have
been a manager in an establishment which is run under the new
principles. The man who undertakes to direct the steps to be taken in
changing from the old to the new (particularly in any establishment
doing elaborate work) must have had personal experience in overcoming
the especial difficulties which are always met with, and which are
peculiar to this period of transition. It is for this reason that the
writer expects to devote the rest of his life chiefly to trying to help
those who wish to take up this work as their profession, and to advising
the managers and owners of companies in general as to the steps which
they should take in making this change.
As a warning to those who contemplate adopting scientific management,
the following instance is given. Several men who lacked the extended
experience which is required to change without danger of strikes, or
without interference with the success of the business, from the
management of "initiative and incentive" to scientific management,
attempted rapidly to increase the output in quite an elaborate
establishment, employing between three thousand and four thousand men.
Those who undertook to make this change were men of unusual ability, and
were at the same time enthusiasts and I think had the interests of the
workmen truly at heart. They were, however, warned by the writer, before
starting, that they must go exceedingly slowly, and that the work of
making the change in this establishment could not be done in less than
from three to five years. This warning they entirely disregarded. They
evidently believed that by using much of the mechanism of scientific
management, in combination with the principles of the management of
"initiative and incentive," instead of with these principles of
scientific management, that they could do, in a year or two, what had
been proved in the past to require at least double this time. The
knowledge obtained from accurate time study, for example, is a powerful
implement, and can be used, in one case to promote harmony between the
workmen and the management, by gradually educating, training, and
leading the workmen into new and better methods of doing the work, or,
in the other case, it may be used more or less as a club to drive the
workmen into doing a larger day's work for approximately the same pay
that they received in the past. Unfortunately the men who had charge of
this work did not take the time and the trouble required to train
functional foremen, or teachers, who were fitted gradually to lead and
educate the workmen. They attempted, through the old-style foreman,
armed with his new weapon (accurate time study), to drive the workmen,
against their wishes, and without much increase in pay, to work much
harder, instead of gradually teaching and leading them toward new
methods, and convincing them through object-lessons that task management
means for them somewhat harder work, but also far greater prosperity.
The result of all this disregard of fundamental principles was a series
of strikes, followed by the down-fall of the men who attempted to make
the change, and by a return to conditions throughout the establishment
far worse than those which existed before the effort was made.
This instance is cited as an object-lesson of the futility of using the
mechanism of the new management while leaving out its essence, and also
of trying to shorten a necessarily long operation in entire disregard of
past experience. It should be emphasized that the men who undertook this
work were both able and earnest, and that failure was not due to lack of
ability on their part, but to their undertaking to do the impossible.
These particular men will not again make a similar mistake, and it is
hoped that their experience may act as a warning to others.
In this connection, however, it is proper to again state that during the
thirty years that we have been engaged in introducing scientific
management there has not been a single strike from those who were
working in accordance with its principles, even during the critical
period when the change was being made from the old to the new. If proper
methods are used by men who have had experience in this work, there is
absolutely no danger from strikes or other troubles.
The writer would again insist that in no case should the managers of an
establishment ', the work of which is elaborate, undertake to change
from the old to the new type unless the directors of the company fully
understand and believe in the fundamental principles of scientific
management and unless they appreciate all that is involved in making
this change, particularly the time required, and unless they want
scientific management greatly.
Doubtless some of those who are especially interested in working men
will complain because under scientific management the workman, when he
is shown how to do twice as much work as he formerly did, is not paid
twice his former wages, while others who are more interested in the
dividends than the workmen will complain that under this system the men
receive much higher wages than they did before.
It does seem grossly unjust when the bare statement is made that the
competent pig-iron handler, for instance, who has been so trained that
he piles 3 6/10 times as much iron as the incompetent man formerly did,
should receive an increase of only 60 per cent in wages.
It is not fair, however, to form any final judgment until all of the
elements in the case have been considered. At the first glance we see
only two parties to the transaction, the workmen and their employers. We
overlook the third great party, the whole people,--the consumers, who
buy the product of the first two and who ultimately pay both the wages
of the workmen and the profits of the employers.
The rights of the people are therefore greater than those of either
employer or employee. And this third great party should be given its
proper share of any gain. In fact, a glance at industrial history shows
that in the end the whole people receive the greater part of the benefit
coming from industrial improvements. In the past hundred years, for
example, the greatest factor tending toward increasing the output, and
thereby the prosperity of the civilized world, has been the introduction
of machinery to replace hand labor. And without doubt the greatest gain
through this change has come to the whole people--the consumer.
Through short periods, especially in the case of patented apparatus, the
dividends of those who have introduced new machinery have been greatly
increased, and in many cases, though unfortunately not universally, the
employees have obtained materially higher wages, shorter hours, and
better working conditions. But in the end the major part of the gain has
gone to the whole people.
And this result will follow the introduction of scientific management
just as surely as it has the introduction of machinery.
To return to the case of the pig-iron handler. We must assume, then,
that the larger part of the gain which has come from his great increase
in output will in the end go to the people in the form of cheaper
pig-iron. And before deciding upon how the balance is to be divided
between the workmen and the employer, as to what is just and fair
compensation for the man who does the piling and what should be left for
the company as profit, we must look at the matter from all sides.
First. As we have before stated, the pig-iron handler is not an
extraordinary man difficult to find, he is merely a man more or less of
the type of the ox, heavy both mentally and physically.
Second. The work which this man does tires him no more than any healthy
normal laborer is tired by a proper day's work. (If this man is
overtired by his work, then the task has been wrongly set and this is as
far as possible from the object of scientific management.)
Third. It was not due to this man's initiative or originality that he
did his big day's work, but to the knowledge of the science of pig-iron
handling developed and taught him by some one else.
Fourth. It is just and fair that men of the same general grade (when
their all-round capacities are considered) should be paid about the same
wages when they are all working to the best of their abilities. (It
would be grossly unjust to other laborers, for instance, to pay this man
3 6/10 as high wages as other men of his general grade receive for an
honest full day's work.)
Fifth. As is explained (page 74), the 60 per cent increase in pay which
he received was not the result of an arbitrary judgment of a foreman or
superintendent, it was the result of a long series of careful
experiments impartially made to determine what compensation is really
for the man's true and best interest when all things are considered.
Thus we see that the pig-iron handler with his 60 per cent increase in
wages is not an object for pity but rather a subject for congratulation.
After all, however, facts are in many cases more convincing than
opinions or theories, and it is a significant fact that those workmen
who have come under this system during the past thirty years have
invariably been satisfied with the increase in pay, which they have
received, while their employers have been equally pleased with their
increase in dividends.
The writer is one of those who believes that more and more will the
third party (the whole people), as it becomes acquainted with the true
facts, insist that justice shall be done to all three parties. It will
demand the largest efficiency from both employers and employees. It will
no longer tolerate the type of employer who has his eye on dividends
alone, who refuses to do his full share of the work and who merely
cracks his whip over the heads of his workmen and attempts to drive them
into harder work for low pay. No more will it tolerate tyranny on the
part of labor which demands one increase after another in pay and
shorter hours while at the same time it becomes less instead of more
efficient.
And the means which the writer firmly believes will be adopted to bring
about, first, efficiency both in employer and employs and then an
equitable division of the profits of their joint efforts will be
scientific management, which has for its sole aim the attainment of
justice for all three parties through impartial scientific investigation
of all the elements of the problem. For a time both sides will rebel
against this advance. The workers will resent any interference with
their old rule-of-thumb methods, and the management will resent being
asked to take on new duties and burdens; but in the end the people
through enlightened public opinion will force the new order of things
upon both employer and employee.
It will doubtless be claimed that in all that has been said no new fact
has been brought to light that was not known to some one in the past.
Very likely this is true. Scientific management does not necessarily
involve any great invention, nor the discovery of new or startling
facts. It does, however, involve a certain combination of elements which
have not existed in the past, namely, old knowledge so collected,
analyzed, grouped, and classified into laws and rules that it
constitutes a science; accompanied by a complete change in the mental
attitude of the working men as well as of those on the side of the
management, toward each other, and toward their respective duties and
responsibilities. Also, a new division of the duties between the two
sides and intimate, friendly cooperation to an extent that is impossible
under the philosophy of the old management. And even all of this in many
cases could not exist without the help of mechanisms which have been
gradually developed.
It is no single element, but rather this whole combination, that
constitutes scientific management, which may be summarized as:
Science, not rule of thumb.
Harmony, not discord.
Cooperation, not individualism.
Maximum output, in place of restricted output.
The development of each man to his greatest efficiency and prosperity.
The writer wishes to again state that: "The time is fast going by for
the great personal or individual achievement of any one man standing
alone and without the help of those around him. And the time is coming
when all great things will be done by that type of cooperation in which
each man performs the function for which he is best suited, each man
preserves his own individuality and is supreme in his particular
function, and each man at the same time loses none of his originality
and proper personal initiative, and yet is controlled by and must work
harmoniously with many other men."
The examples given above of the increase in output realized under the
new management fairly represent the gain which is possible. They do not
represent extraordinary or exceptional cases, and have been selected
from among thousands of similar illustrations which might have been
given.
Let us now examine the good which would follow the general adoption of
these principles.
The larger profit would come to the whole world in general.
The greatest material gain which those of the present generation have
over past generations has come from the fact that the average man in
this generation, with a given expenditure of effort, is producing two
times, three times, even four times as much of those things that are of
use to man as it was possible for the average man in the past to
produce. This increase in the productivity of human effort is, of
course, due to many causes, besides the increase in the personal
dexterity of the man. It is due to the discovery of steam and
electricity, to the introduction of machinery, to inventions, great and
small, and to the progress in science and education. But from whatever
cause this increase in productivity has come, it is to the greater
productivity of each individual that the whole country owes its greater
prosperity.
Those who are afraid that a large increase in the productivity of each
workman will throw other men out of work, should realize that the one
element more than any other which differentiates civilized from
uncivilized countries--prosperous from poverty--stricken peoples--is
that the average man in the one is five or six times as productive as
the other. It is also a fact that the chief cause for the large
percentage of the unemployed in England (perhaps the most virile nation
in the world), is that the workmen of England, more than in any other
civilized country, are deliberately restricting their output because
they are possessed by the fallacy that it is against their best interest
for each man to work as hard as he can.
The general adoption of scientific management would readily in the
future double the productivity of the average man engaged in industrial
work. Think of what this means to the whole country. Think of the
increase, both in the necessities and luxuries of life, which becomes
available for the whole country, of the possibility of shortening the
hours of labor when this is desirable, and of the increased
opportunities for education, culture, and recreation which this implies.
But while the whole world would profit by this increase in production,
the manufacturer and the workman will be far more interested in the
especial local gain that comes to them and to the people immediately
around them. Scientific management will mean, for the employers and the
workmen who adopt it--and particularly for those who adopt it first--the
elimination of almost all causes for dispute and disagreement between
them. What constitutes a fair day's work will be a question for
scientific investigation, instead of a subject to be bargained and
haggled over. Soldiering will cease because the object for soldiering
will no longer exist. The great increase in wages which accompanies this
type of management will largely eliminate the wage question as a source
of dispute. But more than all other causes, the close, intimate
cooperation, the constant personal contact between the two sides, will
tend to diminish friction and discontent. It is difficult for two people
whose interests are the same, and who work side by side in accomplishing
the same object, all day long, to keep up a quarrel.
The low cost of production which accompanies a doubling of the output
will enable the companies who adopt this management, particularly those
who adopt it first, to compete far better than they were able to before,
and this will so enlarge their markets that their men will have almost
constant work even in dull times, and that they will earn larger profits
at all times.
This means increase in prosperity and diminution in poverty, not only
for their men but for the whole community immediately around them.
As one of the elements incident to this great gain in output, each
workman has been systematically trained to his highest state of
efficiency, and has been taught to do a higher class of work than he was
able to do under the old types of management; and at the same time he
has acquired a friendly mental attitude toward his employers and his
whole working conditions, whereas before a considerable part of his time
was spent in criticism, suspicious watchfulness, and sometimes in open
warfare. This direct gain to all of those working under the system is
without doubt the most important single element in the whole problem.
Is not the realization of results such as these of far more importance
than the solution of most of the problems which are now agitating both
the English and American peoples? And is it not the duty of those who
are acquainted with these facts, to exert themselves to make the whole
community realize this importance?
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