The Cooper in Liverpool

Abstract

This report assesses the efficiency in timing and layout of the mass-production system at the Portsmouth Dockyard block mill in the early 1800s. It is based on study of the extant buildings and machines as well as pictorial and written evidence from the past. Early output figures for some of the block-making machines reveal 8 to 17 per cent discrepancies from perfect coordination in timing. This difficulty was apparently offset by use of duplicate machines and by short-term stacking up of semi-finished parts between machine processes. An old line shafting diagram implies that the three sets of machines for making pulley-block shells of different sizes were arranged on one shop floor in a hollow rectangle, each set in its own production sequence. Although not ideal, the machinery's coordination and layout showed a greater rationality of design for efficient production 'flow' than has heretofore been documented for it.