Hi
Originally Posted by: ccranium 
I wonder how, if at all, they pursued continuous improvement and changed the processing over time as someone said "I think we could do this step faster/more consistently?"
Regarding Märklin, I am not a specialist but:
- in the 50s, Märklin was using the traditional drawing board and sliding rule
- in the 80s, Märklin started using computers for designing items,
- in 2010 onwards, Märklin uses Dassault System's Catia (France) a sophisticated design systems used by Boing, Airbus, Dassault aviation and many more. This last system allows to simulate the stress, wear, mobility this means that the prototype phase is reduced to a minimum (almost zero).
Regarding the topic above, M Track manufacturing has evolved drastically from its introduction in 1956 up to 1999.
The first M tracks, even when brand new, was not very precise (ballast not the same level), a little dangerous (I cut myself many times handling new M track in 1960s) and not very prototypical (huge side hole for cables, visible clamps to hold the stud line, etc)
Later (in the 70s and 80s) the M track was modernised:
- small switch lanterns to render compatible long passenger cars
- cosmetic redesign of M tracks so that contact clamps and stud insulation is much more discrete
- precision tooling making that the joint between new M tracks becomes invisible
- redesign of R1 switches allowing a much smaller track spacing
- redesign the double slip switches for cost cutting (no more electrical switches for the current feed)
- redesign, cost cutting of M tracks: removing the paint code under the track (lightmaroon or kaki replaced with metal color)
- replacement of old contact track with slider-operated, directional contact tracks
- new switches were introduced: 3-way switch, double curved switch
- new compact solenoids to drive switches.
Yes this track ended being fabulous 1980-2000 BUT its precision is vastly overtaken by the C Track
Cheers
Jean