The Iron Age 1914-09-03: Vol 94 Iss 10

PEOVUUAUEEDDUOUDADEEDATE LETTE ERASE aa \" a LL OUPDENOUUUUUGURUDUGUONOUENDNONGEOOOOONOUECRODOROROONNES Established 1855 HH New York, Se VEAUVAVANUNDADUEDUEUELODOOUNDUOVEVOEUEDEDUEDEDOEUELET SOON EU OED ADOEUED ELEN ALELOELE NEY Ys a & 7 \ t 4 & “ ptember 3, 1914. Vol. 94: No. 10 Scientific Management in a Foundry Interesting System Adopted by the Aluminum Cast- ings Company, Which with Bonus Wage Payments Has Resulted in Scientific management has been adopted in many nachine shops, but the principles and methods that appear to have proved successful in various other metal working lines have in but a few cases been applied to any great extent to the management of the foundry. An example of the operation of the foundry along modern lines of scientific manage ment worked out in the completest detail is found in the plant of the Aluminum Castings Company, De- troit, Mich., maker of aluminum, brass and bronze castings. About two years ago this company decided to effect an entire reorganization of its shop system and this work was placed in the hands of F. A. Parkhurst, who became connected with the company as organizing engineer. Shortly before he became associated with this company he had completed the work installing scientific management in the plant of the Ferracute Machine Company, Bridge- ton, N. J., and the scientific methods that have been oT Remarkable Cutting of Costs the Detroit 1 ti I i } applied to lant of the are similar in those adopted in the Ferracute pla only in detail in the routine application. on which the sy installed tific management good shop it should be equally advantageous for a dry. Conditions and processes in fou generally similar that the Detroit plant could be applied to an with very little modification of det: conform with the differences in manufacturi methods and shop practices. ings Company stem was thir iS a ng tor a macnine orie effect in the iron system One of the most interesting feat management is the bonus wage systen nection with it the standardization and classifica tion of work so that standard bonus charts are pré vided for practically every combination light work in the foundry. Now that these standard operation times for the numerous operations have ‘ig. 1—Method Used for Preventing Duplication When Assigning Numbers to Bonus Charts 523 aw : : 524 THE IRO Bonus CHART FORM FAP WP THE ALUMINUM NOTE THE FOLLOWING PRICES WILL BE PAID ™ as ON mee } AS BONUS TW ADDITION TO HOURLY waces | OPERATION Molding S US CHART..5558) BASED OF GOOD FIECES WHICH PASS Ww. SPECTION AFTER THIS SPECHIC OPERATION, En SHEETS, SHer EXGEPT THAT DEFECTIVE NOT DUE TO woRK | SYMBOL ly Of SPECHIED ON THIS CHART WILL WOT BE DE- DATE... July..26 ‘ DUCTED I® PAYING BONUS. THESE BONUSPRICES Wilt NOT @E LOWERED | CUSTOMER John Doe INSTRUCTION NO. .. WO MATTER HOw LONG THE JOB MAY RUN WITH THIS PATTERN, COME BOXES COUIP MENT AWD BY THE METWOD AND DESIGN n : “Iner Cope oo} SPECIFIED 1m THE INSTRUCTION REFERern | ECUIPMENT S-ES EA PE. .ON..WOCGL. EPuck, TO ANO WITH THE HUMBER OF OPERATIVES Difterential Class ~ MENTIONED BELOW ” ° rs “ee . = OPERATIVES AND CLASS NO.... 4.2.01) selapniais | — = | | } o | | « i ™ : *. } 8? L.24€ } | j < 93° 1.309 ' | 44 980 | 1.372 | 1.025 | 1.435 4¢ } 7 1.498 j | j 561 i an 69 11.624 | ; 4 6R7 | i a4 | j | | | | i r a | a oe ee | } | } | | | | | | ' L ‘icine ins ki canal aieataecetialla i = N AGE Septem! 1914 been computed, only a small amount of additiona time study work is required. The bonus wage system is in use in few foun dries, the general practice being to pay the men piece rate or an hourly wage rate. Under the bonus system the men are paid the ruling hourly wages that prevail in other plants in the vicinity and i: addition are also paid the bonus. With the hour rate there is no incentive of the molder to do his best and the piece rate system is claimed to have certain features that are disadvantageous to both the employer and employee. It is claimed that it is harder to maintain discipline when men are work- TIME STUDY Form FAF THE ALUMINUM CASTINGS CO | TIME STUDY NO SHEETS. SHEET ! ARTICLE PIECE SYMBOL } SKETCH OR DRAWING QUANTITY OPERATION | woRK J08 MAN NO MACH. NO DEPT OR ORDER NO TIME AM.P.™ MATERIAL OBSERVER DATE te NOTE—The observer must exercise extreme care making time studies to see that the proper sequence of operation is maintained, thet ali ugneccsssry pe ations or movies are climinated, that proper appliances are pro fed and if machir are used. When time is slow, due to man’s natural slow moves, note (ir speed, Have certain operations repeated if necessary to satis yourself that the tim cowaton DETAIL DESCRIPTION OF OPERATIONS SPEED, CUTS, ETc. So Ss ——j AVERACE | rane | a.™ FINISHED ?.™M. ELAPSED TIME FOR «a certain number hours work per day, and that a day or two when working on a new job. claimed that the additional overhead burden has efficiency of workmen, the output can be materiall) © work see that the proper and most economical combinations of Speed, Feed and Cu ) margin at extreme right below) what time should be for a fast man moving at his best sorm ing on piece work than if they are employed to do man depending on the piece rate alone will often be unable to earn satisfactory wages for the first The system has been in operation long enough to assure the management of tangible results. It has occasioned an increase in office employees and salaries for carrying out the details, but it is been far more than offset by economies that have heen effected by increased production. With greater and continue to do so until the study is satisfactory. rding Time Studies -3, 1914 39 that for a given maximum output capacity is required than if the effi- lacking, and consequently less capital d up in buildings and equipment. As employees, the company’s records show earning more than under the hour in and that they appear well the bonus system. A tour throughout npresses one that the men are working mn instead of trying to do only a mod- work or perhaps putting in their time tle work as possible. re use PLANT ORGANIZATION r executive and administrative heads th the general offices are the president, nt, general manager and general super- vho is also the organizing engineer. The es are located in Cleveland, but as the THE IRON AGE 525 intendent, who is directly ing superintendents in over tne core and those two departments, but who deals with the various miscellaneous depart ments through the planning room, which is one the most important parts of the organization of which he is the nominal head. The functions the planning room are to analyze orders and a range delivery dates, route work through the shops control the order of work, control the balances labor, and adopt standard times for various means of time study data; schedule work in th process of manufacture, have charge tores cluding the requisition and distribution of the analyze costs and exercise chief inspection \ only is the planning room able to predetermine de livery dates, but to a certain extent it predetermin« cost. The working force in the planning room include a production clerk, route clerk, order of work clerk, Molds and Pouring Transmission Case Cast lant is the largest one operated by the the organizing engineer has made his ters at the Detroit plant, spending a por- e time in Cleveland. Other foundries are the company in Buffalo, N. Y., Fairfield, Manitowoc, Wis. After the details of have worked out and put into Detroit plant and the forms and meth- rdized, they are adopted in the other e standardization of the system has made in the other plants rather a simple e bonus charts and other data worked indry are equally adaptable to the been local manager and assista! erintendent and assistant superinten manager pays particular attention to sutine and has general control of pur- the general purchasing agent and in the immediate territory. All rtments are under the plant super- nas a it a es in gs, Showing How W on the Fou Floor Is Spe time study foreman, schedule clerk clerks, stores clerk and chief inspector. Within the organ- ization there is a factory board, which is of the assistant general superintendent, superintendent, clerk, assistant order of . wo cost ( omposed local plant production clerk, order of work work clerk and time st foreman. This local plant board meets every after noon, except Saturday, at 1 o’clock and takes up many of the plant production details, including gen eral planning, fixing of delivery dates, the consider ation of any special technical matters or orders fo1 special castings This board also gos a, plant costs for the day befor NI WAGI In app! ng tne onus wage 4 ner are divided nts eliont cla e rcdir t- the character of work and skill require: The amount of bonus paid gradually increases from ‘ \ which includes unskilled laborers up to Ni 2 which takes in the most skilled workme T) 526 bonus paid in addition to the wage rate for laborers who are in Class 1 for the scheduled maximum out- put is 25 cents per day. As illustration of the classification of workmen, Class 2 includes men who knock out cores, knock off gates and risers and do work. In the highest class, Class 8, are do complicated bench or floor molding which the bonus for the predetermined maximum output is per day. The re- quired for making mold, for example, is determined by and a um dail) output is scheduled for produc tion of that mold. some core men who work, for $2 time a certain time studies maxim in good castings) The payments of the bonus start with a production of 80 per cent. of the maximum and the bonus increases in the same proportion as the increase in production. If an employee is able to exceed what has been figured out to be the maximum production he is paid h 7 ] { » +] { 1] > i ‘ ar ats ‘ | differential rate for the numbe. pieces above’ possible to compile standard data tabk the maximum rd bonus charts that can be used { NERAL ORDER at THE inte ns TINGS CO a + LIMINUM CA>*? nt THE AN 191 | t DER von "*” | Order | worK OR! DATE -% Customer { ORDER ON =~ 6 ser of Mer . Date ; \ } Pieces Start Address Molds sh Customer's No.— | Make _ eam Name of Casting Ss ciiaaiia Deliver to Symbol hia \ = oe } Ship to 1 metal Quantity _ mer Via 4 Custom t Metal___ rae \ Charge Time oT ~ ~~ Bonus Chart ee Remarks 4 FiG.0 ae —— Average Weight— A eee Deliveries: THE IRON AGE Septe ered no matter how long the partic with the same pattern, core boxes, e methods of production. The accom, tration, Fig. 2, shows a typical bo) molding work, this particular work hy the drag on the floor with cope on a t1 a number of men are engaged on tl} work requires two molders of Class 7 The differential for and for the molder 6.3 cents 35 good castings per day, or 80 pe: ers of Class 5. 1.5 cents, maximum each helper receives 5715 ¢ 80 cents. For each addit ves in addition the ar molder man differential. eacn rece TIME STUDY SYSTEM In order to standardize the work The bonus for each class of workman is con puted in the following manner: Assume t h maximum production per day is 85 castings and tl maximum bonus rate is $2 per d In computir the premium payments 50 per cent. « the a mum production is taker s, althou 0 onU na | tor te tl S() ner ce? pl ii t1ol | I pe r cent RH 4 ) 14 n) Sa) : le} per cé 1 dedu 1} [ I mu I ! ot $2 CAVINS i.3v cr s d mer tne l er that repres 0) per cen ( cLne i in uLpU n tnis Cast be 15 a tne juotient is 4 cents. The 10 per cent. deducted fri the $2 is added to this quotient, makin 1.4 cents the amount of bonus paid for each cast ide during the day above <1) per cent. of &5 The 4.4 cents is known as the differenti: For each piece of work a bonus chart is pre pared and this shows the number of pieces to be made during the day from 80 per cent. to the maxi mum, together with the differential or the workmen will ve as bonus for each tional unit of production per day. A copy of tl bonus chart is posted in the department work is being done. Bonus payments good pieces, but defects not due to ation specified on any in paying bonuses. recel [ where th are based on the specific oper onus chart | The bonus prices are not low are not deducted iSSé work, various classifications of w en ] ded. The first classification is a ( ethod to be employed in molding indard methods of bench and squeeze! classified under these two heads, bench cluding work rammed on the bench, tubs d machine work covering work don¢ ind or power squeezers. There are two Class 1, which includes no) and Class 2, which is cored work. The ons of each of the job classes, work, single patterns; plain work, work, single patter irk, gated pattern; complicated work, tern; irregular y"? ern; and complicated work, gated patt have been divided into 15 standard sizé to plane dimensions, and this standard been further carried out by classifying ea es according to five different depths. With this classification of work sta for all of the above combinat up from time studies and standard | pre pared. tables combinations of work figured out and For each of the 42,334 conditions thes¢ the number of molds to be made per da ber of castings per day and the standard ! number. These tables of time operatio! on times These referred -3, 1914 THE IRON AGE 527 xy work will be printed shortly in book an idea of their scope and the work o prepare them is indicated by the fact mtain over 125,000 figures and will fill 250 pages. the tables are used can be made clear ¢ to a specific case. Take, for example, ‘b with a gated pattern, six on a gate, red work with six cores to set, to be > x 16 x 9-in. flask rammed on a bench by ng cored, the job comes under job Class 2. egular gated pattern and this sub-classi- ers to the proper page of tables under the thod. On the proper page opposite the and in column headed by “six cores to und that the maximum production for a hours is 126 molds, or 756 pieces. In column is a number that refers to the nus chart for that particular piece of a moment’s time is required to refer hart file kept as a card index system bonus chart all figured out. sifying and systematizing the work ll figured out before the pattern is orkmen know what the bonus rate is tart on a job. In case the work is pecial that is unclassified additional nay be required. In a case of this kmen are always anxious to have the soon as possible after they start on time studies that will be the basis and bonus chart the time required by) an is taken or of a group of men if it work like a large mold that requires of several men. On machine work me for three jobs is usually taken. § time studies are taken on a molding ng on the work. On small bench work and time studies have been taken. In aking time studies of core making and ords are taken of the time required in and of the time required in the trim- last and molding room. These studies i on a blank shown in Fig. 3. Bonus tabulated in the bonus charts increase + } with production of single pieces, lots of 10 and lots of 100, and in some cases with an output of a lot not having a decimal number. In the chart illus trated the bonus increases with each additiona casting, but in the case of a small core the bonus based on additonal hundreds produced. However in all cases the bonus earned is figured to the exact number. An interesting time saving method was adopted by the time study man in assigning bonus chart numbers. A number of long paper tapes were pended over a roller and around a desk as shown i Fig. 1, these tapes bearing numbers from |] 12,000, the latter number representing maximun number of pieces called for on standard charts for small flask work. These tapes were used in assigning bonus chart numbers to standard pré duction. As the same number of pieces have th same bonus and consequent! the same bonus cl number, when one clerk called off the number pieces another referred to the corresponding ber on the tapes to see if a bonus chart number | already been given to that number of pieces for : ? some other work. If a bonus chart number wa found to have already been marked opposite the number of pieces on the tape, this same number wa reassigned to the other standard type of productior thus preventing duplication of identical | is char with different numbers. In this way the number bonus charts was reduced to about 1600. Work is specialized as much as possible thre out the plant. For example, molders do no pi ing, this being all done by a pouring gang. Nor d the molders shake out their molds after a da work. This is done by lower priced, common labot Fig. 4 shows a gang employed molding transmissior cases. A molder is finishing a mold, a helper ramming a mold and the castings are being pour: by the pouring gang. ORGANIZATION RECORD The entire detail of the plant organization, co1 trol and operation is contained in an organization record of several hundred typewritten pages ar ranged and classified for handy reference. The duties of the various office employees and others Sen a 528 THE IRON AGE 6 DAILY SCHEDULE AND JOB TALLY THE FOLLOWING COUNT WAS MADE By NOTE—Planning room must fill in six (x) colums one (1) dey ahead FORM FAP 115 TO BE MADE IN DEPT OATE | APPROVE THE FOLLOWING AS CORRECT TO THE BEST OF MY KNOWLEDGE ANO BELIEF Septem O THE ALUMINUM CASTINGs TITLE Dept. Fore = = => rs YS || = Se = —— = === SYMBOL | Pattern or x xX) } ‘iin 2 X | Core Box . | Time | Bench or | Chart No. | TALLY | No. (x 2. | Floor No. | x be posted every time count is made as pieces are finished during the da ——— ot —— + ————=+ + + + 7 = = outside of the regular plant laborers are explicit]; defined so that an employee familiar with the por- tion of the record relating to his department can have no uncertainty as to the extent of his duti or the limitations of his authority. The record also contains the full details of the shop system. As ar illustration of the scope of this record it may be mentioned that nine typewritten pages are devoted to detailing the duties of the day and night watchmen. The plant is divided into a large number of dé partments which for convenience in keeping records are symbolized by numerals and letters. There are five core rooms and five molding rooms, each a sepa- rate unit. Core room No. 1 is designated, for ex ample, as 1C. There is also a sub-division of the molding and core room units into floors. Each aluminum molding room is divided into 30 floors, two of these being used for the storage of patterns not in the sand, and for the time keeper and for man. From one to six floors are used for a job. All core benches, molding machines and other equip ment are symbolized and numbered. When further identification is desired to distinguish equipment in a particular plant additional letters are employed as symbols. For example, D M 18 designates molding machine No. 18 in the Detroit plant. All shop orders are handled through the plan ning room by the route clerk. An order for a cus tomer’s work, Fig. 5, goes to the planning room from the sales department as a general order. It contains customer’s name, name of casting and quantity, and columns are provided for date and quantities of shipments, the latter items being en- tered on the order as shipments are made. On the back of the form ruled spaces are provided for the shop routing. After the order has been issued and the work routed the entries on the back of the form show what work has been routed and where. The general orders are issued in duplicate, one being for the planning room and the other for the shipping room files. A cost sheet is opened for each general order when it reaches the planning room. On receipt of the general order the route clerk analyzes it and issues the proper orders to the shop known as work orders. The order must be an alyzed to determine what part of the work is to be done by the several departments necessary to fill the order. In some cases the route clerk will have to consult the production clerk or superintendents and sometimes the factory board. A copy of the work order, Fig. 6. is sent to the foundry, core room. or to whatever department is to do the work snecified, and another copy is retained in the plan- nir* room. being hung on the planning board, Fig. 7 1? il that occupies a large wall space in that room. Space Which the Work Clerk Must Maintai: is provided on this board for every ber floor and machine in the plant as well vidual units of various other departm: large letters at the top of the board sh partment is covered by the square hx example, on the squares under “1C” ar: work orders of work that is being don core room. Each space on the board is doubk the lower half is hung the work order follow the one that is being filled. Each department out in the shop h: corresponding to its section of the bi planning room. On it are hung the w that come to that department. When an o1 completed it is so marked on the work order shop and the shop order is sent back to the plan room and its duplicate is taken off the plan room board. There are two methods of checking pent in the shop on an order. One of thes« ing a blank with the work numbers listed in 1 cal order. As each work order is made out the number to which the work applies is listed on this blank. At the same time the routing as provided for on the back of the general order is filled When a work order is returned to the planning r the work number is erased. This prevents being charged in the shop on job time cards aga work numbers that have been completed. The route clerk is responsible for keeping shop supplied with orders, but he is not responsibie for the order in which the work is done, that being entirely up to the order of work clerk. The ™ sponsibility for the maintenance of the deliver schedules rests on the latter clerk, who must sé that operations are completed according to the daily schedule and job tally sheet shown in Fig. 8. Each department is furnished with one of these sheets 0 which is scheduled the work to be done in that oe partment during the dav and on this sheet is posteé the number of pieces finished every time is made. The schedule clerk is an assistant to the order work clerk. His chief duty is to see that var a chedules and records are kept up to date ne works with the order of work clerk in plan! ng and recording the schedules of operations t r formed and follows up details after the wor the shop has started. One of these schedules process schedule which is a graphical re ing the chief operations on all unfilled orders ae compiled from the general order when it planning room. A red ruled line on the s indicates work planned for the future line indicates work already done. This kept up every day and a break in a lin Sont 3, 1914 was done on a particular job during \s indicated by an explanation of their work of the route clerk, order of work schedule clerk are all closely connected nnot work out his day’s detail without with the others. ol the shop methods after the work sued a daily schedule is made out each department of the work he is next day, and this is also used both for his day’s work and by the time clerk tally of each day’s work. The sched- to be very careful in making out the ed parts on various daily schedule and eets so that previous shortage of e provided for as well as to prevent on some parts and a delay in the ther parts. ior ‘ 0 tne some pro COST KEEPING any kind is done without authority anning room in the form of work the work number all and other expense The closes all cost sheets for work com- mns are provided on these sheets for for labor, material and sundries, footed up give the prime cost. To the ided the prevailing overhead burden to tal manufacturing costs. In the upper rner of the cost sheet space is provided ipitulation of Space is provided at the sheet for th a h bears to which 1S charged. costs. THE IRON a29 AGE being filled in daily the daily and the defective castings reported. The timekeeping department consists of a time keeper in charge of the time clerk in each department. reports to the planning sponsible to the production clerk. and men’s time card from production reco! office, and under | Che and IS The ch department are a timekeepe room directly re time clocks racks in @a inclosed in cases and kept locked, except for a few minutes at going to work and quitting time, thes« being in charge « the time clerk of that depart ment. If a man comes in late he finds h ard and the clock locked up and he is unable to 1 his time, but must go to the timekeeper and find he can have employment that day. Possibl other man has been put on the job, so that the tard workman will not be needed. Having tne lock under lock and key also prevent n from ring ing in his time and lea during the day withou the foremen’s permission. The shop time cler! keep record of the time each man puts in o1 rit jobs in the da This is done « ob time card issued daily by the timekeeper for each job, the time of starting and quitti: VOI tne f stamped on the card with K stam] Differer colored job time cards are provided for each de partment. The time clerk as well as the mar gang of men working on a b has a bonus cha for the particular job that is being don rh returned to the planning room as soon as the jol is finished. The bonus charts while in the shop are hung up and protected by a gl: . > : . > . . . ; ; } lé P PI tT production record, this In addition to the regular routine pectior Form FAP ™ M CLASSIFicaTION mETHOO Job Clas leach Aoous Chart Machine Boeus Class | Ma tine - f Castings * es Met L = . ania = i r <== = = + = = = T | T | | ; a r + + = —— oe +— ——+ = =+ = ; . ’ j | | j j | } I i t i ; | | DAILY PLANT REPORT . THE ALUMINUM CASTINGS CO | | | - t ru Plant Report | ? MAN DAY REPORT DAILY PRODUCTION AND Cost REPORT | t } i t t Dete Dete crass A | i ’ } oils my Ansent ait.) Dews. | tere | Sesp | aneent Po. | pane | = Srenatien roune of eer a t " Tora! ” mou Rs Mes ers | Shep Wort 10 = = as j L be. per man dey COST PRR LE } ’ + + ; ; ; ; ; 4 ; | \ i ’ ” Dee casas B : | | } | i | | } | IN OFERATION CASTINGS FroOUNDEY . aoe 1 | ' " Viners “abe) | than) eve “oe fl H + aT T T | t " ; : iad ' 4 , | 7 . | ” Te ? | | Men Deve | Shap Ware ; } . | + + + - 2 seg + + + + + sr > Tt os + . + + + t a Lbs. per man d« OST PER ifs i | | ; : ; ; 4 t | i] ox Dete ass ( 4 ‘ . — x 5 IN OPERATION ASTINGS FOUND 1 f ™ ce Peers ~ ial Lae _ | | | ; ae ¥ > ; ’ | i om i | | om z | ; 1 4 j } + i TOTALS Teal + | | t Remerhe wovas “ = Shee Ware 4 } 1 } } = oS — : par a 2 4 odes 42) 27 | 2) 2 oe u j Lhe per wen dey COST Free La i U } } +—_4._f ; } } | | tt SUMMARY (lest previous production date shove) @ TOTAL oF ciasses A, B, C. | | , t | i Direct end indirect labor was distributed to the folowing IM OFERATION CASTINGS | POUNDEY . ? t t ; ; Clee POURED DEFECTIVES, + wpe | 4 order greepe Pieers . ee te) ereCrive < : | ; ' } | ! | 1 i wouns . A + ; ; + ; t i \ Castings Prodset A. B.« B i | i ; } } } camel + i M eealleneoes Orders Me c ' 1 f | Stock Orders L | | | | q L* t “ Property Acct r + ; ; ; r ' ’ 4 ; = i 7 o i i i } = j = LD Gasiy Daa . Furi OVERS aT woes aaa al tai le _ OES sun aneenaen ao = ———— 7 AVERAGE TOTAL Lie per eee ders Coe per Le cording Production for Every Day on Each Pr: ict for Giver I I x Production « tr P t standards of production are established from time to time on various work by agreement with the customers. If the question is raised as to whether a piece is up to the standard the matter is referred to a committee consisting of the service inspector, superintendent and chief inspector, the latter being responsible for the shop inspection. Otherwise the decision of the chief inspector is final. A perpetual inventory of stock is kept on stores cards, one of which is provided for each class of material. As material is taken from the rooms the amount left and also its value is entered on the card. The danger limit for stock is entered on a space provided for that glance at the card will show its replenishment should be given. Miscellaneou stores are kept in tiers and bins, the space in the section being recorded on the Requisitions for material aré¢ made out by the foreman of a department where wanted, approved by the requisition form store purpose, so that a whether an order for section and ecard. the purchase of superintendent, and a is filled out and marked O.K. by the manager, who sends it to the purch asing agent. When employees are to work overtime a form is used for an overtime order issued by the room containing the date and employees’ names and numbers, this being filled out from a slip requesting the overtime work, approved by the superint A copy of planning endent. order goes to the watchmal ail, the overtime and unless a mal! name is on the order the watch not to permit him to enter the Li man has instructions plant. The making memoranda on pad calendar of an appointment or something t done at some future date has been by the substitution of a memo.” The necessary one of these blanks on which is also entered the date on which the matter is to receive attention and this is taken in charge by the filing clerk, who sends the memorandum to the employee or official for whom it is intended the first thing in the morn ing of the day shown by the the randum. By use of this form a department head can have his own attention called to something that he is to do on a certain future day or he instructions to some employee to do a particular day. dum of matter his attention. usual method of pe done away known as a memorandum is witn form “tickler made o1 date on memo- can ISSue something 01 In the latter case the memoran course + goes to the who is to give the man Other forms used previously referred to include a production card production for entering a detailed record o! shipments for each day of the month, a summary compiled from the cost sheets, daily metal report, daily } report, show ing total daily production, and standard core rout ing card which also tells where every core is and how many are used to a mold. and cost plant nade EMPLOYMENT, SHOP AND OTHER RULI The employment agent is under the direct charge THE IRON AGE pepten 1914 of and responsible to the superinten sole charge of hiring men, but cannot tional labor without the approval of tendent. A rule somewhat out of line practice is one that requires that ever for work be given the satisfaction of and be asked to make out an applicatio. of this policy is to make the men feel t pany is taking some interest in them they are again looking for work the likely go to that plant first rather than 1 where they were quickly dismissed wi mation that no help was needed. W plentiful and labor is scarce, the compa it will secure a better class of workme: consideration when additional labor Various shop rules form a part of th tion record and these are posted thr plant. Employees must report to foreme condition of tools, machines and other and the latter must report to the prod If repairs are not made within reasona foreman must so report to the superint: accidents, however slight, must be report: ing by the department foreman to ths dent, who must pass the report on to with may be nec: care and maintenance of the plant is unde: tenance foreman who is responsible to the su whatever comments af intendent through the planning department. under his direction have charge of the janitor W daily inspection, repairing and cleaning of chinery, inspection of the electrical equipment the operation of the power plant. COSTS CUT BY SCIENTIFIC MANAGEMEN! Coming to the vital question as to whether or! scientific management in this plant has reduced t cost of production, a very complete record ot! cost of making castings under the new systen management and bonus payments has been kept the figures found in this record show conclusiv' that there is a remarkable reduction in the as compared with the old form of management the day These figures also ine that the employees have also fared well 1! ing their earnings by increased effort. Compa over 400 jobs, job for job, with similar rk @ inder the old system with day wages, the ngu! show an average increase of production 0! - with scientific management payments, a reduction of 58 per cent. rate system. per cent., labor cost of production and an averag‘ wages amounting to 28.9 per cent. Th in the total costs, it can be assumed, wi! what below the 58 per cent. saving on la reason that it is admitted that the cost ' ing the system is greater than under of management, so that the overhead higher As examples of the greater efficienc) -3, 1914 THE IRON AGE 531 onus system it is stated that 60 to 65 molds was an average day’s work under ystem. Under the bonus system this been increased to 135 to 140. The latter s a bonus of $1.25 per day. The former f six-cylinder crank-case molds, in- setting of cores ready for pouring, was lds per day; now it is 45 to 50. The ng table contains examples taken at the company’s record of several hun- and shows the comparative costs, in- duction and per cent. the cost has been A Case of Quantity reduced, each case being the comparison of similar jobs under the old and new systems. In a very few exceptional cases the figures show a slight increase in the cost of production, but in practically all cases the cost of production has been reduced at least 30 per cent. The figures show a wide range of percentage through which the costs have been reduced on different jobs. That there is this wide range in the percentage of cost reduction is att uted to the rule of thumb methods ordinaril ed in foundries and the inaccuracy in figuring out costs under these older methods Production Molding Pattern All in the Cope, Which Was Made on a Stripping Plate Machine —The Drag Made on a Dummy den’s Foundry & Machine Company, Ga., has developed an interesting method what are called gin saw frames or gin f the frames are exact duplicates of the are finished smooth on the face by It was figured that as 100,000 of the re to be furnished each year, it would be mount the patterns on a stripping plate nd to use a pneumatic ramming head for pe of the mold. These gin ribs or frames ’ the same thickness to provide an equal pull the cotton through, and the chill for this p pose was placed in the drag, as is shown in one of the accompanying illustrations. After the drag was rammed up and the sand struck off it was rolled over on the ball and socket joint to a bed made for it back of the dummy. This bed was made by striking off the sand back of the mold level with the track. The joint on the drag was of the ball and socket type, the same as that on the cope. Two copes were placed on each double drag and separate gates were provided for pouring the cope. 1 Gin Saw Frame Pattern Showing the imatic Ramming Head + he saws. The patterns are chilled on edges to prevent wear. this work it was planned to have one the molding, and with that idea in erns were arranged on a stripping ’ with a pneumatic ramming head, the flask being the same shape as the the mold. The back of the rib is cast in that the face or the flat side which is will be perfectly clean. There is a ball nt on the cope, as indicated in the vas made on a dummy, the surface of the shape of the face of the rib. This inted on wheels and rolls along the on a track. One man can handle ming up and rolling over of this por- old. The surface of the gin rib has to space of 2 in. where the gin saws The Dummy Drag with the Chill in Position A Group of Molds Rea: for Pouring e Manufacture of the Steel Rim Pulley The Successive Operations from the Casting of the §] Grinding of the Steel Pulley Face The success which has attended the use of the steel rim pulley lends interest to the process of facture of this type of construction. The steel plate rim gives to this pulley a much greater tensile strength than the solid cast pulley; the cast- iron spider a stiff construction in comparison with the pressed steel pulley, while the combination of steel rim and cast spider, accurately assembled, vields a true running and well balanced pulley. Exactness in construction rests on grinding both yider to the Final match plate has radiating grooves cor: each arm of the spider, the arm pat being cast with lugs which fit into th securing both the alignment and cents patterns. A drilled hole in the cente: centers the core print. Cope and dr; tically identical except for the gating vides for pouring the casting through one on each side of the core print. The taken from the cupola in 1500-lb. ladle: spider and rim to finished sizes, while the steel handled by crane and ladle car to the px plate gives a bette where the hot met: pulley face than is transferred has been found pos bull ladle sible to secure b about 750 The grinding cast iron. Around this style of pulley the business of the Medart Pat ent Pulley Company, St. Louis, has large- ly developed, al- though the company now manufactures a full line of trans- mission machinery. The steel rim pul- leys are made in sizes from 8 in. in diameter and 3-in. Fig. 1—Molds and Match P face to 168 in. in diameter and 50-in. face, using plate up to °s in. in thickness for the rims. Illus trating the successive operations from the casting of the spider to the final grinding of the pulley face, the accompanying views are here presented. The pulley spider is cast in a two-piece mold made in cast-iron flasks from a match plate with metal patterns. The match plate is laid on the foundry floor and the mold rammed up by hand. Fig. 1 illustrates the match plate for a 24 x 40-in. pulley with the arm patterns and core print mounted and the cope and dray molds ready for setting the hub core, locking up and pouring. The 9 532 air hoists used handle the and molds _ serv also in support the ladle for pour- ing. For all pulleys up to 144 in. in diameter, the molds are made from a match plate, and the spider arms are cast solid as_ indi- cated by the pat- terns, the arms for Pulley Spider } trindinge Snider to Finished C I the largest sizes only being cored out in w! the spider molds are made by ordinary met To reduce the amount of grinding on the face the arm lugs when finishing the spider, th - are cast with corrugations. In the case 0! SP pulleys, two of the lugs are cast longer anc to give a bearing for making the rm this is only for the smaller sizes and lig ice pulleys. In the larger pulleys the staggered with the spider arm contacts, '' being made and reinforced with a T-shapee Sie casting. The number of arms in the stee! rm ley is larger than for the same diameter C 3, 1914 il cross-section is, of course, smaller. machining operation is the usual one he hub. For the largest vertical boring machine with jigs for accurately centering the spider is used, smallest th lathe head and chucking dog. In- es are bored out in an upright drill- with a vertical boring bar. The spider on the face plate by gauge and the hub at high speed. One light finishing cut Fig. 2 ] Les hee sizes a spe- pulleys a simple horizontal ken. This set up is shown in ng for the set screw follows, or in the pulleys this drilling is for the holding hub. 1 In casting the split spider the away except for a thin fin which is now uugh but left rough so that when the THE IRON AGE ddd straight and crown face pulle he t rim to the spider is hand work consisting three steps illustrated in Fig. 4 The spide mounted on an arbor and the rim circle as rolled is drawn up around it to an exa t th a serew 1 steel ring clamp. The erlay} en market shearing. The rim is fitted again, the of the rim being filed to an exact fit wit] é arm in full contact with the rir \ ing the ring clamp securing the rim o1 the rivet holes are then d ied W 1} the adjustment of rim to sp W1 The pulley is then mounted on a stand, th bottled up and yoke riveter suspended tne rivets arivel Vil a f The finishing operation consi face and edges of the pulley rim iwain fitted together they will be brought exactly the same relation as when cast. r is then mounted on a horizontal arber ral adjustment and outboard bearing and grinding the faces of the rim lugs to a concentrically with the pulley axis and red diameter as shown in Fig. 3. steel is standard flange steel shipped ll in pulley face widths and approxi- ference lengths. The rolling into cir- ne on the usual bending rolls, the equip- } 1; i ing both parallel and taper rolls for This grinding is illustrated in Fig. 7. In order to preserve the normally uniform cross-section of the steel plate rim, the greatest irregulariti n the rim are trued up before grinding. This preserves the balance of the pulley, saves metal in the rin and reduces the amount of grinding necessat The special rigs upon which the pulle: ire mounted are made in a range of sizes t ‘ date pullevs of different diameter and are equ ed with hand feed. The operators become very ex- pert in finishing the pulley face with the result that there is a minimum cutting of metal. Dry and Green Sand Castings Compared Reason for the Superiority of the Former —Precautions in Using and Preparing the Molds for Small and Large Castings Dry-sand molds produce Ci f 1G f t after by machine tool builders, those made in green sand. While the metal poured creasing the hardness. Some found: into the green-sand mold may be identical with the smile at the suggestion that metal can metal poured into the dry-sand mold, the dr -sand after it enters the mold but nevertheles casting will be more easily machined, and will be and is done successfully. freer from internal strains than the casting made The reason the dry-sand mold produ in green sand. The surface of large castings when casting than the green-sand mold is e) made in dry sand is much smoother and more uni describing the reason why a stronger form, and more true to pattern than any made in produced. green sand. The dry-sand casting develops fewer The dry-sand casting is cleaner bec: sand holes and other similar imperfections while is less danger of the surface of the mold going through the machine shop. We mig detail that the dry-sand mold produces the follow- and it is recognized that nine-tenths ot ing results in castings: makes them smoother, holes found in machine castings are th stronger, softer, cleaner and reduces internal § the action of the metal on some part of ht say in or cutting when it comes in contact with strains. It is possible to allow the metal to drop o1 The reason the casting is smoother is becaus« surface of the mold for a short period the surface of a dry-sand mold when properly _ iron reaches this point in dry sand, whicl rammed, is hard enough when dry to allow the very dangerous in green sand. The qu workman to stand upon it without making any im freeing the mold from foreign matter, suc] pression in it. This hard surface when proper); etc., that has been created in placing the cor vented, resists the pressure of the liquid metal anchors, is simplified in dry-sand work as a he: when the mold is filled and overcomes any irregu blast of air can be introduced into the corners a1 larity caused by soft spots in the surface of the crevises without damage to the mold. In mold which is always in evidence in green-sand the same casting in a green-sand mold, it molds. As the material used to make these molds _ sible to extract all the sand and dirt tl is necessarily very open and the mold is thoroughly cumulated after the cores are placed. dried, there is no necessity of surface nailing. pl , which eliminates one more objectionable decoration ANNEALING EFFECT OF THE MOLD always found on a large green-sand casting; as the The annealing action of the mold on a surface nail mold produces numerous small imper- is ver) beneficial in reducing the internal str: fections at every point where the head of a nail is in large bed or cylinder castings. Dry-sand exposed to the metal. The fact that a heavy coat are not shaken out until the day after the of carefully prepared plumbago is applied to this poured. This provides 12 or 14 hours annea kind of a mold and carefully slicked down and fin which improves the quality of the casting, as I: ished with a camel brush is one more reason why a_ internal strains are concerned, at least 25 per smooth casting is produced. The hard surface of the mold and cores caust casting to retain the weight and sections provid DRY-SAND CASTING STRONGER nt for by the designer, who has, no doubt, taken The dry-sand casting is stronger than the consideration internal strains and _ contract green-sand casting because when the metal in the With a green-sand mold this is possible onl; mold begins to solidify, the heat from the same has limited extent. a tendency to expand the material that constitutes One more advantage of the dry-sand m the cores and mold; and a compression of metal which is very important, to the manufacturers takes place which has a tendency to close up any machinery, is the fact that the castings thal open or soggy spots that usually occur in a casting produced after this method, are closer to the « of many irregular sections. Not so with the green- signer’s weight than any made in green sand and mold. When this expansion of metal takes a green-sand mold was rammed hard enoug! place just before the solidification, instead of a withstand the pressure of the metal, the iron compression of the metal, the surface of the green- not lay to the surface of the mold, but w sand mold gives way. it very badly and produce dirt. Another reason why the dry-sand mold pro duces the stronger casting is, that the character of the surface of the mold is such as to retain the The above description of the advantag* heat which tends to anneal the casting. This, and dry-sand mold over the green-sand mold makes t the absence of the chilling effect of the damp sand former appear as a remedy for all the ills t that is experienced in the green-sand mold, make fall a casting. However, it must be reme! PRECAUTIONS IN USING DRY-SAND MOLI it possible to use a metal very low in silicon and that unless certain rules are carefully observ! un high in combined carbon that will machine readily dry-sand casting will not always be perfect For and at the same time, develop a high tensile instance, the molds must be thoroughly dried strength. The carbon being in the combined state, not burned. The material for the mold produces the close grain surface that is so much open and the mold must be well vented. 5?! = . aS his provisions must be made to avoid crushes, as ™ pany, Gaetomtel Se ee ee a eee ee dry-sand mold will crush much easier thi r ¢ r 3, 1914 re is no give to the mold and if one joint bring excessive the same is sure to be enough to pressure on broken made for portion of his reason provision must be rance on joints than mold. While this additional objectionable fin on when making a clearance the casting, it is to make these molds. All between re Way near is the joint and drag or must be an iron to iron effected by driving metal tween the flask and the plate after the put on. cope te and drag This can be The iron to iron bearing pre and joints from crowding each other mold. drying necessary for large reduced a deal by built up in the flask or three inches of the pattern. These p to al the reduce the ramming necessary and provide a vent f 3 ver reak the { : 1 ount ol molds scription can be great : rick which can be sorb dampness, desirable. nportant items in successfully making rk are as follows: flask should be made strong enough nd the pressure of the metal and of the that while the : ; takes place casting item is the sand mixture Important ’ ; ng are several dry-sand mixtures that very successful: PREPARATION OF THE MOLDS hard: all solid When finishing the mold is with a drv-sand mold 1 particles of sand leave the mold an lds must be rammed very recesses must be made e, the question of ple matter; as blacking swab when the wet blacking is ed. The facing sand must not be too ne surface of the mold will swell irving. A burnt mold is more dangerous sand mold and the best practice is to mold out when it is discovered that it is Vhere large deep molds are made in a very often necessary to brace the walls | before putting them in the oven. To thout marring the surface, a good plan is heet of oil paper next re the blocking is put in. that at is not thoroughly dried or is con and to the wet sur- aterial that is too fine or close, produces with the sand burnt to it very badly ld j properly the Sometimes a poorly vented cut or scab, but will cause the plum- sh off in thin flakes which makes an un- irface on a part of the casting that is old is not vented, Same ( <perienced. \? are some sands that produce dry-sand the mold only dried two or three inches In making castings in molds of is the best practice to allow this half surface. ? THE IRON AGE ID moid to ol Dbetore it 18 ¢ se dried I a i t casting: because wnen om d that 3 oughly dried is closed up while it is warn almost invariably fills with steam which conde: and the moisture is absorbed by the cor When the metal comes in contact wit thes cores that have absort ed this moisture, tion is created that has a tel ‘ 1 here and there particles of the core rise to the top of the castir id pi | producing castings in dry sand with a desirt benefited by the additio trength wit reasing the hardness, the ving ple of how the iron mixture ld « ev an iron mixture for a similar casting made green and. A green-sand st } ! analysis of silicon, 2.25; phosphorus, 0.50; ganese, 0.60, and sulphur, 0.09 per cent made dry sand, should be made of mixture tl produce an analvsis as follows silies S 3.40% phorus, 0.40; manganese, 0.60, and sulphur, 0.09 per cent. The tensile strength of the ture will be several thousand reater thar tensiie strengt! the firs nixture And ever" ise tne second analvsis VI } I e¢ hrough the sel nnealing proces the dr nold, will chine ich « er tl t I tr rs ! stil tl I We? “ ) ARGI ASTINGS IN DR \ Viat i