The Iron Age 1915-12-16: Vol 96 Iss 25

gre New York, December 16, 1915 ESTABLISHED 1855 Economy VOL. 96: Ne. 25 in Scrap Yard Arrangement Handling Costs Reduced in Youngstown Plant by Having Raised Platforms from Which Material Can Be Shoveled Directly Into Cars A scrap yard recently established by the Joseph Joseph & Brothers Company, in Youngstown, Ohio, has some interesting features designed for conveni- ace in handling the material and for reducing the handling costs. One of the most distinctive features of the arrangement of the yard is that all scrap iron instead of being discharged from cars on the ground level and being reloaded from the same vel is placed on raised platforms, of a height that permits the shoveling of the material directly At present there are four platforms, one 1700 ft long and 40 ft. wide and the others 500 ft. long and ranging from 70 to 100 ft. across. These plat forms are 4 ft. 6 in. high, providing clearance for the rotating part of a locomotive crane. A num ber of railroad sidings extend through the yard providing at present two miles of trackage. One main siding is built along each side and a numbet of cross tracks extend through the yard between the platforms so that cars may either be run back The Four Platforms As Seen on Approaching the m0 gondola cars, doing away with the handling t wheelbarrows. It is stated that this results in a ving of from 10 to 15 cents a ton in labor costs loading. The yard occupies a 15-acre site, about 81 acres E which is now fitted up for use, adjoining the e Erie & Eastern Railroad, a part of the New otk Central system. As the site is located on low mound a fill was necessary and this fill was made th 4000 fis to a depth of 13 ft. in some parts and its age depth is 9 ft. measured from the top of the forms. At present 3000 tons of scrap per week being handled by the yard, but the capacity will increased to 5000 tons by spring by an enlarge- a of the yard by filling in the remaining sec- i during the winter and by providing additional bad tr Kage, ar loads of blast-furnace slag. This on the same track on which they enter or be run to the main yard track on the opposite side. The platforms are built of 2-in. oak, boarded on the inner side of posts, the posts being spaced 4 ft. apart, and anchored back with wire. The plat- forms were then filled in with slag and in the course of a vear when the slag is hardened it is the inten- tion to remove the wooden inclosures, leaving the solid slag as platforms. One of the views shows a view of the four platforms and some of the tracks, this view being taken near the entrance to the yard. What appears to be a small extension above the platform at the left of the crane is a coal bin for supplying the crane. The spaces between the first and second and second and fourth platforms are of sufficient width for a single car track with a 4-ft. clearance between the track and the wall. Space is provided between the third and fourth platform 1403 — eee " — a ses er oe ts 4 ; eee Ot Ta vo 3. a ” “ 3 Lee tee ese THE IRON AGE Decem 6, 19] i . ~~ oe ~~ _ Py =~ >. ae — “* «"“e a —i . ~ <~ SEs ss > a 2 . i ae ri ee — _ eee ns en “a 2 a Vn a ae SS ts ~~ Transfer and Unloading Track at Left and Loading Track at Right Large size scrap from cars on the left t yn tl st tforr it t left and sn | pieces are thrown into the car at the right. After shearing, ect into the car adjoining the shearing and loading platform for two tracks, these being an unloading and trans- a box beam girder 18 by 24 in. and 18 ft. high, fer track and a loading track. These tracks are firmly imbedded in concrete so that the use of guy close together so that when transfers are made the lines that would interfere with the operation of a cars on the tracks are only 1 ft. apart. When locomotive crane is unnecessary. The derrick has unloading cars of scrap in pieces of large and a 40-ft. boom and is motor operated. Heavy pieces , small sizes the small pieces are thrown into the of scrap are taken from the cars with the derrick, adjoining car and the large pieces are thrown over’ which holds the material while it is being cut-up the other side of the car that is being unloaded, on the large shear. onto the storage platform to be sheared. For handling material around the yard and { ry For shearing the scrap a No. 3 and a No. 4_ spotting cars a 20-ton McMyler-Interstate locom ‘ Doelger & Kersten Company, Milwaukee, shear, and tive crane is used. This is equipped with a 46-in a No. 6 and a No. 7 shear built by the United Engi- Electric Controller & Mfg. Company magnet. At neering & Foundry Company, are located near the each end of the platform there are water connec edges of two of the platforms. The larger United tions for supplying the crane so that it does nof shear has a capacity for shearing 10 x 10-in. mate- have to be moved to replenish the water supply rial. It has an 18-ft. fly wheel and is driven by a The steam turbine driven generator on the crané 125-hp. motor. that supplies the magnet also furnishes current fo Another view shows a view of the transfer and 250-watt lamps in the crane and boom so that the unloading track, the adjoining loading track and crane can be used at night. one of the larger shears on the platform at the side There are no overhead wires in the yard. Cable of the loading track and the convenient arrange- for supplying electricity for power for the shears ment for handling scrap. Shearing and loading and for lighting purposes are carried in fiber con are done by the same workmen, the material being duits, these conduits being placed in concrete thrown or shoveled directly into the cars after it is Electricity is supplied at 220 volts. Each shear ha cut up to proper size. As the sides of the high an independent power line and switch so tha Fi gondola cars are but two feet higher than the plat- trouble on some of the lines will not necessitate ! form the loading of cars with shovels is made a shutting down of all the shears. practical as well as economical and the use of wheel- On one side of the yard is a two-story offi barrows for this purpose is eliminated. building and the second floor of this on which thé Adjoining the large shear is a derrick built of NUTS A 50. anal Youngstown Forge C 0 Layout of Tracks and Platforms, Including Proposed Platforms—the Four Platforms at Left Being Alr¢ 16, 1915 is shown at the extreme left of Fig. st floor is used as a scale house, store- timekeeper’s room. A scale track runs aan he 46-ft. scale platform adjoining the [he scales are of the Fairbanks self- woo istel type. All cars both loaded and empty weighed on entering and leaving the yard. Battery of 6-In. Cutting-Off Machines At the Montreal plant of the Dominion Iron & Stee] Company, a battery of seven 6-in. cutting-off é iilt by the George Gorton Machine Com- sany, Racine, Wis., is producing between 8000 and pnel blanks a day. This installation is a wlicate of the one at the Sidney, Nova Scotia, slant of the Dominion Company and is one of sev- recently made in Canada. m nines Dav iisas Ou snra THE IRON AGE 1405 New Huge Power Plant Near Wheeling Ralph W. Cooke, Pittsburgh, industrial agent of the Pennsylvania Lines West, states that the American Gas & Electric Company, capitalized at $7,500,000, with general offices at 30 Church Street, New York, and operating plants in a number of cities, has pur chased about 600 acres of ground at Windsor, W. Va.. between Wellsburg and Wheeling, on the Pittsburgh division of the Panhandle Railroad, on which it will build a large electric power plant This will supply power for the company’s present operations at Wheel ing, Canton, Newark and other places in that section and to outside electric companies, street railroads and manufacturers. The original installation will consist of two 30,000 kw. turbines, but the plans contemplate an ultimate capacity of 200,000 kw. The plant is be ing designed by Sargent & Lundy, Chicago. Contracts have been let to the Foundation Company, New York City, for the installation of intake tunnels and build- of Seven 6-In. Bar Cutting-off Machines Producing Between 8000 and 9000 Shrapnel Billets in 22 Hr chines in general are the same as the one ted in THE IRON AGE, Sept. 30, 1909, and use the internal-tooth type. The bed and head are of massive construction and the ittached to the main driving gear. This ingement which provides but one joint between irce of power and the cutter teeth and that the driving pinion meshes with the main the cutter head is claimed to increase the the machine. The cutter blade is fas- tirely around its periphery, which is re- to prevent deflection and the inserted ced on the internal bore instead of the re keyed in position. It is explained that nent enables the cutters to be fastened place without likelihood of their becom- flying from the pockets. The cutters in number and easily changed. nines are operated 22 hr. every day ts of operators. The approximate cost is between $1.60 and $1.65 for the | to handle the bars, place them in the them to length, remove the burrs =r4 : : of the blanks, mark them and load irs, Po = r of Munitions, David Lloyd George, mela t there are now 2026 government con- establishments in Great Britain. ing of turbine foundations, and it will also erect the main building. The General Electric Company will furnish the turbines and the Babcock & Wiitcox Com pany the boilers. A contract has been made with a nearby company to supply coal for the entire plant for the next forty-five years. A double circuit heavy steel line will be constructed to Canton, Ohio, and operated at 140,000 volts. Connection will also be made with the company’s present system at Wheeling and Newark. It is expected to have the plant completed and in op eration in the latter part of next year. A 20-In. Heavy-Duty Manufacturing Lathe The Shook & Fletcher Supply Company, Inc., is building a projectile turning lathe that is being mar keted by the Dewstoe Machine Tool Company, Birming- ham, Ala. The machine has a nominal swing of 20 in. over the bed, and forgings as large as can be swung over the carriage can be machined. Work 31% in. long can be handled, and it is pointed out that by reducing the swing greater rigidity and increased convenience of operation have been secured, while at the same time the machine can take care of work usually handled by larger lathes. The single-pulley drive is used in con junction with a two-speed countershaft to give at least six different spindle speeds. A 1%-in. belt and a four- step cone pulley provide four feed changes ranging from 0.020 to 0.080 in. per revolution of the spindle. An automatic length stop is provided and the equip- ment includes the customary attachments. em ee en ep etnies Bente septinrmeranen hl an 3 oat aa hh hei ini rial nn . , ’ eRe aa ee ee car ee Ly 4 Methods of Controlling Machine Tols Automatic Mechanical and the Electric Operation Discussed Last Week by the American Society of Mechanical Engineers yy One session of the annual meeting of the American EK. H. Neff, New York manager, B 3} Society of Mechanical Engineers was held under the auspices of the sub-committee on machine shop practice. It was given over mainly to a discussion of methods of operating and controlling machine tools and was held on the afternoon of Dec. 8. Luther D. Burlingame, industrial superintendent 3rown & Sharpe Mfg. Company, Providence, R. I., pre- sented the first paper on “Automatic Mechanical Con- trol of Lathes and Screw Machines.” He illustrated with specific cases the general principles and organiza- tion of devices for automatic mechanical control of lathes and screw machines, which afford the most highly developed examples of such control. The most promi- nent and essential features in this control were spindle drives, means for inserting and removing the work, feeding and indexing mechanisms and the controlling means for the various mechanisms. The first of these included devices for changing the spindle speed, revers- ing the spindle and also stopping it. The means for in- serting the work comprise bar feeding devices, devices for inserting and removing chucked work and devices for transferring work for secondary operations. The feeding mechanisms were classified as controlled by removable strap cams, permanent cams, adjustable cams and dogs, adjustable dogs on drums, cams which are specially formed for each job and permanently set dogs in combination with adjustable stops. Methods of revolving the turret and locking and clamping it and the means for rectifying the index were included in the discussion of indexing mechanisms. The paper was illustrated by numerous drawings of different ma- chine tools showing the application of the various auto- matic mechanisms. The accompanying table gives a list of the machines shown and the means employed for con- trolling the spindle speed changes, the feeding mech- anism, the motion of the turret, etc. j Feat es of Diffe Machine Spindle Speed Inserting Work C} nee Gisholt Lathe Dogs on dr tuating gear Potter & Johnst Dogs on disk Screw Machine ting gears Gridle Automat Cams on drum oj ’ ting ty ley Srown & Sharpe \ istable cam Screw Mac Jones & Lamsor Gears and worm Screw Machine d worm wheel New Britain Scr Machine Cleveland Automati: Machine Comp Wart «& S Company Bullard Vertic Lathe Davenport Machins Company The discussion on this paper was opened by Ralph E. Flanders, Jones & Lamson Machine Company, Springfield, Vt., who commended the paper and pointed out that higher speeds and feeds were possible with hand-operated machines for certain classes of work, as the operator was present all the time and could see what was going on, which was not true in the case of the automatic machines where one operator handled several. On the other hand he pointed out that the time lost by the slower feeds of the automatic machine was more than made up by the increased production possible from a group of automatic machines. 1406 rent Lathes and Screw Machines Mfg. Company, said that while he ag statement made by the author that th was less in evidence with automatic with those operated by hand, at the san necessary to have one man of even a of intelligence than was required for t! the hand machines. He also mentioned th feeding as another method of bringing position for machining. He took issue wit] speaker on the question of speed and stat: opinion the use of automatic machinery, employed for cutting gears, would grow The second paper of the session was E Operation and Automatic Electric Control Tools,” by Louis C. Brooks, industrial cont ment, General Electric Company, Schenectady, N This paper was in a sense a companion to the } one, and also to that on automatic machines by Ralph E. Flanders before the International Eng neering Congress at San Francisco and printed IRON AGE, Nov. 18, 1915. The paper traced th cation of electric motors to machine tools f time when hand starting devices were employed the present, when automatic starters with remot trol are considered best suited for this class of work although there are a number of cases for which hang starters are better suited. The advantages of automa control such as the attaching of the operating switch t the machine and the location of the main panel at som distant point, the regulating of the starting time of ma chines automatically to suit load conditions of the mote and the attaining of accurate stopping points dynamic braking were touched upon. All panels sh be provided with a fool-proof inclosing case wi meets all of the Safety First requirements that applicable, and automatic starters and contr Feed Mechanism Turret Motion l Adjustable dogs o1 Geneva stor Wedgz drums es Permanent cams ce and dogs Permanent cams nd dogs Specially formed Geneva sto} cams Removable strap Geneva stop cams on drums ” Permanent cams and adjustable cams and dogs Adjustable dogs o1 drums Permanent dogs ind adjustable stops Crank operating curved sliding block paratus should have protection from 10) tag also from excessive overloads. The three general types of automatic st# depend on the time element, counter em! limit, were discussed. In general the starters motors consisted of line contactor, over| ud rheostat and connecting board, while f where resistance must be inserted in the switch and fuses, line contactor, counte! ing contactor and connection board were last being modified in still larger motors date additional accelerating contactors. emi. a pecember 16, 1915 control to machine tools, such as lathes, and planing and slotting machines, was it being pointed out that at the present blem of purely automatic control for gen- as not been entirely solved, although special Sia es have been controlled with safety and “Reiet [The question of the type of motor to be “jd was discussed. The shunt motor was applicable i nting presses, ventilating fans, small ma- vyoodworking machines, etc., and can be used athes, planing machines and boring mills speed is to be varied. The series motor, the desirability of having a certain friction be employed for centrifugal pumps, cranes TI ission was opened by Harry F. Stratton, on eTa ager and chief engineer, Electric Controller ¢ Mfg. Company, Cleveland, Ohio, who spoke of the de- the motor starter of his company and he advantages of adjustable-speed direct- or for driving machine tools. The main ¢ to the decision as to the particular type » be used on any machine was the increased James, Westinghouse Electric & Mfg. Company. Pittsburgh, exhibited a number of lantern slides diversity of machines to which motor been applied. : D. Knight, industrial control department, General Electric Company, Schenectady, N. Y., pointed th the automatic control it was possible to speed constant at any time, and that the use matic control system also tended to increase y of the operator. K. Hathaway, consulting engineer, Philadelphia, lack of automatic means for stopping the ase of accident to the machine tool and t that the application of motors to tools, such a milling and drilling machines, that were not strictly yitomatic machines, afforded a fertile field for inves- L. Eberhardt, Gould & Eberhardt, New- : mentioned the necessity for co-operation tetween the electrical engineer and the machine tool signe rder that the apparatus might be properly ph E. Flanders, Jones & Lamson Machine Com- Springfield, Vt., spoke of the use of belts on ven tools, and Charles Fair, power and mining ng department, General Electric Company, N. Y., said the type of control must be entirely by the needs of particular cases and it was therefore not possible to lay down any hard and fast rule. E. H. Neff said that in his opinion constant-speed e best suited for driving screw, gear-cutting aid grinding machines and that the proportion of ma- id with the motor attached was small. He ise of gears mounted on the machine itself necessary changes in speeds and feeds. To Promote Baltimore’s Manufactures rganization has been formed in Baltimore, Md., te the development of manufacturing inter- city by helping to finance established in- securing new ones. The organization is the Industrial Corporation of Baltimore City. make thorough examinations into the financial "g and possibilities of profit to industries need- ‘lal aid for the purpose of helping them to mal capital or banking accommodations tigate manufacturing enterprises seeking n. It will not offer a bonus to new enter- » . +e president of the organization is John P. ent United States Fidelity & Guaranty e treasurer is Eugene Levering, presi- Sank of Commerce. The secretary, to mmunications should be addressed, is C. C. *, <0) United States Fidelity & Guaranty Com- ‘ding, who was formerly assistant treasurer ed States. The directors represent a large most prominent manufacturing com- incial interests of the city. Siries and 4 and THE IRON AGE 1407 World’s Ample Iron-Ore Supplies G. D. Chamberlain of the open-hearth department of the Carnegie Steel Company’s Edgar Thomson works addressed the students of the University of Pittsburgh last week on some phases of iron and steel manufacture. The world’s principal iron-ore deposits were referred to at some length, and the speaker used numerous lantern slides. What was said as to the world’s iron-ore supplies and as to the importance of the Brazilian deposits is given in the following extracts: “A few years since not a little anxiety was felt as to the possible exhaustion of the world’s supplies, by economists in many lines, some going so far as to say that within fifty years the world would be in a bad way for iron ore. Fortunately, nature has been ever bountiful in providing for man’s wants and her prodigality has not been lacking in this. In the last ten years additions to the world’s ore reserves have been enormous, so that the possible exhaustion of known deposits has been pushed so far forward that the least confident do not worry as to the near future at least measured by several generations and pos sibly several centuries. Geochemists tell us that about 4% per cent of the lithosphere, or crust of the earth, is iron and that this holds approximately throughout the entire surface. Now, as essentially the same geologic forces have been at work throughout the world to produce ore deposits, it is only reasonable to expect the same results, and therefore in partly known and in unknown sections to anticipate accumulations of ore approximating those in thoroughly prospected sections of the globe. Looked at in this way, and it seems a rational view, there would seem to be no oceasion to worry over a future ore supply. a a “The feurth great deposit on the Western Hem isphere [Lake Superior, southern Appalachian and Cuban mines being previously mentioned] is that of Brazil, located in the State of Minas Geraes, some 300 to 400 miles north of Rio and about the same dis tance from the coast. By every mining geologist and engineer who has visited the region, it has been pro nounced the greatest known deposit in the world. While extended developments may modify present knowledge, enough is definitely known to place it among the larg- est, and there is enough reason to believe it may exceed the present conservative estimates. By way of com- parison, the estimates of some half dozen eminent geologists essentially agree in stating the deposit con tains approximately double the tonnage of our Lake Superior region. “It is interesting to note these four deposits lie in a straight line, extending from northwest to southeast at an angle of about 45 deg. I do not know that there is any significance, geologic or otherwise, connected with this; possibly only a coincidence.” New Electric Steel Casting Plant at Milwaukee The Electric Steel Casting Company is the name selected for the new corporation which has been in process of organization by Leo G. Smith, former man- ager of the Prime Steel Company, Milwaukee, Wis. Articles of incorporation were filed Dec. 9. The capital stock is $300,000. Officers have been elected as fol- lows: President and general manager, Leo G. Smith; vice-president and counsel, Chauncey W. Yockey; sec- retary and purchasing agent, F. G. Wetter, formerly purchasing agent for Prime Steel Company; treasurer C. F. Taylor. Plans are being prepared by the Raulf Construction Company, Patton Building, Milwaukee for a concrete, brick and steel foundry, 80 x 500 ft. The exact location has not yet been determined. The equipment will include one 3-ton electric furnace, two wall cranes and one 5-ton electric traveling crane. The Model Foundry & Machine Company, Findlay, Ohio, recently incorporated with a capital stock of $25,000, has elected the following officers: J. J. Zwis, president; Arthur Hosler, vice-president; A. C. Heck, secretary and treasurer. The company will at once begin the operation of a foundry in the plant formerly occupied by the Ohio Well Supply Company. It will engage in general foundry and machine shop work. % nt A NER ne i a Ree. , 4. a ; Donia See, Bir oe ‘ — = rs pce Tp rt a me rape: re a ae ec eaten me | 2 ny i i : ; x 7 , 7 ; ‘ Jonge Queen oe rer Pipe f Ff 1408 THE IRON AGE HUGE GRINDING MACHINE Weighing 55 Tons and Taking Rolls 21 Ft. Long and 50 In. in Diameter A precision grinding machine of the most mass- ive size yet constructed has been delivered to the Carnegie Steel Company by the Norton Grinding Company, Worcester, Mass. This giant machine weighs 110,- 000 lb. and is designed to grind rolls up to 50 in. in diameter, 21 ft. in length and weighing 64,- 000 lb. The rolls can be swung on centers or supported on their necks. The machine is capable of removing from 2 to 4% cu. in. of metal per minute, using wheels 24 in. in diameter with an 8-in. face. It has been com- puted that with the average wheel used for such work over 3,000,000,000 grains or cutting points are at work each minute. The importance of design and con- struction in a ma- chine for the serv- ice it is to perform may be appre- hended when it is stated it must pro- duce parallel rolls, free from chatters, wave marks or feed lines, the presence of which is quickly discov- erable in the fin- ished sheets. This machine is built along the — care was taken t ore : de ¢ bt Front and Rear Views of the Headstock of a Roll Grinding : + these general lines of Machine Weighing 110,000 Lb. and One of the Pillowblocks in Which see that t)® the machine built the Roll Rests While Being Ground The Speed Variation Is Ob- ards formed aa ; tained by Moving the Handwheel at the Back of the Motor to Permit ae tantiot by the same com- the Shifting of the Speed Changing Lever at the End. The Pillow- quate protectiv pany for the Na- block Shown, Which Is Nearest tional Tube Com- pany, Lorain, Ohio, which was described in THE IRON AGE, July 31, 1913, but this second machine has been changed in several features to meet new requirements and to take larger rolls. In this type of machine the wheel is carried on a sliding table and the work does not reciprocate in front of the wheel as is the standard Norton practice. The the Footstock, Has a Micrometer Adjustment to Permit Taper Grinding Decemb ‘ace operator stands on this sliding table see all parts of the machine and wo; the operation of all the units by lev wheels. The headstock is rigidly fixe; but the wheel table and the footstock , along the ways or the wheel slide m by both hand and power. The spindle in the headstock is 12 eter and 64 in. cast iron with a ing for the bea) spindle with the gear, which is a] diameter, weighs ey The chrome nick¢ centers in the hea stock are 6 in. i; with a 70-deg. taper of the usual lathe tyne cop. struction. There are a nur ber of different pillow blocks or journal rests for s ipport ng the rolls when grinding sak ing them on their ow or journals and re volving as they d in the sheet mill. The weight the grinding wheel, wheel slide, wheel spindle and pulleys, including the whed guard, is approx! th mately 6000 |b., the solid steel guar! covering the whee alone weighing abou 650 Ib. All movin and revolving part of the machine protected and the operator water pum] ble of delivering 30 gal. of lubricant per ! the point of contact of wheel and work There are four motors on the machine rated total of 65 hp. A 20-hp. adjustabiesp® motor is mounted on the headstock to drive 7 work through a set of change gears; a 40-P. - on the sliding table makes the table reciprocate ™ ta AL with ¢ 16, 1915 vheel; a motor on the footstock moves forth on the ways to permit placing sition to be ground and a motor drives nt pump. In operation these motors d upon for short periods to deliver up There are only five leather belts on fteen months was necessary to produce lrawings and 5000 patterns required ng of the 1200 parts in the machine. Universal Sawing Machine for Shapes esign of universal cold saw cutting-off tended particularly for use in bridge een placed on the market by the New- ne Tool Works, Inc., Philadelphia, Pa. A ; the table construction which is ‘relied upon rapid relocation in connection with the 4 THE IRON AGE 1409 addition to controlling the alignment, is relied upon to insure the proper location of the work and take care of the pressure of the cut. To furnish addi tional clamping convenience in extreme positions a lamping flange surrounds the entire table. Arch lamps arranged with a secondary base which per nits the screws to be used in either a horizontal or a vertical position for clamping the work are em pl ved. The machine illustrated is equipped with moto! drive and has hand rotation on the sub-base through an are of 180 deg. The saw blade ordi narily employed is 36 in. in diameter, which will cut through 24-in. standard beams or rounds 11 in. in diameter in all locations. By using a suitable cutter head it is possible to face sections measuring 30 in. high and 47 in. long. The general design of the machine embodies all of the builder’s high-production machine features, itting-Off Machine for Structural Shapes with Special Table Construction to Fa and Rotary Planing or End Milling ! milling of structural forms and fabri- pes. With swiveling of the main table is three-position arrangement for the top mbination furnishing a means for hold- us shapes in the different positions re- niter and square cuts and for rotary d milling. tion shown the top table furnishes a or I-beams as it reaches high enough flange. In this way it is emphasized ease in the rate of feed is necessary as ‘ration in the work to be transmitted le with a resulting decrease in the rk turned out. When the top table is egular way the portion with the open- ne main table. In this position it is a single central clamp which per- to swivel without employing a crane ie clamps. When cuts at right angles the section are to be taken, keys are slots to engage with corresponding ottom table. This arrangement, in y such as taper shoes for the vertical and horizontal saddle fits, underlocking gibs which are cast in tegral with the saddles, geared feed changes with out removing any of the gears, automatic release and power quick return. The machine is designed for either standard or Bethlehem sections, and for occasional square cuts on the latter a blade 44 in. in diameter is used Record Erection of Giant Hydraulic Press What is believed to be a record for the fastest tims ever made in erecting a large hydraulic press was re cently established at the new plant of the Knox Pressed & Welded Steel Company at Wheatland, near Sharon, Pa. This press, which weighs 160,000 lb. and is capable of exerting a pressure of 400 tons, left the plant of Mackintosh, Hemphill & Co., Pittsburgh, on a special train consisting of a locomotive and two ears at 6 o’clock on the evening of Nov. 30. The train reached the Knox plant shortly after midnight and the pres was unloaded, set up and grouted in place by the after noon of Dec. 2, or in less than 48 hr. from the time it left the builder’s plant. ~——e 5 —— pf Exact Control of Manufacture in Prac ‘ice’ Applying Scientific Management Discussed in the Light of Four Years’ Effort Required for Introducing It Well Repaid BY GEORGE D. BABCOCK+ Recently the speaker addressed the Manufacturers’ Association of Auburn, N. Y., on the subject, “The Executive’s Problem.”t The theme of this address involved different types of executive action as applied to the conduct of a business. Three fundamental types of executive action were presented, the third one of which is commonly known as scientific management. It is a type of management promulgated and practised by our late Dr. Fredreick W. Taylor, in which the executive assumed a more detailed control of work than practised under other forms; in which facts supplant opinion and exact instruction supplants general orders. Tasks are set for each element of the work, and a per- petual check of accomplishment to these tasks is main- tained. I shall go into a somewhat extended discussion of the application of this type of management to a manu- facturing business, and from examples gathered over a period of four years of its practice in a most intensive form acquaint you, perhaps better than in any other way, with what repayment may be expected to offset the strenuous effort required for its introduction and continued application. Preliminary to any active work in the factory the management and more important supervisors must at least agree to be in accord with the new efforts and to give their honest support to such efforts. Those re- sponsible for the work of reorganizing will be reflected by successful or chaotic results. If they fail or go into it with a half-hearted or unscientific approach, condi- tions will be worse than before the start. If they sup- port and carry it to a successful conclusion, as it will invariably be if carried through, they will marvel at the comfort and lack of discord which permeates the whole works. The principal elements which enter into a manufac- turing effort, arranged in the order in which they will be discussed, are: A) Stocl a \ ble I Productive mater Patter Supplies B) Material and worl process Buildings Machines Materials 4. Tools Men C) Mone y 1. In production Ir upplies and indirect expense THE CONTROL OF STOCK MATERIALS Develop a set of controlling records for the stock which are designed to be absolutely dependable with- out undue supervision. Perfect the inspection of incoming materials to the end that inspection precedes receipt into the stock room or stock records and that no rejections shall occur after such record. To secure this, specifications must be exact and the education of the inspectors with respect to the specification complete. At the end of our year 1911, the variation in stock room physical inventory with the rec- cords was 2% per cent of the value of charges handled during the year. At the end of the year 1918, the variation was 0.03 per ce nt. At the *Address given before the University Industrial Society, Bridgeport, Conn., Dec. 3 +Production manager H. H. Franklin Mfg. Company, Syra- cuse, N. Y {THE |! wn AGE, Aug. 19, 1915 1410 Experience—Strenuous end of the year 1914 the value was 0.0 of all such charges. Upon this foundation material sched out of stock, can be attained with unbeli ness. To insure materials being in stock dates, the purchasing agent must provide fi ules, standard purchasing times for e:; class, as forgings; gray, malleable, bronze castings; cold rolled bars, nickel ste: These standard times are the minimum days in which the representative can reg gain, buy and deliver to stock each cla item. From time to time such list will bé changes of conditions require. The standard list now in service cont r classes and items. It is dated May at which time it was last revised To with all the assumed difficulty of obtai +4 Ai terials, only six changes have been mad: f allowances in this list. At this date 4000 are on order with the purchasing agent. Ab 100 lots are issued to the shop each day. Ni) lots are now waiting to be issued as o This represents about one day’s delay. The purchasing representative must be specif requiring that deliveries of materials neither precede the specified date or delay beyond such date. Som variation must of course be provided between the dat of delivery to stock and date to send into process. This should be a standard time. The present standard of stock time i days; i.e., if no more stock were received issues continued per schedule the stock would entirely depleted in ten days, assuming that) ceipt and issues occur exactly to schedu Practically we have attained in late months actual stock reduction to 11% days’ sw without detrimental effect upon productive o put or direct productive costs. Previous to w methods and present control plan the stocl vestment represented a 50 days’ supply. T! automobile stock is admittedly composed great variety of classes as well as charact parts. Some material is stocked for a compli schedule of six months or more up to three yea for lumber. Such material is usually small bulk, large in numbers and of relatively sn value. Other material of appreciable bulk a value may be stocked to the short period of 0 week. From the above we conclude that control of has been obtained. Six principal items require ] Requisition of material °’—Placing of purchase order. Securing of acknowledgments i—Receipt of invoice showing shipment Receipt of material into stock é—Issue of material to process Pattern Control The For castings a pattern must accompan) sition. This therefore must be control. The pr! items entering being: 1—Pattern order placed. 2—Work started. 3-4-5—ete. percentage completed. 6—Delivery to foundry for test casting 7—Casting received. S—Issued to shops. 9-10—etc., percentage of casting tested eted and if satisfactory release the pattern g agent to ship to founder for production, or inder, from the local pattern control If not recall the pattern and repeat. ol of dies for forgings is similar to that The control items are: 1. Order dies. Secu d inspect lead proofs. 3. Release dies for s. 4. Test out forgings to jigs or for chemical analysis. Release of dies for Supply Control Supt for the shops are controlled under a budget In recent years there has been accumulated a of information relative to the consumption le supplies at the different classes of ma- hines [his includes grinding wheels, polishing waste, perishable tools, ete. From this information budgets are prepared for lepartment for each month and dates of deliv- pply materials are controlled to agree with rets. While there may be now some varia- ‘rease of accumulated information will soon yractically exact. ‘S ipplies are dispatched from the stock rooms some- “mes with the tools for the job, and at others to the workmen directly as they come for jobs. NTROL OF MATERIAL AND WORK IN PROCESS OF PRODUCTION ss of factory effort calls for the greatest the part of the organization due to the ex groups which enter. These principal 1. Buildings. 2. Machines and equip- Materials. 4. Tools. 5. Men. p or subdivision of a group can remain in without control and the final results be If the product is complex the least un- the schedules of the groups will cause imme- restion with a consequent temporary sus- work in some divisions followed by a cor- g period of excessive activity. There will first yment and later overemployment; idle plant es, with a later congested plant and ma- Delayed or limited material may be the cause : greater congestion than material in advance of Either condition causes not only extreme tion to all persons affected but it means large nvestments in buildings and other fixed well as unsalable material and labor. rm burden on the works at the minimum in- so desirable that all possible effort in this be amply repaid of the classified plan obtained and perpetually applied. Building Control ntrol of buildings for an ascending schedule lifficult. Plans are laid as for materials and All of the activities which are represented ilyzed and classified. Each class is further ed into its elements, and the date for each element rt, proceed and finish is set. The setting of each ide with reference to the date for the finish ompleted structure. The time for measure- e., the time required to produce each element edetermined from exact knowledge and estimates. architects and contractors are not alto- tsfactory, since rarely do they have the oppcr- plan and supervise as intensely as is cus- er the highly developed factory method. trol of buildings for a descending schedule an be sold for cost less depreciation is factory. Some relief can be obtained by F peak loads in outside rentals, never car- Ming ding equipment for probable peaks. The sSIOUIt securing such outside rental is a factor ed, for without it, it is either build or ness, and the latter is not always the nable, spaces for materials are constructed is for manufacture. As these spaces (pied with manufacture, materials are t into rentals until the permanency THE IRON AGE 1411 of this rental is evident, then new buildings are provided to house the permanent part of the overflow. Control of Machines and Equipment The fundamental of control of machines is the bur- den. “What machines” and “how many” for a given rate of output of a known product is a perplexing question. Expert mechanics of highly inventive abil- ity in the planning room will specify the first part of this question, i.e., “What Machines.” The regulation of the quantity to produce a varying schedule of output can be secured through exact record of the time in which the machine can produce each operation on each piece which is routed over it. If the product is such a one or similar to that now ¢onsidered, a burden record can be compiled to show each machine by num- ber or symbol with all operation time routed to it for one unit of the finished product. The sum of such times for each machine multiplied by the number of product units to be made each day will give daily task. This daily task divided by the number of machines will give the daily burden. This burden divided by the number of time units in the standard day will show the number of machines required. Two essentials for the success of this plan are proper time allowance for machine breakdowns or idleness and exact knowledge of unit times for each operation. There is no way of securing their latter except by elemental time study. Since the machine operator’s activity is a factor in the time taken by the machine, the operator must also accomplish his effort in the set time. This is prescribed in the instruction card with which the operator is provided. Regardless of the payment of a premium or bonus to the man for special attainments, it is absolutely essential for the welfare of his fellows, as well as the stability of the business, that the machine unit times be obtained and applied. Any delay of a part causes a delay of the assembly into which it goes with a consequent sus pension of work of the assemblers. There will also come overdue shipments to the consumers. The operations on parts which go over each ma chine having been recorded, from the schedule of the particular operation of that part which must be first worked upon, a date can be obtained for the delivery of the machine to its place on the work floor. All machines planned for the same kind and quality of work are speeded, powered and made exactly alike in all mechanical respects. They are then classed in groups so that work routed to one can be placed with any of the others with certainty of predetermined standard performance. The group carries the group burden, and in all respects acts as one machine. Each machine in the group is regularly inspected and re paired. Lubrication for cutting edges is controlled by a central equipment circulating to all places of use in the shops. There are a considerable number of groups with from four to six machines in the group. The most diffi- cult group is that of the turret lathes. Slight varia- tion in the alignment of turret or spindle will elimi- nate the machine from the group. With a larger pro- ductive output the number of machines in each class would grow practically proportional to the output. Control of Materials No plans for control of materials over the varied paths in the works can be successful unless controls previously mentioned have been established and are perpetually maintained. Even with this satisfactory maintenance under the usual plans the detail in this effort is enormous. For exact control, and this is so much more satisfactory than that which is approxi- mate, each activity on each part and assembly must be specified. One chief essential, but one seldom prac- tised, is the determination and standardization of lot sizes for each part. These lots will be moved from station to station on the routes as units. Each lot to remain at each station until the work specified to be done at the station is completed on each piece in the lot. Without exceptional orders, once the work at a sta- 4] 5 . + L. i te a me ee eT ae a A a er ee ere ee enn | eS ptm oe ait ip ee ate ee oan ae a aes 8 ~ A AES Be neers ere a] oa i a ; 1412 THE IRON AGE tion has been started on a lot of one part until it is finished, no other lot of another part can be started. This precludes the use of stock chasers or other local shop authority since they are not in a position to judge the relative importance of delayed parts as against other work waiting at the machine when the de- layed part reaches it. Under a standard lot size plan, the variations in quantity of output are obtained by corresponding va- riations in the frequency of dispatching individual lots. Assume a standard lot of finished product at final assembly to be 50 units, and the schedule to require 10 units per work day. T he n lots of parts for final assembly will be dispatched from finished stock each 5 working days. If a product part, 1 of which is used in each unit of the fin- ished product, is moved in lots of 500 pieces, this quantity will satisfy the assembly for 50 work days and will be dispatched from raw materials stock at that frequency. The same frequency obtains at each station on the route. If each lot is 25 days in process from raw stock to fin- ished parts stock, then 2 lots will be in process at all times. If the lot is in process 10 days, then 5 lots will be in process at all times. Since the same kind of machine work will occur on many different parts, the order of approach of the parts to the machine must be controlled. The parts must be moved to the machines and be recorded at the machine before the work order is given to the operator. If machines are grouped the material must be deliv- ered to the location of the group and this recorded as received. The first free operator in the group must then be given the part next due. This action is readily secured by dating each operation job card at the control board, which insures accurate relative order of work. The jobs for a given group of machines are arranged in a machine job card box in the order of these datings. Dispatch boys local to the shops are held strictly ac- countable for the giving out of jobs to the operators, in the order of dates. Any job not issued by a given hour, on the day specified is marked with a “Lot Urgent” card. This card is signed by a superior in the planning depart- ment, and upon this signature becomes a standing order to the superintendent and foreman to provide overtime or night work for the job. If any one part becomes overdue with aggravating frequency, or if a machine or group of machines is constantly marked with urgent cards, the routing division is called into consultation to advise a solution. At the present time there are 12,000 jobs standing in the machine racks. There is an av- erage of 600 jobs started per day. There are 450 urgent tags standing; i.e., one day’s extra activity of the working force would bring all work in the shop up to schedule. The variations in hours work on overtime or night shift is slight. We conclude from this and from the fact that final product follows its schedule exactly, that average errors in operation are constant. We also conclude that if no urgent tags stood against work, that the investment in work in process account would be excessive, i.e., we would be ahead of schedule on produced parts, which product would re- main in an unassembled state, lacking finished pur- chased parts for its completion. Scheduling of standard lots, coupled with sure methods of dispatching over well planned routes should obtain most beneficial results from the reduction of investment charge as well as the delivery of salable product. These are two of the most important accomplish- ments in factory conduct. Known time elements are fundamental for this conduct. When known they must be obtained regularly in practice. Previous to the control of our factory work by the above plan, the work in process invest- ment account represented three and one-half cars for each car produced per month. Now it is one and one-tenth cars for each car produced Decembx 1915 per month; i.e., we turn our money . times as fast as before. Control of Tools Coincident with the routing of opera chines is the specification of tools. Thes: templates, gages. drills, taps, dies, wren forms and sizes of all cutting edges. tools due in tool rooms is specified, and t} Ba quantity to carry entered on the tool | The stock is maintained thereafter by the too! sition. As each job comes up to a machine ordered out to agree with the tool list fo tion. These are delivered to the point of receipt therefor by the floor executive, « the dispatch clerk releases the job if the material has been filed. After tools are used they are returned stock for inspection, shaping of cutting edo repairs as are deemed necessary. Control of Men Where large quantities of the same part a ade or where the limited performance of a special ma chine is continuous men are naturally employed steadi) on limited work. This limited work is not a functioy of a particular kind of plan, but rather an econom activity from the engineer on a limited train to the farmer at his plow. The miles to go or the aer the field limit the time of change of applicatior effort. A complete knowledge of what is to be done and this taught to the workmen by written instructio allows quite unskilled men to become useful productiv units. So many men and their work are misfits and employing men for what they can learn to do and not for wifat they know makes rather easy the task of the employment agent. Employment centered in a representative of the chief factory executive, and dis- charge possible only upon the written approval of this executive secures steady permanent workmer Wages sufficient to interest them in outside invest ments, work hours which allow them time to supervise and enjoy such investment, permanency of employ- ment assuring