The Iron Age 1924-10-09: Vol 114 Iss 15

ESTABLISHED 1855 EY VOL. 114, No. 15 New Annealing Equipment for Strip Steel Electric Mule on Rack for Charging—Ample Combustion Space in Furnaces- Arrangement for Cooling Boxes and Quick Charging of Furnaces HEN the Worcester Pressed Steel Co., Worces W ter, Mass., decided to revamp its annealing de- partment it was working under somewhat heavy handicaps, through having five annealing furnaces in a narrow shop and with insufficient room for properly handling the product. Too much time was being used in charging and discharging the furnaces, with conse- quent loss of their internal heat and with severe expo- sure of the men and the crane to radiated heat from AT Right, the LX Blectric “Dis- tant-Control” Mule Has Pulled an An- nealing Pot from the Furnace, Shoved Another One In by Pushing the Two Pots Forward and Then, Dropping Its Hooks Over the Lugs on the Car- riage of the Hot Pot, Has Hauled it Back and Permitted the Door to Close Over the Fresh Batch the boxes being withdrawn and set aside to ccol. Head room was deficient, so that the crane had to take sev- eral “bites” on the hauling chain before getting a pot into or out of the furnace. To remedy this condition, a furnace lean-to was built alongside the old annealing room and two new furnaces placed in that lean-to. At the same time three of the old furnaces were removed, thus clearing a good part of the floor, and special charging arrange- T Left, the Two Furnaces of the New Group Show Unusual Height Above the Door Opening, for the Purpose of Provid- ing Adequate Space for Complete Com- bustion of the Fuel Before Discharging Its Gases Through the Floor Flues and Thence to the Stack. Each furnace has two burners eee vieegae * eam men aa tc tae por Se or ale Agha oti * oes instep St ed ee ty yn UO une ssa ; PPR pe Mis ee 4, Ea ae iret aul ae 4 J eran 0 Ss fae os ey Se ie i bah lll 0 i Salt hee) | | 908 THE IRON AGE October 9, 1924 ments put in, making a much more convenient method of handling, with less loss of furnace heat and much less exposure of men and crane to the heat from the withdrawn pots. The new outfit is from designs of H. A. Fisher, plant engineer, the charging mule being the subject of a patent application. The Fisher annealing furnace differs from the older furnaces, mainly in the arrangement of burners, flue and arch. In particular, the space above the pot was made large enough to provide for proper combustion of the oil without sending too much of the heat up the stack. At the same time, the burners were so arranged Me TUM) ” New Lean-fo \K. Furnaces Installed __ Proposed furnaces, = ! { be 1 ANNEALING DEPARTMENT meee ee yy ‘oie ie po ! i ! 1 | j ! 1 \ | ! | 1 i i - ! t | 1 Old Furnace Old Furnace Old Furnace aoe ee General Layout of the Annealing Department, Showing the Relative Extent of the New Furnace Lean-to and the Locations of Old and New Furnaces. This indicates the extent to which the working space has been improved by removal TtTT TTT HHH TTTTT yrrrrty HHHHE HH a H ‘SESE S ES! mre HH ——— 44 At Right Is a Sec- tion Through the Annealing Depart- ment and the New Furnace Lean - to. The crane places both charging mule and annealing sau- cers and pots on the tracks where needed of the old furnaces Insulating C emert Lnsulating Brick Three Sections of the New Furnace a Longitudinal Cut Along the Axis, a Cross Section Through one of the Burners and Showing the Center Flue Beneath the Rails and a Horizontal Section (at Left) MMT ea HUnne ANE ANaNaanaanaaNUrogeN Etat erneaennit October 9, 1924 that the oil under atomization would not impinge upon the pot and thus, through disintegration, produce smoke. In operation, oil (26 to 30 deg.) is pumped from tanks which hold enough for about one month’s supply at full load on the plant. It is delivered to the burners at a pressure of about 35 Ib. per sq. in., by a motor- driven pump. Air is used for atomization, being deliv- ered from a motor-driven blower at a pressure of about 14 oz. The furnace has two burners on one side and as the roof has a considerable spring of arch—differing from the flatter arch construction common in such fur- naces—radiation to the pot is directed in such a way as to obtain splendid results. Sil-o-cel insulation is placed between the interior fire brick (two courses) and the outside wall brick of the furnace. Charging Mule with Remote Control Weighing about 5000 lb., the Fisher charging mule is driven by a 7%4-hp. motor mounted on the rear, but controlled from a post on the wall and trailing its power cable after it. This permits the operator to keep well away from the hot pot being hauled out of the furnace. The mule operates on a floor rack at a speed of about 25 ft. per min., the rack being used to take up the thrust in either pushing or pulling a pot. Cast steel rails are used inside the furnace and cast iron rails outside. The racks are cast steel and the speed reduction between the mule motor, which runs at 500 to 1000 r.p.m., and the rack pinion is about 150 to 1. Pretty nearly the whole interior of the mule is taken up with the gearing necessitated by the heavy reduction ratio. In the operation of charging a fresh pot into a fur- nace which contains a pot ready for withdrawing, the mule first hauls the pot of annealed material from the furnace by means of the hooks shown in the photo- graph, and dropped over the lugs on the saucer. The pot rolls out on cast steel balls running in a grooved track and is withdrawn far enough so that the fresh pot may be placed, by the crane, upon the track be- tween the withdrawn pot and the furnace. The mule thereupon shoves both pots forward until the fresh pot is entirely within the furnace. It then hauls the hot pot back a short distance, permitting the lowering of the furnace door. The hot pot is left in that position for perhaps 15 hr., until it becomes cool enough so that it may be handled without distress. As only one mule is provided for the furnaces, it is necessary to transfer the mule from track to track, as needed, by means of the overhead crane. The pots are designed for a maximum load of about 18,000 Ib. of strip steel. As the pot and saucer together weigh also about 18,000 lb., this makes a maximum load of some 36,000 lb. Tests on a load of about 33,000 Ib. gross showed that the (weighed) oil consumption for complete annealing amounted to 650 lb., over the an- nealing period of about 15 hr. This was at an anneal- ing temperature of from 1400 to 1450 deg Fahr., which is common for low-carbon steel, and works out at about 87 Ib. of oil for each net ton of steel annealed. Aluminum castings, bars, plates, sheets, ware, etc., produced during 1923, are reported by the Census Bureau at $106,930,367, an increase of 133.4 per cent over the $45,822,161 reported for 1921. The number of establishments increased from 87 to 119, the aver- age number of wage earners from 9584 to 16,288, the amount of wages from $10,835,597 to $19,843,546. The horsepower used in 1923 was 58,272, while 174,261 net tons of coal was consumed. Aircraft produced in 33 establishments in 1923 amounted to $12,945,263, compared with $6,641,988 from 21 establishments in 1921, according to figures of the Census Bureau. Wage earners increased from 1395 to 2901; their wages from $2,202,307 to $4,521,949, and the value added by manufacture from $4,234,593 to $9,115,689. Horsepower used in 1923 was 5443, while the coal consumed was 10,042 net tons. THE IRON AGE 909 WELD BETTER THAN A NEW PART Punch Press, Welded Once, Broke Again at a Different Point BY J. F. IRBY* VERY shop working with metals may not have in its equipment a punch press of the same dimensions as the one illustrated. But few shop owners are not faced, at one time or another, with the specter of a shutdown because of damaged machinery. Thus the main point in the following incident may be typical of the wide variety of repair and reclamation work done by welding. Broken equipment carefully repaired with a rein- forced oxy-acetylene weld is stronger at the repaired section than it was originally. Some skeptics might say: “Undoubtedly, in laboratory tests, but does the After a Second Break, Which Did Not Dis- turb the First Weld, a Second Weld Was Made in the Crank Bearing and the Machine Again Passed into Service As a Result of One Accident the Frame Was Welded Clear Across the Middle, 20 In. x 19 In. in Outside Section (Above) Hee tnenebee Gace ennneRERS ORR RERTOENEN THERES FOREN same hold good in practice?” To answer the question most satisfactorily is to prove it. Fig. 1 shows a punch press frame, a gray iron cast- ing weighing about two tons. A piece of metal too thick or tough broke the casting square off at the level of the table. The frame was cracked through a hollow rectangular section 19 in. wide by 20 in. deep, 6 in. thick at front, 1% in. at the back and 2 in. thick at the sides. After the edges were carefully veed and the frame accurately alined, it was preheated by gas burners and a good welding job done by competent oxy-acetylene operators. The casting was carefully covered to pro- tect it from drafts during welding, and this covering was left in place until the casting had cooled. After proper annealing the punch press frame was put back in service and stood up under the work for a year. Then someone again fed it too big a bite and it went. Of course, the frame was sent to the same shop which had welded it after the first accident. Again it was repaired and is shown in the second illustration, ready for another term of service. The point in the story is not that one good job de- serves another, nor that the competent welder is an ever-ready help in time of trouble, but that the second break did not run through the old weld. This was left unharmed. Nor was the new break in the region pre- heated for the old weld. It was in the crank bearing, 4 ft. away. This, then, demonstrates the original prop- osition, that a second break in a properly made weld need not be feared. *Allmetals Welding & Mfg. Co., Baltimore. SSRIS ha 5 is haa a Budget Methods of Metal Product Company Sales Estimated in November for Following Year and Manu- facturing Program Planned—Selling Expense, Advertising and Administration Budgeted Cleveland Metal Products Co., Cleveland, manu- facturer of oil stoves, oil heaters and porcelain enameled steel products, is outlined in a report on ‘Budgeting for Metal Working Establishments,” re- cently prepared by the policyholders’ service bureau of the Metropolitan Life Insurance Co., New York. The procedure is offered as applicable to enterprises manufacturing specific metal products rather than to those which are engaged on special order work. It is based on the practices developed by D. C. Lowles, audi- ter, and C. E. Anderson, manager department of statis- tics and commercial research, of the Cleveland com- pany. The thorough faith of the chief officers of the Cleveland company in the budget is emphasized as hav- ing made possible developments not ordinarily found in metal working establishments. The size of the com- pany’s operations may be noted from the volume of sales, which in 1922 were more than $14,000,000. Two plants having a combined area of 816,372 sq. ft. are operated. The outstanding feature of the budget system is the consideration given to forecasting reasonable sales ex- pectations. The unit accepted by the company for the accumulation of data and for purposes of forecasting, is the “county,” which unit was chosen because the com- pany’s product obtains its best distribution in rural sections. A detailed analysis has been made for each “county” of all conditions which seem to affect the sale of its product, and the resulting data is entered on a “county card,” which is shown as Form A. On these cards the shipments to dealers are tab- ulated monthly by counties, a report being sent to each district manager every three months showing the county totals by items for his district. The manager has a duplicate set of cards and is advised of any addi- tional information or changes. The card provides for the leading competition the company has to meet. The information therefor was obtained mainly from a “poll” of oil stove users, conducted by magazines and journals in which the company advertises. To supplement this condition of competition, the company’s own salesmen check up from time to time by questioning the dealers they call upon. It is admitted that this data is not com- B ‘cievets procedure based on the methods of the plete, yet it does give an exceptionally good “cross-sec- tion” view of county conditions and is proving in prac- tice an accurate basis from which to work. The last Government and other reports of crop, financial, and trade conditions are carefully analyzed and used to modify the expectation of business to be done as well as to reveal the sections where special advertising or in- tensive work is required. The “county card,” on the reverse side, shows what business has been done for several years back, and there is now being accumulated by means of the punched card system monthly shipments. This knowledge of gen- eral conditions and best sales is considered essential for a reasonable estimate of prospective business. As soon after the first of November as the October statistics are completed, the statistical and research department make up detailed statements covering .the ten months’ business, January to October, plus an esti- mate from November to December. These statements are then forwarded to each district manager for a pre- liminary estimate of the next year’s business. The estimates after being carefully reviewed, are then translated into a “manufacturing budget” so that the cost department may develop a manufacturing program and figure standard costs for inventory purposes. As it is a six weeks’ job to make entirely new standards for the new line of product, che necessity of beginning this work by Nov. 15 is clearly seen. After the preliminary sales estimates have been re- viewed and the manufacturing program decided upon, the budget officer visits the distric offices and works out with each manager a revised s: s budget, adjust- ing the ratios of the various products and increasing or decreasing items which appear to be out of line. Upon the budget officer’s return to Cleveland tl * figures are again carefully reviewed and then approvex by the gen- eral sales manager and the directors. Sales Expense Budget Established Once the sales budget has been determined, a sell- ing expense budget, or “sales operating expense bud- get” is established. This budget is n de up by districts under the following five groups of expense: office and general, salesmen, warehouse, transportation, and sales Form C—Production Schedule—N Esti- Actual Esti- mated Actual Shipments mated Produc- -—Estimated—, Produc- to Dirs Work- tion Production tion Actual and Dist. ing per Day, Per Month per Production Calendar ( at the Right ser it Working (| Production Schedule roduction programs sed factory departmental udgets are made up Inv’ty. at Cleveland 12/31 Produce in January Total made to Jan. 31, i Produce in February... Total Produce in March Total made to March 31. Produce in April........ Total made to April 30.... Produce in May Total made to May 31 Produce in June........ Total made to June 30 Produce in July Total made to July 31 Produce in August Total made to Aug. 31. Produce in September Total made to Sept. 30.... Produce in October.... Total made to Oct. 31 Produce in November.. Total made to Nov. $05 Produce in 910 made to Feb. 29.. treaanaaenn HHLNEDAETTEALHERUREDENNONED 849. cover eneneveEREHERE eeeernerntenortneeHEErRNENeRDONE Days Gross Gross Single Day per Month Year, 1923 ae Be ae 8,568 Seas wane > Nae 0 0 0 8,612 nel hi sie 23 8 184 23% § 117% ie an ‘5 120 nt oe oe 70% 23 0 0 24 0 0 ai "33% Se 23 2 46 25 2 "50 21% 0 i. aye 3 60 October 9, 1924 THE IRON AGE 911 Te SCC RETNERELS DUEUORUTEAT ONAL COPEOREANELISONE9 CEOEDGRUOREOUOSEEED BortResESTOSOLTE DO AT HTENTHNDYS 1411069 °FTYETED |CUROMMEREDENER CCRERTDEL BENDER HONS: DEDEDE eH rRAERENEEY HEEL ONDE Vets e600 ceanenane + ecw ory Form A—County Card, Front Side 1 2 3 4 5 6 Ratin CGS o'siccindd hiwescctelceyudvarehiix o UACE. oc crcccvccce csscecseccces K6ees eee RUE (DOGS ce eeecucucee: eeveees 7 Bia ghto ws eNeeph os.0e 64 eet CET s 68450 cb hud 00 ceeee <0 0 Bene hon diknduous ans dedeesctelsacecaes nee seshbecoeeeeen Yumber of Families...............-.. Buying Power Per Capita. .....ccccsc ccvcceces Population ED inne. <'nths 04 44a oes runes COREG: CINE ok Fea'cc cb Gem ebe vee Per Cent of Saturation. bin 6 40g Se tans ua wie oad ee Cee EE: OF TRO. Pe OE Ni 6 6c a 0 once 4606.ciwencanidiness octane th oenhed dea dnatakdend aadudine Number of Illiterates...........e+es) a ee. (‘i ae hl ORC oe Per Cent Illiterates to Population... Per Cent Dealers to Families....... Life of Stove “Year” N.P. & Pur. Superfiex Heaters Ce rar SER DS inxs os 62 60:4 cen: et is we a 4 Ue dencuntenn ee ee Qe TE bs ve S byrne ds CabtocbvencaGibedesadiedeatascntkndcneaeee v.w:e 0 ahdheanin elena iad nae Guinea Sa Cs nth ccsins ¢éuins Per Cent Competitive... ._ |... . Competition .... Kind Manufactured... .°). 1) **! Source of Income....................Manufactured Products.......... Pe Weenie cnc eneaseeisanebwe DRE «cock ound envebauesasvcatennvcacstaeucd eens LUllEee inn <nhdiGds than vnakiihniiiesdmnnan Form A—Reverse Side rc—— —Stoves———— ~~ ——§Cabinets———_ Ovens—, -~Heaters— -—Wicks—, 2 : Per Cent Total Per Cent Per Cent Per Cent No. Date N.P. Sup’x. Pur. Total Farm's. Bur. N.P. Sup’x. Total Stvs Stws. W.H. Qnty. Fam’s. Qnty. to Bur. CNHUTNTUNE AUDOREED EE TbeE HUEDHONE TONED OOHMOENEREESeDeEC DUNN LORDONERONTEN EOLEE NEEL revaEMEREEEHENS UoeeD etraane ry ernte Lets freight. The total expenses for the year for sales oper- ating are then allocated to the individual months. In determining the sales operating expense budget, the addition or elimination of warehouse points is decided upon as well as the required office force and salesmen. There is thereupon made up for each district a “sales and operating budget,” Form B shown herewith, which gives a final percentage of total estimated operating cost to planned sales. This budget shows the actual results for each district in comparison with planned figures or established standards. The marginal allow- ance shown in the report is the cost to sell allowed the district by the budget and is the total estimated operat- ing cost computer? as a percentage of anticipated sales. The next ster s the preparation of budgets for gen- eral administrat e departments and for advertising. The advertising budget is usually worked out by set- ting up a definite percentage of estimated sales, say 4 per cent, ‘4 an appropriation. This appropriation is then referred to the advertising and sales committee for development into a éomplete program of publicity. Upon the completion of the budgets for sales, sell- ing xpense, advertising and administration, the stand- ard stocks or inventories at each warehouse point are then determined for each month of the year. Such standard require 1ents are based on 30, 45, 60, or 90 days shipments, according to the distance from the fac- tory, the speed with which the stock can be replenished, Qnty and the available storage space. Each sales district is split up by kinds of product and different styles, and the amount expected to be shipped each month is then entered on the district warehouse report for each stock carrying point. From such standard stock requirements it becomes an easy step to work back to a complete revision of the manufacturing program, which up to this point is con- sidered only as preliminary. To the manufacturing de- partment is left the task of coordinating the sales re- quirements with efficient manufacturing, avoiding on the one hand the peaks and valleys due to making the factory force carry the load and thus giving an ex- cessive labor turnover; while on the other hand avoid- ing an unbalanced and unduly large inventory with its burdensome carrying charge on the investment. How the Production Schedule is Worked Out The manner in which the production schedule is worked out may be illustrated by one of the company’s minor items shown on Form C herewith. The form provides for the estimated working days in each month; the estimated production per day in terms of gross; the estimated production for the month; and the actual pro- duction per day and for the month; the actual shipments to dealers and district offices last year and for the com- ing year; the planned shipments for the current year; the stock on hand after allowing for planned shipments; LEvePeReRPeREETRRERSOEREEDEEENE DEE epHEHRRUTEPRENEDEEN THETA DETER EHnETCANEDS TNE Wen erees+-sonene w ” nesnees Sennneenencers sennereberemmensseeeneses a0000* rn sseeessversenersenepensss sernasacosens 441 Wicks—Calendar Year 1924 Cleveland’s Actual Budget Differ- Stock Shipments Shipments Total ence is Per Cent to Dirs. to Dirs. Stock After Branch Equals of Next Actual and Dist. and Dist. Deduction Stock Cleve- Month’s Cleve- Actual Actual Calendar Calendar Budget per Sales land Budget Sales land Branch Total Year, 1924 Year, 1924 Shipments Department Stock PerCent Stock Stock Stock ate aan Cl. 8,568 pws el oy ine b0o ro eee coos BE. SA,ket snea'’ ~~ een” "Vist. fie @ ceeaee wn. sen 29,725 suse 8,568 21,157 29,725 9,224 9,224 cates? vase’ a? 1/15 ied ; To the Manufacturing De- an’eee Oe aoe 8,044 12,467 69 at partment Is Left the Task 27,224 28.997 9,520 19,477 101 2/29 of Coordinating the Sales 19,203 2,283 a . . dee eds 3/15 Requirements with Eifi- 46,427 26,714 9,130 17,534 128 3/31 cient Manufacturing. 13,737 3,643 >"> ae one 4/15 Peaks 4 i h 60,164 30,257 7,742 22,515 146 4/30 and valleys wit 15,470 5,318 jiee | fr beees cnn 5/15 excessive labor turnover +o Ss aos 6,446 18,493 146 sae see be are avoided as well as un- 87,462 13,111 4,892 8,219 146 Se! vesas. dares balanced and unduly large 5,633 en eed ees cen UE BSS ee inventories 93,095 7,478 4,397 3,081 123 eo ga ak > eee 2,495 889 eees cases oon eit °° acace 4 Werner 95,590 8,367 5,119 3,248 82 ee). en ead = onlin 3,983 2,641 eae. pee gee ete! | sdéee ”.- aman 99,573 11,008 6,135 4,873 106 eat. seve 4,600 2,600 Seth! ele itl | ovewe. ~. : eats 104,173 13,608 5,796 7,812 167 nn " posed eaae 4,674 4,674 ain. °- « lempith san Sa) veces... ~ ae 108,847 8,934 4,557 4,377 250 Ree.) aietee i>... ana 1,752 6,888 sa deed ok geal ana et. senkh.. | > aapekn 110,599 15,822 7,257 8,565 93 aevee °. weeds ow Ce cere genet gp ope eer at eens ees ee SE FRE REL REEL TTT SEEN ALL LL TTT TT cm ee a Te a, TT i ana iy haa 5 asia hs ; j ve ai € § Fe Th it . np? ‘ ‘Be ES 2 cf BE S ats Be vee we: , ® i aS o he i af a + ie oe H aS . ie = ‘ i: s a 4a ie wv - ia — HY ne # or a! oak} = 5 toe wei ed a mg ae ae ae “* 2 i THE IRON October 9, 1924 AGE suvecoenoueesrneoevennnns One; 0He08001 BOAO: UTTOERSORDTOOCOEREDEDEREDEUAENTEDUORCTUATTDERELEDELESRORTEALLORUELSMELOHEREGOOEUEDETYTHTTEEDEDEVURREDEONOHPLELTTR’ POERET RDO SHOREUHZEGUHLANNEALITIZIEAE*T*OHORORE HtMnAdierten pcs Form B-——Sales and Operating ee oc cde ec ane enh bade e eee teres ie oc va hava e Reba nearks meee Ra ACER SAW ON Wied oo —Actual—__—___,,_->—— Budget— r—Last Year— Per Year Per Year Per Total Per Year Per Month Cent to Date Cent to Date Cent Year Cent to Date Cent Sales: Choke Stove and TOater. vic cc cove, sedene srccte seceee cee ene | Avnet SE SOe SREB Ree) = ena erw en ee aekeee TORU on. 6.0.9 oe ndape wes eekeetess§ wesees eccubbeeco serees C8RSES Bev en wen eee OOO) (Mare ales FU armnnee © ee tear G ls. Mitel Met Melee. ....cccccvccests saseve esenes Conses Santee 9 Soames Rieh ooen = Stent eee mn ee Marginal Allowance: Qaok Stove emMG Heaters .ccsceaccs pescse cveces cvseee <cbeins tenes Seed es) =e Sees |e eee = tmerames TIGOMAN cccccveveveseccsdscercese pebnte Chenss canbed SeSnbel SNe. baer e bh eS) eee tore eens Mintel DEOPOIN, 6 .ccccesciescccccses seoees ‘ennevs deseet wEeent “Seay aver Rs SNCS 7 eee eee Operating: Dine OH General...c.ccccccscnces sevees criecee Cevees) sceces SsNE ul eheeee: ‘Seen e | «6 EMIN MEN Mamie Mew, Ce gc accorocesvdberdetencve teeors cevees 98808 “COUP OE Caples Rew ET a 50 eee een eee THAEOMINS .ccccccccusecncbesnees sesces. Severe SOePEe SOE Res nage eiee Seieeg es! " sire athe} core renee ies TAMSMOPERTION 2.202 ccccccccccesess snecee eeeces ‘e68ne0 (Boner e Ubsvees Wersee C5ESSD | Se eww NMG MeeT we was. alae WHOM .ccccccccccccrccvenes Abecce veeevs C8000 eames (eeakem Vesiews, (WOO ue) seem me ees Total Oper. CG. G. & Ha... ccsccee covcce oesee seocee se edbe! Yednse setes® weCes¥ See Rew me nw eel Usne on « Total Oper, Utenelle........scecs coocce cvcoes Ceevee Seeses seseee Ssesee seeses SRG eee SROnSR NOs se otal OperatiN......cccccrecsesge scucen seeece Sseves waseet (F5506 8) louse eet Cees es iNew ee Vee eee... On ee lo kcs se cetees odeeee. sareem Cab ehee, — 6 en heel ele ets lee eee nen Bo Marginal Allowance TO kcs cee «(teense wenéue seekes Sevuss evebee “tN heS bir 5 eee eee the branch stock standard which, subtracted from the total stock on hand, gives the home office stock; the percentage this bears to the month’s sales; and the actual home office, branch and total stock. From the Form D—Budget Estimated Operating Statement Year 1922 Per Cent Net Sales: of Total Cass “A” $8,000,000 80.0 Class ‘*B” 800,000 8.0 Class “C” 1,000,000 10.0 Class “D” 200,000 2.0 Total .. . $10,000,000 100.0 Per Cent Production Costs to Sales Class “A” $4,800,000 60.0 Class “B” 560,000 70.0 Class “C” 650,000 65.0 Class “D” 160,000 80.0 I i i ial as ae lr ae eh ae $6,170,000 61.7 Per Cent Gren WEAPTER. 2 oc cv essvesecevseen $3,830,000 38.3 Selling: Sales administration .........+-eseee-. $200,000 2.0 General sales department expense.... 50,000 5 Special promotion, etc...........++- 50,000 oD District operating expense 1,600,000 16.0 Advertising “A” aes 400,000 4.0 Advertising “B” 50,000 5 Advertising “C” 100,000 1.0 UE 6p aes $2,450,000 94.5 Net margin . $1.380,000 13.8 production programs, final revised factory depart- ‘ mental operating budgets are then made up. The foregoing information, which deals with sales and production budgets, should be supplemented with the financial budgets of the company, which information was first supplied to the fabricated production depart- ment of the Chamber of Commerce of the United States Form E—Budget Estimated Loss and Gain Year 1922 Net gain from operating statement Cash discount receivable i PCT Te Pee Miscellaneous items $1,380,000 50,000 20,000 10,000 Deduct Net interest cost ; Estimated inventory $1,460,000 $100,000 260,000 ach 360,000 $1,100,000 Federal taxes and contingencies. . 150,000 Total available for dividends and surplus. . $950,000 and appears as a part of its pamphlet, “Budgeting for Business Control.” In making up the financial budgets the first form used is an estimated operating statement as shown in Form D, the figures given being hypothetical and used for purposes of illustration. The second form is an estimated statement of loss and gain, Form E, from AOUULOEOTLALLEELPDOGHET EDEL EOOOOEDPROEDRELTIOADDIVOEES FDbOOERODE |” MOOT DOLOOOREHLOMEDORT ORR PNeEPORAERTERORER OM ETIEL Mec which it is easy to forecast changes in the balance sheet over the budget period. In regard to preparing the monthly profit and loss statement, it was stated to the fabricated production department of the Chamber of Commerce, by D. C. Lowles, auditor Cleveland Metal Products Co., that the cost of goods sold is compueted on the budget or standard cost, the excess or reduced cost being taken up as a separate item. Inventories are all figured at standard. These standards may be changed during the year if conditions warrant it, and are always revised for inventory purposes at the end of the year. From the estimated statement of loss and gain, an estimated balance sheet, Form F, may be made to re- flect the changes arising during the budget period. In preparing such an estimated balance sheet it is neces- sary to determine what portion of the estimated surplus should be shown on the estimated loss and gain state- ment as a distribution to dividends. For this purpose a capitalization of $8,000,000 is assumed, of which $3,000,000 is preferred stock. Form F—Estimated Balance Sheet Assets Est. Current: Dec. 31,1921 Changes Dec., 1922 IR oe oto Bar adage ee $25,000 $15,000 $40,000 Notes and accounts re- ceivable less reserve Tor Gomera) sax ass 1,225,000 125,000 1,350,000 Government securities. . 1,250,000 100,000* 1,150,000 er oe 3,200,000 400,000 3,600,000 $5,700,000 i ...s«- $6,140,000 ne eee $850,000 $50,000* $800,000 Investment and other SEN Kecivce da ean 475,000 25,000 500,000 ROE «56 6:6 i kane hin ei 00,000 5,000 505,000 Plant and equipment less depreciation 4,500,000 100,000* 4,400,000 Total assets ...... $13.006.000 ~ sswxbua $12,345,000 Liabilities Current and accrued: Accounts payable ...... $275,000 $15,000* $260,000 Accrued taxes, etc..... 80,000 20,000 100,000 Reserve for Federal taxes and contin- Re ree 175,000 25,000* 150,000 Funded debt (Notes)... 3,000,000 ...... 3,000,000 Capital stock (Pre- SAVORED iss aaron ia DOGS BOG «ne canie 3,000,000 Capital stock (Common) 5,000,000 ...... 5,000,000 DETERS i scGucddsle 495,000 340,000 835,000 $13,035,006 ~~ .oGaxvses $12,345,000 *Deductions. The loss and gain shown on Form E is $950,000. If dividends on preferred stock at 7 per cent of $210,000, and on common stock at 8 per cent of $400,000—or total dividends of $610,000 are deducted from the profit of the period, there is available as an additional surplus $340,000. On the following estimated balance sheets, Form F, prepared by D. C. Lowles, auditor of the Cleve- land company, such $340,000 increases in surplus is re- flected together with other changes. Electric Furnaces for Heating and Melting American Electrochemists Cover New Ground in Discussing Electric Industrial Heating and Corrosion—Round Table Luncheon Session on Electric Furnace Cast Iron at its forty-sixth general meeting at the Hotel Tuller in Detroit on Oct. 2, 3 and 4, staged three which (Fist new emphasis to its excellent record in conducting symposia, the American Electrochemical Society added notably to the literature on electric industrial heating, on electric furnace refractories and on corrosion. two sessions. variety and in animated discussion. The corrosion sessions stood out in respect to papers and the time devoted to them—i2 papers and The symposium on electric industrial heating, with only five papers, was unusually interesting in As in the past the attendance was large and the discussions full. A feature of the convention was the round table luncheon at which electric furnace cast iron was the topic. The chief papers and events are reviewed in the following pages: Symposia on Electric Industrial Heating and Refractories T Montreal, two years ago, at its annual fall meet- ing, the American Electrochemical Society con- ducted its first symposium on electric industrial heat- ing. It was a highly successful one—the first one also ever held by a technical organization. It dealt more extensively, however, with low temperature applica- tions. (THE IRON AGE, Sept. 28, 1922.) The one last week at Detroit was less pretentious in the number of papers. read—five in all. The dis- cussion was ample and the variety as well as the quality of the contributions were satisfactory. The organizer and chairman was C. F. Hirschfeld, chief research department Detroit Edison Co., Detroit. In his preliminary remarks Mr. Hirschfeld said that while Detroit engineers were not the fathers of electric industrial heating, much had been done in that city. In the early days it was considered a gamble to start an electric industrial heating process. Now there are many on a large scale in Detroit, which is at present one of the centers in this field. Because of too many “crazy ideas,” electric industrial heating is still too much of a gamble in some places. “I personally am trying to bring about more education so as to have fewer failures. Our program today is a record of successes.” Electric Furnaces for Heat Treating Based on an investigation of considerable scope, Col. A. E. White, University of Michigan, Ann Arbor, Mich., introduced this symposium on Friday morning, Oct. 3, with his paper, “The Use of Electric Furnaces in Heat Treatment.” It was not available that morn- ing in printed form, but is by this date, so he presented a liberal abstract. Professor White compares the various types of heat- treating furnaces, giving examples of performance using various fuels, and also costs of operation—most of this based on actual operating conditions. From this information he is enabled to formulate recom- mendations for furnace design. Among the factors which the author considers are dimensions, heat dif- ferences, distribution of heating elements, insulation, heat circulation, accuracy of temperature control, re- sistors and various furnace types. From all these standpoints and others he pronounces the electric fur- nace for heat treating to be advantageous. Appendices to the paper contain definitions, a table showing heat- ing values for iron at different temperatures and heat treatment data from a number of actual plant runs. There is also a complete bibliography. Describing Professor White’s paper as a vast amount of data from a special investigation, the chairman called for the presentation of two other papers before general discussion. Hardening and Tempering Wire Electrically The first of these was “Electric Furnace for Con- tinuous Hardening and Tempering Wire,” by R. H. MacGillivray, industrial heating engineer, Westing- 913 house Electric & Mfg. Co., New York. It was pre- sented in abstract by M. B. Carr in the absence of the author. The paper is based on experiments carried out for the Stewart-Hartshorne Co., East Newark, N. J. The author asserts that the electric furnace has proved an economic factor in hardening and tempering steel wire and that it has been extremely successful. Even dis- tribution of heat throughout the furnace chamber, with absolute control of temperature at the proper point required insure a uniformly satisfactory product, with few or no rejections due to improper heat treat- ment. The paper is brief, and contains illustrations of various phases of the process. Annealing Brass Tubing Electrically The subject of the second paper was “Annealing Brass Tubing in the Electric Furnace,” by Robert M Keeney, industrial heating engineer, Westinghouse Electric & Mfg. Co., Boston, Mass., also presented in abstract, in the absence of the author, by Wirt S. Scott. This paper demonstrates that the annealing of small brass tubing is more economical with elec- tricity than with wood; the installation described is that at the plant of the French Mfg. Co., Waterbury, Conn. The details of the furnace are given and some facts as to cost, together with other information. Discussion In the discussion of the three papers Mr. Mac- Gregor, Wolverine Tube Co., Detroit, said that the use of wood had long since been abandoned for anneal- ing brass tubing; that oil had largely taken its place. He agreed with Mr. Keeney that the brass and copper industry has been, and in many cases still is, too secre- tive and conservative—“as many as 200 years behind the times.” He considered the annealing of copper as important as that of brass, and declared that the in- dustry was getting more and more into the use of electric heating and melting. In some of the General Electric Co. iron plants oil furnaces are used in preference to electric for certain purposes, said E. F. Collins, heating engineer, of that company. They had investigated the relative merits of the water-sealed electric furnace with the oil-fired, and one striking fact they had discovered was that with electricity it had been possible to obtain a degree of softness impossible with the use of oil. The funda- mental proposition is one of cost as between oil and electricity—one to be rejected for the other and vice versa in certain Cases. Replying to a question by George M. Berry, chief chemist Halcomb Steel Co., Syracuse, N. Y., as to the flexibility of the electric heat-treating furnace, Profes- sor White said he had not much data on the increased flexibility of this furnace—‘“a furnace is a furnace.” The degree of flexibility is probably the same as in a gas or oil furnace, for in heat treating it is not prac- ticable to go above 1700 deg. Fahr. The efficiency of ‘ © Mpa SEs OA RE er 8 SE oer eer seas oat PE eee Sen Ae ee ‘ < pt = sey eal a, ; et as pa parte ean ona Se puke ‘ Sr er ae ergntlididieniiad ad —s ee a 914 THE IRON AGE coal is from 40 per cent up to 85 per cent when the furnace is hot and the relative difference is the same for gas or oil. Present resistor elements have a limit of about 1800 deg. Fahr., but there are one or two products reported about to come on the market having a range up to 3000 deg. Fahr., which, it is understood, will be successful as soon as proper methods of contact are perfected. Professor White spoke of a new so-called “compen- sating” furnace for heat-treating with electricity which has been described as having an efficiency of “150 per cent.” This electric furnace, which was visited later that day in operation at the plant of the Hudson Motor Car Co., is used for heat-treating cast iron—that is, annealing small iron castings. It takes care of about 22 lb. of metal per kw. hr. and increases the output of the machine shop decidedly. Fast Electric Brass Melting A more interesting paper at this same session dealt with another application of electric heating—‘Electric Brass Melting,” by F. S. Heath, works manager Fed- eral Mogul Corporation, Detroit. Mr. Heath read his paper, which was still in the printer’s hands. It is full of valuable practical data and deals with his own foundry’s experience in melting about 15 dif- ferent bronzes—about 23,000 lb. per day. The author stated that one of the greatest potential fields for the electric furnace is in small foundries and that small furnaces are more flexible than coke-fired crucible ones. The secret, in his opinion, of economical melting is to keep the furnaces melting on as high an electric input as possible. His company has three (two more later) 250-Ib. Detroit electric furnaces, taking care of about 230 lb. to the charge in 70-lb. crucibles. From 12 to 15 heats per day is the rule. On one day 21 heats were made from 6.15 a.m. fo 3.15 p.m., with the aver- age time per heat 17 min. plus 6 min. for charging and emptying, or 23 min. in all. The largest number he has obtained from his coke- fired furnaces was 6 heats per day. The limiting fac- tor to the electric furnaces was a lining. The aver- age consumption of electricity had been about 325 kw. hr. per ton and 6.5 lb. of electrodes per ton. The author enumerated the advantages of these electric furnaces and gave the physical properties of the elec- trically melted bronze as compared with the coke-fired furnace’s product. The comparative cost he put at about $3.50 per ton in favor of the electric melting. Discussion The speed element was pointed out by George K. Elliott, chief metallurgist Lemkenheimer Co., Cincin- nati, as the feature of Mr. Heath’s paper. At the round-table discussion on electric brass furnaces at this society’s convention in Dayton, Ohio, a year ago, a fear of rapid melting was mentioned. The speaker said he was not surprised that the metal was unin- jured at Mr. Heath’s plant and cited as a parallel the rapid melting of steel. Mr. Elliott added that he had heard of a rapid oil- melting process using high pressure, the time required being 10 to 20 min. per heat. This might develop into a competitor with the electric unit. Responding to a query by F. A. J. FitzGerald, Niagara Falls, N. Y., as to why linings fail, Mr. Heath said this was due not to the melting of the lining, but to its tendency to crack, resulting in harm to the in- sulation, etc. Gray [ron Made in NFORTUNATELY for those unable to be pres- ent, many interesting problems and _ solutions brought out at the round-table luncheon Thursday noon on electric furnace cast iron cannot be published. It is always understood that these gatherings are not to be reported and that each speaker can be free to speak his mind. Only a few features can be outlined. At the fall meeting in Dayton last year the first round-table luncheon ever held by the society was in- augurated. (THE IRON AGE, Oct. 4, 1923). Its suc- October 9, 1924 A discussion of the speed of melting would be in- complete, said H. M. St. John, chief metallurgist Detroit Lubricator Co., Detroit, if the mixing of the charge were not included. Rapid mixing insures faster melting and this is a feature of these furnaces. Lin- ings, of course, fail from cracking. John A. Leede, electrical engineer, General Electric Co., Schenectady, N. Y., also cited agitation as to the feature of the splendid results described in Mr. Heath’s paper. In reply to Mr. Leede’s question as to how many days do 1000 heats mean, the author said 60. To other questions Mr. Heath explained that 0.60 per cent loss meant entire metal loss and not zinc alone, and that the $3.50 saving did not include the crucibles used to carry the metal to the moids. This symposium closed with a paper by Harry Allen on “Electric Japanning,” presented from manu- script by the author. Symposium on Refractories The second symposium of the two on this program was a brief one of three papers on “Electric Furnace Refractories.” This was a direct outgrowth of the round-table discussion on this subject at the Philadel- phia convention last spring. (THe IRON AGE, May 1, 1924.) In the absence of the organizer of this symposium, Dr. M. L. Hartmann, director of research laboratory, Carborundum Co., Niagara Falls, N. Y., the chair was taken by F. A. J. FitzGerald of the same city. Carborundum Refractories The first paper, “Thermal Conductivity of Carbo- rundum Refractories,” by M. L. Hartmann and O. B. Westmont, both of the Carborundum Co., was presented in abstract. The authors contend that of all refrac- tory materials commercially available there is none which even approaches silicon carbide, or carborundum, in its ability to transmit heat readily and which at the same time possesses sufficient mechanical strength and chemical] inertness to resist the destructive forces in modern industria) furnaces. Tables are given showing the coefficients of therma) conductivity and heat flow through various types of walls with a temperature of 1500 deg. C. in the combustion chamber. Artificial Sillimanites “The Preparation of Artificial Sillimanite for Re- fractory Uses,” by C. E. Sims, H. Wilson and H. C. Fisher, northwest experiment station, Bureau of Mines, Seattle, Wash., was abstracted by C. E. Williams of the same station. A brief summary follows: The experimental work leading to the adoption of a furnace for the preparation of artificial sillimanite is described. Clay was found to be peculiarly difficult to melt, but could be reduced to sillimanite by elimination of the excess silica. Natural sillimanite has a different composition from the synthetic product. Artificial silli- manite containing excess silica is vitreous; that with excess alumina is stony. The latter form has excellent refractory properties as compared to silica and mag- nesite brick. Lime is a particularly undesirable im- purity. Fluorine in the Slag of Basic Electric Furnaces A paper by Frank T. Sisco, metallurgist, Air Ser- vice, War Department, McCook Field, Dayton, Ohio, entitled “Fluorine in the Deoxidizing Slag and Its Influence on Refractories in Basic Electric Furnace Practice,” was the third of this group. Electric Furnaces cess was so pronounced that another was conducted at the spring meeting in Philadelphia. The first one dealt with electric brass furnace melting; the latter with electric furnace refractories. About 150 sat down at the luncheon last week, which was organized by George K. Elliott, chief metal- lurgist, Lunkenheimer Co., Cincinnati, who was gen- ‘neucesvennarevousvenenueruusasevnsserscerenccauenseactsaret eeuennoserceneesnen et veeunesonenonnte:renusennecessensetcennocnervestener=ennearuwernneranenenore erxpesaroessse"0e4#re@ (Continued on page 959) October 9, 1924 Direct-Drive Movable-Head Drill The direct-drive movable-head upright drilling ma- chine shown in the accompanying illustration, which was developed by the Cincinnati Bickford Tool Co., Cincinnati, primarily for automobile shop use, was among the new equipment shown at the International Steel Exposition held at Boston, Sept. 22 to 26. Simplicity and durability are among the features claimed for the machine, which drills to the center of 21 in. The spindle operates at but a single speed and feed, a range within the general limits of 48 to 707 Gee evpenennensssvennennaseraasaeuen ss senate paneenpeny peesDeneniat camtrnens svenoensnenaeNE eH te Direct - Drive Movable - Head Upright Drill The head may be placed in three vertical positions, the extremes of which permit a range of 5 in The spindle operates at but A single speed and feed, a range of 48 to 707 r.p.m and 6 to 30 thou- sandths, respect- ively, being available r.p.m. and 6 to 30 thousandths per revolution being available. The spindle is 1 5/6 in. in diameter and is bored to fit Morse taper No. 3. The vertical travel of the spindle, with and without the trip dog gives 8 in. and 8 15/16 in. respectively. The spindle sleeve is 24%, in. in diameter. The head may be placed in three vertical positions, the extremes of which permit a range of 5 in. The motor is mounted upon a bracket which is made to adjust vertically in order to obtain a correct meshing of such ratios of gears as may be required. An eyelet at the top of the machine facilitates handling, and an opening is provided at the back of the column to permit of convenient access to the counterweight and chain. The maximum distance from the spindle to the table is 2 ft. 45% in., and to the base, 3 ft. 8% in. The table of the machine, which is 19 in. in diameter, may be moved 17% in. vertically. Its maximum height from the floor is 2 ft. 10% in. The diameter of the column is 6 in. The machine may be provided with a hand-feed pilot wheel and tapping attachment and with a belt drive, pump and oil grooved table. A 2 hp. motor is employed. The height of the machine, from the floor to the top of the spindle is 7 ft. The weight, plain, is 1275 lb. net, the weight with power feed and tapping attach- ment being 50 lb. additional for each attachment. Arranged as a single table gang drill, the machine may be provided with from 2 to 6 spindles, which may be mounted on a high or on a low base. The executive committee of the Associated States Opposed to Pittsburgh Plus will hold a private confer- ence at the Old Colony Club, Chicago, Oct. 11. The ex- ecutive committee consists principally of attorneys general of Western States. THE IRON AGE 915 Hammer for General Shop Service A utility hammer for general shop service, and arranged for either belt or motor drive, has been bought out by the Beaudry Co., Inc., Everett, Mass. Three sizes, having a ram of 25, 50 and 100 Ib., respec- tively, are available. The general construction of the hammer may be noted from the accompanying illustration. The rara or hammer head is of steel and has external elliptical- shaped tracks. Two steel spring arms with steel rollers at the lower extremities and a helical spring at the top operate upon the curved tracks and lift and throw the ram, which, with increased speed of hammer is said to acquire increased travel and force of blow. The full stroke ean be had on varying thicknesses of stock and change of adjustment is unnecessary except for unusually heavy or special work. The hammer is started, stopped and regulated by a foot treadle extending around the base of the ma- chine, as shown, and by a varying pressure on which is obtained any desired speed or force of blow. The ram is fitted to heavy guides and is adjustable on its connecting rod for varying heights above the dies. It has an adjustable taper gib for taking up wear. The machine is intended to be worked with equal advantage from all sides, the anvil clearing the main frame cast- ing, allowing bars of any length to be worked either way. The hammers may be operated by an overhead belt running at any angle or by a motor attached to the or) Three Sizes Are Available The hammer is started, stopped and reguiated by means of the foot pedal, by a varying pres- sure on which any spee a or force of blow may be ob tained. The ma- chine may be worked from all sides sae frame as shown. They may be converted into a motor- drive unit without any mechanical change except for the bolting of the motor bracket and the attaching of the motor to it. The smallest machine will work stock up to 1% in. square, the largest machine being rated for work up to 3 in. square. The number of blows a minute are 400, 350, and 300, for the three machines. The floor space occupied by the smallest machine is 16 x 21 in., and by the largest 24 x 28 in., the height of these ham- mers being 60 in. and 76 in. respectively. The motors employed are of 1, 2 and 3 hp. The weights of the machines are approximately 850, 1500 and 2500 Ib., respectively. During the first eight months the Class 1 railroads earned $561,059,355, or at the annual rate of 4.09 per cent on their tentative valuation, according to the Bu- reau of Railroad Economics. iad? Sy ee Way inbs s sthegy, 2a Ps rahe ea ke a Ai vs -~ RE i Re eae na ah gm yt 916 LARGE BORE LATHE Hollow Spindle Construction Permits Telescoping of Work Inside of the Headstock A lathe having a special enlarged hollow spindle construction, which permits the