The Iron Age 1928-06-14: Vol 121 Iss 24

IRON New York, June 14, 1928 ESTABLISHED 1855 Best Test Steel Accelerated Tests Not Conclusive—Many Acid Tests for Corrosion Are Misleading—Variables Which Discredit Are Numerous HAT the importance the time element testing metals? This question challenge the chemist, the physicist, the engineer and the metallurgist—and one not easily answered. The time element has but BOYLSTON rosion upon iron and steel, are dependent upon time. Science has repeatedly conducted research investiga- tions determine some fair and accurate measuring stick which relative corrosion resistance might computed. All little effect some the im- portant tests such those for hardness and tensile strength. The metallurgist gages hardness with the Brinell testing machine pressing ball surface the metal under known pressure and then meas- uring sulting indenta- tion. Since the load applied for only few seconds, elapsed tests does not affect sult. (Even the case ten- sile tests and Brinell tests well known that different results may obtained the tests are made Salt Spray upon Metals. The Salt Spray Test Helpful Determining the Effect seacoast conditions—it only indicator immediately af- ter the test bar has been machined the metal has been quenched than will obtained after waiting min. hr. during which so-called “aging” effect occurs.) Brinell test made today will show the same result one made next week. Other tests, devised determine the effect cor- *Professor metallurgy Case School Applied Science and metallurgical engineer, Cleveland. this study has been conducted make possible prediction the performance specific ma- terial specific environ- abling the pur- chasing select the ma- terial best adapted par- ticular effort terminations short length time, many tests have been conceived for which the ac- tion speeded up. Laboratory conditions are recorded, but the results clusive since true service con- not comparable with actual ditions cannot simulated accelerated tests. Observations have been made through artificial tests, but the many difficulties experienced have elimi- nated them true criterion service. Salt Spray Test Not Conclusive interesting test has been worked out which iron and steel sheets are placed box and subjected accelerated salt spray. Exact records are kept 1665 VOL. 121, No. the strength and amount spray, the tempera- ture, and the time during which the test conducted. These tests merely show that the particular samples used will withstand given spray for certain length box, there assurance sheet that this the deteriorates will same way the same rate used roofing sea coast buildings where vastly different conditions prevail. The ocean spray might much more severe, i 7 ~ i | | i T he S¢€ Sample S We re Expose d for Six Hours 5; Pe r Ce nt Nitra Acid. At the le ft is u fhe riant 78 stainie fee specia d: at The Acid Test Often Misleads but the stainless stee iffered little deterioration In the second test, samples were immersed for two week per cent hydrochloric acid. The special iron nained good condition, whil stainless steel was Imost eaten aw other word other conditions remain changed. The mentioned, not reflect dis- credit the special iron upon stainless steel, but show that acid tests can used prove superior orrosion” resistance the same material, Variables Which Discredit Tests Such tests, course, bear relation the actual ot metal ce pome f the variabl credit the est change the result 2—Time. the period during wl h t test 1] conducted chat Strength solution. For each acid there particular strength solution } n t eft chosen acid strengt nanifestly imp le. olution brings more the acid contact 1666—June 14, 1928, The Iron Age 5—Aeration. The presence air the solution often greatly increases activity. Naturally, practically impossible have different locations “acid test” solution contain equal amounts air. 6—Kind solution. Different acids react dif- ferently, the illustrations show. acid test shows only that certain piece metal lasts longer shorter time the particu- lar acid and particular strength acid used. 7—Foreign dust particles. Such factors may have retarding accelerating effect upon the reaction. specimen. great deal depends upon whether the specimen completely im- mersed, only partly so. also impor- zontal position. Such minute details affect the rate the acid corrosion. area. very important com- pute the ratio between the surface area the sample and the volume the solution. thick piece metal with comparatively small surface area will not lose, any given time, great percentage its weight corrosive solution will thinner piece metal the same weight with compara- tively larger surface. Therefore, the weight all samples would have exactly the same proportional ratio the volume. 10—Time changing solution. The strength solution dissipated after certain length time. may changed and brought full strength. When this done, the time changing introduces variable difficult evaluate comparing results acid effect different materials, since the acid not consumed equal rates with different metals. the metal. general, polished surface less subject attack corrod- ing medium than rough one. And on, almost without end, can uncon- trollable factors making comparisons acid tests lead erroneous deductions. Sur- These Samples Were Exposed for Two Weeks Per Cent Hydrochloric Acid. Special iron the left; stainless steel the right. Change the acid and the results are reversed. Almost any desired performance can demonstrated ac- celerated tests different annealing treatments, different processings manufacture, surface density, and many more variables preclude the possibility securing representative imples different metals. From review all these variables, ipparent acid corrosion test quite atmacn]) To atmospnerlic, Views Testing Engineers ting note the stand scientific bodies the question acid tests. the American Society for Testing Ma- which other metals have been might only intermittent The temperature would also vary. The test, therefore, cannot looked conclusive. Another instance whi the time important factor the acid test. Two the illus trations show the confusing results obtained putting a speci il iron, to which other metals have been added ee a and stainless steel, acid solutions. the first acid tests, the two samples were sub merged for hr. per cent nitric acid. The specia | | | mreliable water soil corrosion. terials regarding such tests was given early the 1911 report, Vol. 11, page 100: The results such tests are unreliable truly measuring the tendency natural corrosion. For this reason, the committee desires at this time to aga disclaim any recommendation or acid test measure natural like the British Institution Civil Engineers faced the same question and went record 1920 saying: indorsement of the corrosion, manner, Numerous attempts have made to determine the relative corrodibility various samples metals elaborate laboratory tion method held high esteem manufacturer within recent years consisted exposing the metal the action time, and noting the was found, however, way give no indication offered been methods, known as “accelera- sulphuric acid for set periods weight due to solutior results losses in that obtained in tl whatever the relative metals to corrosio n actua sistance practice. mous with solution, which may suit some chemists, but will not suit all If we know anything at all it is that failure, when it comes, or begins, often occurs very suddenly, and that “simulated” time tests may often give the most misleading results Other Tests Questioned addition acid tests, other forms artificial tests have been used effort simulate service conditions and still not wait the length time that service usually necessitates before conclusions can drawn. affect These tests not escape the dangers which those mentioned They remain isolated examples and, due unknown unappreciated vari- ables, can give and have given results which run en- tirely counter the testimony years experience those would seem proper question the value the test rather than the material tested. Among the most comprehensive tests this nature above. gained before and after such tests were run. cases. Actual Service Proves the Durability this Iron Culvert Installed the Riviera Santa Barbara, Cal. The picture below was taken 1913 when the culvert was installed The other view, taken 1923 shows eucalyptus tree that grew during the period the service 2 — = “> : < > , The inaccuracies such methods have been recog- nized the United States Bureau Standards, which has also gone record regarding the value ac- celerated tests. Bureau Standards Circular Let- ter No. 192 corrosion tests, appears the following: Proof superiority servit requ different materials sl have be ind condit error in the t ssum } at r pe ! under or et dit I I n e will be milar under ! é ve oft ‘ d as di similar statement appeared the (London) Jan. 1928: ghest repu hav Zs ( ded nd have l I f alloys re » I sub ed to tl ( specific acids s } ( were those run the American Society for Testing Materials. Every effort was made keep these absolutely scientific basis, but some the results ob- tained showed surprising variation with the facts established from many years service life. The Bulletin the society for November, 1925, makes the comment that interest connection ith the foregoing +} } ‘ te | M re- litions The } th n r r e | hold Scientists well practical engineers agree that The Iron Age, June 14, 1928—1667 the only true and sure method forecasting the dura- bility materials through the observation service rendered actual installations. turn the field service, find what different metals will do. “In studying corrosion economic problem, the experience actual users equipment phase study occasionally overlooked, whereas reality com- mercial usage the final criterion the real worth any says Dr. Demorest, professor metallurgy Ohio State University, the June, ind Metallurgical Engineering. That’s the question—what will do? iron ulvert, for example, lasts years its first location, tands reason that another iron culvert, similarly manufactured and installed under the same conditions will last the ime Investigations have been made which various types culverts were compared service life, in- stallation conditions, and on. the basis such facts, one can estimate quite accurately how long cul- verts will last. Service the Only Authoritative Guide Metallurgists everywhere have come the con- clusion that service the only conclusive and authori- tative guide. They know that accelerated labora- tory test theoretical, and further that, when certain metal lasts for years the roof building where lashed corrosive salt spray, this fact speaks volumes for its durability and carries complete justification sound basis purchase. Double Plate Turn-Over for Inspecting Device for Turning Plate Twice, Permitting Examination Both Sides Before Shearing plates, after their final pass through the rolls, undergo series rigid inspections. plant lack- proper equipment for such inspection usually suf- fers heavy loss time the manipulation and han- dling its product. This obstacle production has been eliminated the Lukens Steel Co., Coatesville, Pa., mechanical device for turning over steel plates from one side another facilitate inspection. Known “double plate turn-over,” this equipment was de- signed and built Birdsboro Steel Foundry Ma- chine Co., Birdsboro, Pa. After leaving the rolling mill, steel plates are fed through annealing furnace, where they jected heat treatment which also gives them their ) final coloring. From the furnace the through leveler, machine employed straighten the plates, removing warps and flute Upon leaving the leveler, chain conveyor takes the plates forward the first inspection table. The rollers this table are roller bearings. this table the Inspection the plates made here and now that the first examinati } mounted Hyat plates excess scale, ete. one side onl device performs. Between rollers the inspection tables, every are movable arms approximately 5-ft. length, rest- ing beneath the roller surface recess cored table aprons. These arms are pivoted one end heir own bearings, and operated through ponding arm, lying opposite direction, with seg- turn-over ment gears cast them and meshed with one other. The arms, whose position rests opposite those 1668—June 14, 1928, The Iron Age the first inspection table, are operated main shaft which they are keyed. This shaft oscillated crank movement one end through gear re- duction unit and 20-hp. motor, compound wound, 600 r.p.m. the operator works his controls, the shaft moves slightly, drawing the opponent arms together, with scissor-like movement and almost vertical posi- tion, with slight lean toward the second inspection Both Sides the Plate Facilitated the Use This Double Turn- Over Device. After ond turn the back the shears for trim- ming ship- ping size table. The operator now returns the arms their former position and the plate has been turned bottom side up, and rests platform supported rails between the two tables. second inspection now takes place the reversed side the plate, after which ready for its final turn-over the second roller table, which identical with that the first, with the exception the direc- tion travel. second tier arms, operated like the first, second driving unit the same power and reduction, grasps the plate and gently turns over and the second table. The turn-over operation now complete and the ate moves backward over the rotary shear approach table the shear, where its edges are trimmed. final shearing, that cutting the plate given length, completes the making this steel product. This double plate turn-over capable handling plates with maximum dimensions in. wide, in. thick and ft. long. The minimum dimensions are in. wide, 1/16 thick and ft. plates I ong. urn-over has capacity light plates 4 4 Iron Industry Facing Great Changes First Period Sharply Arrested Growth 150 Years Puts Premium Operating Economies and Marked Departures Proc- esses—Ore Reserves Under Strain EDWIN writing the subject world ore reserves the early summer 1914, was possible sum- both the status and the prospects our pre-war world regards the iron industry, and without laying excessive stress upon political governmental influences the future then prom- was necessary give possible government actions first rank future factors iron day, with the war years behind us, the effects such action the iron industry can perhaps esti- mated more closely. the present brief study at- tempt such estimate will made. Chief Factors Trend World Output Looking back over the industrial trend the past years, can see now very clearly indeed that the broad effects have been about follows: (1) The demand for war supplies, emergency demand practically without price limits, gave un- natural stimulus production the few countrie where raw materials and labor were still abundant, and whose output could shipped into military zones. (2) This forced demand certain countries served cover the fact that, though these showed increased output some lines, world demand and supply, taken total, had fallen off almost every line industry. For the first time 150 years are passing through decades which the world iron industry, which for that long period had consis- tently expanded some per cent each years, now merely holding its position. Boundary changes resulting from the war have markedly changed the relative importance our lead ing European competitors, seriously crippling the for- mer leader, but creating new industrial center. (4) Every nation the world, urged both finan- cial necessities and the outstanding lessons the war, has embarked definitely upon policy protec- tion—or still higher protection, case was al- ready tariff country. Wherever look find the definite idea, whether publicly expressed not, that each country must for its own safety make every thing possible the way necessary manufactured products. (5) Meantime, world commodity prices are falling *Mining geologist, 1503 Decatur Street, Washington, D. C +“Tron Ores,.””’ New York, 1914 Iron and New York, 1920 slowly, and are likely fall irregularly for years come. Wages, which theoretically should fall concurrently, are not likely so, least imme- diately, the labor groups all countries strength- ened their position greatly during the war. Yet unless prices and wages move together, the result will choice between extensive labor troubles and very sharply reduced rate profit. Production Likely Become More Decentralized Each these factors has been noted separately and independently. But will seen that all them are working the same direction, acting brakes increased output heavy commodities. seems diffi- cult, not impossible, escape from accepting two conclusions. The first that are not likely re- sume our normal pre-war rate world increase for good many years come. The second that the world output heavy commodities likely show increasing decentralization, rather than, before the war, increasing concentration certain countries and centers. against these factors may, however, set an- other far different type, whose action the near future may look forward with entire confidence, even though must admit that cannot foretell exactly when that factor will intervene and exactly which industry will favored first. This favorable factor, which all progress ultimately depends, technical improvement and invention. During pe- riod great prosperity there inducement work out new processes, adopt them they are in- vented. But during long period narrow profits, and especially with relatively high wage level, there every reason search for improved methods and adopt them promptly when they are found. may look forward with confidence the fact that just the hot blast and the Bessemer processes came out the long post-Napoleonic depression, and the basic Bessemer and open-hearth processes out the post- Civil War period, some new epoch-making discovery will develop within the next two decades. may the success our long-awaited direct process; may something entirely new and unforeseen the way new steels alloys. cannot tell what will be, but may absolutely sure that the stage being set for its appearance. New developments the sort suggested are far iron industry the world has temporarily stopped growing, not even keeping pace with increases population. World production pig iron 1920 was per cent lower than 1910. This was the first decade show decrease since 1780. 1913 world output pig iron reached high point million tons; took years regain that level. The need for economies production and better marketing more pressing than the past, the incentive for new processes greater and new epoch-making discoveries may pected within the next two decades. The Iron Age, June 14, more likely arise Europe than America, not because any superiority the European mind, but because the industrial strain greater there than here, and because the industrial and financial units are smaller. The first condition incentive search for new processes; the second condition makes get them adopted. was continent with vast amount accumulated but with very slow rate rea that wealth. The war swept away and rrine nother wa may ta ‘ ‘enturv poor, and barring anotner war may take century regain her pre-war During very long reason to work hard i ind t 1Sé I iethods for cuttir ( or extending narket Within Europe itself the and the velopments have changed the iron and iron ore situa tion rea present and j \ Along with this tremendous gain tonnage due boundary shift, France has gained another almost equally large increment through mere recognition 1 geologic fact which seems obvious enough but which French geologists were very slow realize the fact that the iron ores Brittany and Normandy are not mere surface patches but are very extensive sedi- mentary beds, exactly like our own Birmingham and Wa- bana deposits. now, place hundred million tons reserve credited western France 1913, current estimates would probably put around 1500 million tons more for that neglected portion the coun- try. The first flat statement the facts of these deposits was, I the origin think, own book 1914. The very obvious deduction had not permeated the intelligence the French British steel companies when was there year ago; and may easily that some our own people will first take advan tage the situation. present not much dif ferent from what the Birmingham field must have everyone was busily working outcrop and overlooking the fact that the ores were sedimentary they could found under cover well. Franco-Belgian Industry Looms Serious Competitor The war, therefore, plus slow recognition geo ogic fact, has made possible very serious Franco Belgian industrial unit, replace compete with German adversary. true that efficiency has been decreased the process, since the main coal fields were still left the German side the frontier. Under normal conditions might feel that ultimately the ore would the coal fields for iron making. But, under the conditions which actually exist, this otherwise normal process may reversed. Under the pressure reparation payments there far more necessity for Germany sell coal coke than for France sell ore. And, look upon European furnaces and mills chiefly export points, log- ical that the assembling point for ore and coke should near the Atlantic the Channel, rather than the interior. The other changes Europe not seriously affect our problem. Great Britain will still have buy her main ore supply from Spain, Algeria, France Scan- 1670—June 14, 1928, The Iron Age dinavia. Austria has disappeared unit, Czecho- slovakia being her chief legatee far the iron in- dustry concerned. Italy has become first-class political danger, but still negligible coal and iron. Russia slowly coming back into industry, but can never become serious exporter steel. the chief center for use iron ores will still west Germany, Belgium and Luxemburg, and northern western France. And here there are ample reserves cheaply mined ores; the limiting factor will coke and not ore. Pressure Lake Superior Ores Likely Checked Before saying anything about our own country and sely related areas, the other continents may dis- missed with brief mention. South America and Africa are still, and always will be, producers raw mate- rial and consumers manufactured products; all development those continents makes for the ad- Tons, 1920 1930 and World Pig Output, 1900-1927 vantage European and North under Socialist labor control, will able produce her chief manufactured necessities but will unable export heavily. Asia, Indian iron output growing healthy rate, but possible Chi- nese development has been dampened for years recurrent revolution and civil war. The very satis- factory iron ore development Manchuria Japa- nese control; and the output will probably lim- ited supplying Japanese necessities. the United States, despite the fact that for years has been the one continuously prosperous por- tion the world, ore reserves apparently have not fallen off proportionately the tonnage mined. part this stability due drilling which has put more ore into the estimates; part, increased concen- tration ores, which making use grades earlier disregarded. This last factor has become important enough check the slow falling off average grade Lake ore shipments, gradual decrease which had been progress for many years. Within the United States the two matters which are likely have most future bearing iron ore use and reserves are the recent growth Southern out- put and the decline importance the merchant furnace. The Southern growth tends extend the average life our ore reserves, because increases the amounts taken from the vast red ore deposits, whose life has never been estimated terms dec- —— ades even centuries. the process continues will finally decrease also the strain the Lake re- serves, not necessarily actually decreasing the an- nual draft the Lake supplies, but discouraging any large future increases that draft. The second feature—the decline merchant furnaces—bears some extent also against the smaller merchant mines; and that effect very directly economic gain. The larger units can general operate, through alterna- tions good and bad times, with less wastage ore reserves. Wabana and Mayari Ores Possible Sources Alumina Cement The two vast ore fields near our borders the south and north, Cuba and Newfoundland, have not lived the expectations pre-war days far growth annual output concerned; neither them important today, relatively other ship- ping fields, was 1912-1913. the case the Wabana field the prostration the Canadian and British steel industries has operated restrict growth, the bulk the 1928 shipments from this field being destined for German they will re- place Breton and similar European ores. the case Mayari, the repressing influence seems that the ore itself does not fit well with the technical policy the chief owning company. But may not out place call the reader’s attention the fact that these high-alumina ores, difficult perhaps when looked merely sources iron, assume very great importance when looked sources alumina cement with iron by-product. Since the growth these new cements apparently just beginning, may look see Cuban north-coast ores brought back the center the stage new and very profitable way. one thing use tons difficult ore merely make $15 $20 worth pig iron; ob- viously entirely different matter if, while making that iron, also make $40 worth cement. And those are rather under-statements the facts prices run today. Taking the North American continent whole, may say therefore that the pre-war pressure Lake ore reserves seems likely lessened steel interest turns southward; but that the annual tonnage from the Mayari and Wabana fields has not grown expected, that these two great deposits are still doing little toward conservation our Lake ore re- sources. The Projected and Actual Trends World Output Meantime our chief concern with regard the probable future rate iron and iron ore production, and here the past service merely affording basis for estimating the unknown years come. attempting this will refer some own earlier work that subject, and will take this occasion admit frankly that, though prophetic ability seems shine comparison with many other published forecasts, estimates were still more optimistic than were justified subsequent events. The full extent the change that has overtaken the iron industry the world does not seem, many quarters, realized even now. may service put into both statistical and graphic form, doing here. During the whole period our modern industrial civilization based steam and steel, say from 1780 down recent days, the world has become accus- tomed steady and rather high rate progress that any slackening the rate involves serious finan- cial and social dislocations; and absolute cessation increase would suggest even more serious conse- quences. Yet some such cessation what have been experiencing for over decade past. the first such period complete failure progress that the world has seen 150 years. Yet the face the stock exchanges register mad enthusiasm, the labor unions ask for still higher wages, and the politi- clans point with pride this period prosperity. World Market Has Stopped Growing The facts our own industry are easily stated. the little table which follows have noted the per- centage increase for each decade since 1800, shown the iron production the world. The table, ex- cept for the last lines, that which worked out and published 1920 book, when figures for 1920 were still unobtainable, but when hazarded the prediction that were likely find the lowest rate increase any decade since 1800 understated case. Decade Per Cent Decade Per Cent 1800-1810 1810-1820 1880-1890 1820-1830 83 1890-1900 46 1830-1840 1900-1910. 1840-1850 1910-1920 1850-1860 1920-1927 1860-1870 * De From 1800 1910 the rate increase our in- dustry was the average per cent each years, and everything connected with the industry was planned the idea that some such rate increase would continue. that rate had held the world pig iron output 1920 would have been around 100 mil- lion tons 1920, and 140 million tons 1927. somewhat over half that now, and the result what one amiable commentator has called “profitless pros- perity.” The high point the industry was reached 1913, with output some million tons; has taken years regain that level. And, whether look the facts tables diagrams, whether consider world outputs our own national pro- duction, come back always the same conclusions: That are now passing through stagnant period entirely unlike anything known our industrial world the past 150 years; that the world iron industry has temporarily stopped growing, not even keeping pace with ordinary population increase; and that have really sound basis for estimating when new period renewed growth likely commence. have been looking world-wide phenomenon, and giving merely local explanations. America talk foreign competition, France ruined mines, Germany lost ore-fields and reparations, Eng- land dear coke. Each these explanations may sound for one country, but the final truth that for almost two decades the total world market has stopped growing. for the re-commencement growth, that an- other matter. All know that will come about from factors world-wide importance, such the intensive development and modernizatior one the backward continents—probably Africa, possibly South America. could delayed some years world-wide depression, arising from poor crop seasons other broad causes. could put off indefinitely another great war. the meantime, pending resumption growth something like the old rate, there will closer com- petition between and within the nations, serious in- centives rigid operating economies, and over- whelming reasons for rapid adoption any improve- ness and stupidity may survive boom times, but they disappear, via the bankruptcy court, during periods cramped world markets. The strain ore reserves will not noticeable, but the necessity for econo- mies developing, mining and marketing the ores will greater than the past. The Iron Age, June 14, 1928—1671 Increase of World Iron Output \ H 4 Larger Production Lower Cost Rearrangement Enameling Department Reduces Floor Space Required, Handling Expense and Time Process OURTEEN ere requ end the basement, were placed trucks and car- putting the enameled finish cabinets and parts ried elevator the enameling floor. After comple- for cash This great deal tion enameling they were returned the same man- handling, with the possibility much potential dam- ner the finished stock room the opposite end age materials process. The complexity the the same basement. When maximum production was problem rea from the fact that upward under way the elevators frequently were congested 15,000 parts day are put through, ranging siz with this cabinet traffic interfere wtih produc- from that piece cabinet cover. tion other departments the building. The enam- The eling department itself was badly congested times, making difficult obtain the required production during periods high output. total han dlings parts was needed, high labor cost. How Get Better Results studying means alleviating this condition, the effort was made obtain greater production without BLACK JAPAN \ 7 Ks 7 Fray rth & t0 Basement-Down » * “7 \SEMENT rmel } ] A} hed, a) d ot Its Conve yor Connection to the Base- ent for Movement, Upward, Raw Cabinet Stock and, Downward, Finished Parts wood increasing the floor space; reduce the cost for each Spray lacquer smaller amount supervision, under conditions 110 deg. group bonus system for the whole department. Rul soon became evident that With that system use the enameling department method handling would effect great reduction occupied entire floor, 540 ft., and 2400 sq. ft. the time each cabinet part was the department. another floor, aggregate 34,800 sq. This would also correspondingly decrease the number handling daily output 600 cabinets 625 trucks cabinets process any one time. were required, fitted with 8400 trays. These truck there are parts each cabinet, schedule occupied almost 4700 sq. ft. floor space, per 800 cabinets day means that 11,200 parts must cent the total area. pass given point hr. conveyor speed was Raw stock parts, taken from the stock room one therefore desirable which would slow enough engineer National Cash Register Co., permit the spraying operation, without removing the Ohio. Abstract paper delivered part from the chain. The speed the same time was illustrated both lantern slides and moving reasonable dimensions for long min. 1672—June 14, 1928, The Iron Age — y i 4 4 4 \_ «<>< « y + 4’ Bur fF Or Sanding Room Showing, Left, Cabinet Parts Coming Out Oven; Right, Parts Leaving for Next Operation Much time and attention were given the desigr suitable hangers for the work, such that could grouped properly and conserve space the moving chain. Some different hangers were made ind tested, but only nine were retained for permanent se. studying this problem, short length chain was set up, conjunction with temporary spray booth, and many arrangements and designs were tried out before the present system was definitely adopted. One the first changes from the old procedure was the installation a.conveyor type burn-off oven take the place the washing machine. This oven installed the raw stock room the base- ment, whereas the washing machine was the floor above the enameling department. The cabinet parts, taken directly from stock, are inspected and then put through the burn-off oven. This does away with placing them trucks, hoisting them the fifth floor for washing, and then lowering them the fourth floor for enameling. also saves the 2400 sq. ft. space occupied the former washing room. Chain Conveyor Replaces Elevators After passing through the oven the parts are wiped off and hung suitable hangers conveyor chain installed shaft back the elevators. From this point they are carried the fourth floor series turns and risers, the angle rise being deg. Here they pass immediately through spray booth, where the first ground coat color applied without removing them from the chain. Still remaining the chain, they are baked the upper deck oven for min. temperature 230 deg. Fahr. This oven 100 ft. long and about ft. wide. Its size was determined consideration the chain speed set for other operations, and the length time the parts had remain the elevated temperature. Leaving the oven, the parts are removed from the chain and receive work benches whatever putty treatment may necessary. They are then hung another chain and, while motion, are sprayed booth with the second ground coat color. They then pass through the lower deck the same oven, with- out removal from the chain, and are baked for another min. Again they are removed from the chain, for sanding work benches, being immediately after hung third chain, which transports them other benches where they are removed for graining. After this operation they are hung fourth chain, passing through second oven, where again they are baked 230 deg. for min. Leaving this oven, they are sprayed with the first lacquer coat while moving through booth, and are then baked 120 deg. for min. third oven. Continuing their travel the same chain, second lacquer coat ap- Graining Room, Showing Left Delivering Cabinet Parts. right, parts are being removed The Iron Age, June 14, plied another booth, after which they into another section the oven they have just left and receive another treatment 120 deg. for min. Parts then are removed from the chain for rub- bing. After this they are hung fifth chain, which carries them back the other end the basement descent curves and inclines similar that which they came from the raw stock department. Here they are inspected while still the chain and then are packed trays for taking the different assen b rooms. Conditions Operation Altogether there are five chain units, varying from 586 ft. nearly 2200 ft., with aggre- gate about 6500 ft. the chain, operation, regular rate travel minute. There are nine different patterns hangers, each suspended from the chain swiveled hook. This permits the operator turn the part around will, which par- ticularly essential the spraying booths, where al! sides must readily accessible for lacquer. 1674—June 14, 1928, The Iron Age UBBING Sec- tion, Showing Chains Running Down Inside Parts. Those outside room (reader’s left) are removing parts and taking them down the spiral conveyor basement Between the five runs chain are four stations where the parts are removed from the chains. de- tailed above, these are the stations for puttying, sand- ing, graining and rubbing. each these loca- tions racks are suspended from the ceiling permit loaded hangers placed alongside the operators. This provides also small temporary storage space each side the operator, that need never without material. also facilitates keeping together certain parts, when they must grouped. eliminate fire hazard the spray rooms, and the same time keep the atmosphere those rooms the best possible condition for the operators, each spray room maintained under slight static pres- sure. air delivered into the room from avoid drafts, the air leaves the end the pipe through large canvas bag. Fumes are removed from the spray booth the exhaust system the top each unit. All paint lacquer removed from the air through filter screen excelsior before the air discharged outdoors. Each operator each spray room has three spray blower. the Four Spray Booths, Where Cabinets Receive Either First and Second Ground Colors, First and Second Lac- quer Coats. For the first coat two men are em- ployed, taking alternate pieces 4 5 4 = * : guns carrying that many different colors. Two opera- tors are required apply the first ground coat color. regular procedure the first operator takes every alternate piece comes him along the chain. The second man takes the pieces not taken the first man. This provides even distribution the work. One man can take care the second ground coat color, and one man provided for each the lacquer coats. Thus five operators, altogether, apply four coats mate- rial 800 cabinets day. Heating the baking ovens mentioned above air blast over steam coils. The burn-off oven, which carries temperature 1000 deg. Fahr., and which the parts remain for min., gas fired, with burners both above and below the parts carried through. Results Obtained Are Excellent the new process, the number handlings has been reduced from 20. The number trucks required has been reduced from 625 150. The length time part the enameling department has been cut from seven and half days one and half days. The inventory finished stock and stock process has declined per cent. greater uni- formity finish obtainable this method, partly because the regularity and celerity the move- ments. After this system had been put into full produc- tion, was found that the output had been increased from 600 complete cabinets day 800. The floor space required had meantime been reduced 10,000 sq. ft., nearly per cent. estimated that the annual payroll for the enameling department, the basis average 700 units day, has been re- duced $59,000. Better working conditions partly the air control partly due elimination congestion various points. Uniformity baking, together with decreased handling, are credited with improvement the have systems mentioned and quality the product. Elevator service, badly needed other departments, has been almost wholly released far the enameling department concerned. Salvage Conference Plans Clearing House for Scrap Disposal conference salvage disposal held June and mington, Del., and attended about representatives industrial and public utility corporations, plans were made for the operation clearing house, through which members may dispose surplus supplies and surplus obsolete equipment. The meeting was organized the National Asso- ciation Waste Material Dealers, Inc., New York, and those attendance were guests the Pont com- pany. Among those who delivered addresses the conference were Henry Lissberger, president Federated Metals Corporation, who president the National Parts Coming Through Burn-off Oven Basement and Being Hung Conveyor, Which Delivers the Enameling Department, Fourth Floor. This the finish the first opera- tion the parts re- ceive after com- ing raw cabinet storage Association Waste Material Dealers; Harry Western Electric Co.; Thomas Wright, Lucius Pit- Co.; Steel, Eastman Kodak Co.; Louis Birken- stein, Birkenstein Sons, Inc.; John Bayliss, chairman Purchases and Stores division the En- gineering Association American Electric Railway Association. The new benzol plant the Lake Superior Corpo- ration Sault Ste. Marie, Ont., will operating Nov. according Jones, general manager Algoma Steel Corporation. The contract, which has been awarded the Wilputte Coke Oven Corporation, New York, calls for expenditure $250,000. The plant the Ashland Steel Co., Ashland, Ky., was sold public auction June John Russell, Ash- land, for $176,000. The sale was conducted Hayes and Field, who had been appointed the Federal Court trustees the property. The Iron Age, June 14, 1928—1675 a Incentives Aid Good Management Bonuses for Quality, Quantity, Waste Elimination and Time Saved Promote Operating Proper Training Foremen Also Requisite Good Supervision relation monetary incentives for both man- ual workers and supervisors labor the train- mao 4 ] by ight these employees was clearly out meeting the production executives’ Hotel Statler, Buffal June number cific subjects “Group versus Individual Incentives for Supervisors and Indirect Labor,” ‘The Training and “The Training M ial Worker t s made evident that incentive particular pplied group labor, eration and increased and more economical production. the consideration training methods, both applied foremen and manual workers, spirited dis- cussion arose the best methods approach, and was brought out that two definité techniques fore- man training have sprung up. One these empha- sizes the value good theoretical foundation the teaching, while the other tends discard textbook practice and approach its individual prob- lems without preconceived ideas how each one should handled. Discussion led mutual accept- ance the fact that the training foremen one important functions industrial management. the most Bonuses Should Not Nullify Savings Made duct and that group incentives should lead au- production are principles the establishment rth Walter Polakov, con- York. Speaking broadly, Mr. complexity the problem plans, dealing they with iman energy, and thus involving situations that cannot handled with the definite Human engineering, stated, growing more important industry than engineering b assurance of science. applied directly materials and equipment. outlining the establishment group incentive plan, Mr. stated that the group should made men the same sort work the same job. Each function should then analyzed and rec- ords kept both individual and the performance the group. Further information the working individual and group incentive systems was brought out papers describing the used three large rmance plans now being companies. Paying Incentives Dollar Basis Reduced Jabor costs, lower inventory, better super- vision workmen and the establishment group rather than individual effort were cited the objectives group bonus plan installed the National Cash Register Co., Dayton, Ohio. describing this plan, Whisler, head the company’s rate and time tudy department, stated that first the incentive standards were expressed decimal hours. This sys- tem was not understood the men the plant and was discarded for one which the standard changed from hours dollars. Definite rates various types work seemed necessary and standard rates were set the time study and job analysis departments. Under the dollar standard the foreman given full supervision the distribution the cost different required turn out certain number pieces costing much, the distribution the cost and the consequent bonus earned the group depending entirely upon him. this manner cooperation within the group obtained, the bonus earned must depend entirely upon group effort. Under this bonus plan the quality the manu- factured product went up, but secure further preci- sion quality bonus use which entitles the group additional reward there are rejections work above certain fixed standard. Inventory costs are also reduced under the group bonus plan, work soon was articles and process cleaned the workers, who are anx- 1676—June 14, 1928, The Age ious turn out much production possible. Budg- etary control also made more feasible this plan, enables the management know definitely the cost work before scheduled. Bonus Plan Shipping Department Introduction incentive plan the shipping department the Eberhard Mfg. Co., Cleveland, en- abled the management reduce the working force that department per cent, reduce the payroll per cent and increase the wages the remaining employees the department per cent. which was described Brooks Shepard, production manager and secretary the company, has placed the work done the department upon tonnage basis, the bonus being paid tonnage got out above cer- tain fixed amount for which the men are paid day-work rate. The company has since applied the incentive plan its foundry, the trimming and sort- ing and the annealing departments. Paying Men for Time Saved The Bridgeport Brass Co., Bridgeport, Conn., pays its men bonus for time saved under the standard task rate set its time study department. Clark, general works manager for the company, who outlined the plan, stated that believed could also applied continuous assembly work and that equally successful for group endeavor and individual piece- work. The incentive computed dividing the actual production the amount time saved the operator compared with the standard time set for the job. Mr. Clark stated that the earnings employees under this plan are usually from per cent above the base rate, particularly since they have become accustomed its operation. placed the readiness with which workmen are able understand incentive plan one its essential features, not the chief requisite. Perry, production manager Hudson Motor Car Co., Detroit, stated that his company has been able apply incentive plans very large groups with consid- erable success and thus able down greatly the cost time study. The Hudson company also places limit the amount bonus which can earned, that way preventing the cost its incen- tives from nullifying the amount gained increased production. discussing the difference between the group and individual bonus plans, Mr. Polakov stated that group better when there difference the unctions performed several men one operation, } i while the individual incentive should used when each worker performs complete operation. Application Incentives Art paper upon incentives for workers and exec- utives and their use the training new personnel, Carle Bigelow, president Bigelow, Kent, Willard Co., Boston, emphasized the fact that, although science plays important part incentive plans, their actual application art. “In the application incentives,” said, “the best results seem at- tained not the application any one theory set theories, but the practical, intelligent, experienced application individual peculiarly fitted for such effort.” Mr. Bigelow stressed the instruction value incen- tives and stated that the important considerations which should made before placing task position upon incentive basis are follows: “Is definite ir- structional procedure necessary for the proper accom- plishment this task position, and essential that incentive paid order obtain the best effort the individual?” also expressed himself being strongly favor direct financial incen- tives, based far possible upon individual accom- plishment. This led consideration individual opposed group incentives, and the speaker stated that believed any attempt establish group rates without proper background the application individual rates very carefully compiled past per- formance records would not lead satisfactory re- sults. “In paying incentives executive,” the paper stated, “it necessary determine the exact result over which has individual control and that propor- tion his reward receive for control his individual functions, well that proportion the incentive which allowed for the results the operations whole.” Eliminating Waste When the raw material involves large part the cost product, incentives for eliminating waste are more important than production incentives. intro- ducing the subject waste elimination bonuses, Fran- cis Mack, production manager Mohawk Carpet Mills, Inc., Amsterdam, Y., stated that this sort incentive plan may usually introduced determin- ing the method which the best results may ob- tained with minimum waste, thus setting standard upon which bonuses can paid. many cases waste elimination incentives may consolidated with production incentives, but payment should made separately impress workmen with the importance saving materials. Blair, Newport News Shipbuilding Dry Dock Co., Newport News, Va., stated that his com- had been able eliminate many wasteful meth- ods asking for suggestions from the workers prize contest, and that since that time further sug- gestions had been taken care under the organiza- tion’s employee representation plan. Quality and Attendance Bonuses Quality incentives were suggested Oscar Grothe, vice-president White Sewing Machine Corporation, Cleveland, means bringing management’s atten- tion poor quality raw materials. Under quality incentive plan, pointed out, the machine operator quick report any defects the materials given him work, and thus the source th