The Iron Age 1928-07-05: Vol 122 Iss 1

| THE IRON AGE New York, July 1928 ESTABLISHED 1855 VOL. 122, No. Output Increased the Systematic Scheduling Shop Work modern management and production methods used large manufacturing plants can- not adapted economically shops which employ only few hundred men. based the increased overhead often possible that the increase overhead need only frac- tion the savings which accrue from more efficient use man and machine hours. logical that the plant owner should first turn means making the best use the capital which already has been expended, and greater flex- ibility his working force. When these combinations have been improved their practical frequently asserted that CRIS BERG* Faced with the necessity larger output and lower costs, comparatively small manufacturer ° contractors’ equipment took under considera- tion shop expansion program estimated $250,000. But investigating the possibility more effective use equipment hand and labor time, per cent increase capacity was obtained expenditure ap- proximately $30,000. the systematic routing and scheduling work through the shop, described detail Mr. Berg, attributed the marked increase output with the minimum additional invest- ment, The costs were high and was urgent need increased pro- duction. first gave thought expanding his shop and ob- tained estimate $250,000 for the work. new foundry was cost $150,000 and $100,- 000 was provided for new equip- ment increase the productive capacity the shop per cent. the final analysis more effective use the equip- ment hand and labor time resulted the per cent in- crease productive capacity and not more than $30,000 was expended. Included this fig- ure was one item $15,000 for new electric furnace. The capacity the plant was increased that was limit then, conditions war- necessary take new lines rant, should turn addi- tional capital expenditure. obviously unfair equipment builders install time and labor saving devices under conditions which they cannot perform, even are not allowed perform, work the manner and the quantity for which they were designed. Frequently shop capacity reduced because the fore- man swamped with flood details which prevent him from performing his duty true supervisor. Routing and scheduling work through the shop and giving detail work clerks often well worth its cost. striking example the results brought about planning afforded the present practice small shop which contractors’ equipment manufactured. Pro- duction for the most part standard line equipment, but due making extra parts and repair parts for obsolete models, fair share the shop capacity engaged what not unlike jobbing work. This plant, which valued about $800,000, comprises machine shop, struc- tural shop, electric steel foundry and erection assembly department. About 175 people are employed. *Consulting engineer, Chicago. order keep operating capacity. 10-in. turret lathe and three-spindle drill press only were installed re- place old equipment. Several machines were turned around rearrange production groups, and few machine drives were altered obtain more suitable feeds and speeds, this often entailing not more than the change single pulley. change was made from the use hand trucks and wheelbarrows for transporting parts the shop. The old plan scheduling work through the shop had grown with the plant. orders became more numerous was necessary get out more work, but the only effort put forth was that brute force. Foremen were entan- gled mass details, such hunting jobs for the men, hunting drawings, etc., that they had little time properly supervise either the quality quantity output. They were almost entirely without records, depending upon mem- ory, although was not uncommon have 30,000 pieces more the shop one time. far the most important change made the metheds this plant was brought about systematic scheduling orders and machines. This change permitted foremen function their proper capacity supervisors and, providing checks material process and the store- house, eliminated much the previous delay. Shop Order Forms Prepared Production Department the manager’s office. Standard bills all drawings needed the production the various models machines manufactured are furnished the present practice this plant all manufacturing orders origina and material + engineering department. Files blueprints stand ard machines are kept each shop department, and the duty the engineering department keep these files complete and up-to-date. Blueprints for special jobs are at- tached the manufacturing order the engineering de- The make-up these cards and tags may noted from Fig. The shop order sheet then put through duplicating machine and number copies, one which shown Fig. obtained. the same time complete set the castings issue and other cards shown Fig. hecto- graphed from the original shop order sheet. The cards are then checked and clipped together, forming package for each part lot manufactured, that they are handled the shop they will not accidentally become sepa- rated disarranged. The card top always the one removed for the next shop operation. The writing the one order form, Fig. from which all other instruc- ° ROUTING OF MATERIAL NUMBER OF FORMS FEQ Rtv} MATERIAL THE COMPANY LOT 5-19-26 ROUTING OF MATERIAL 8820-1 20 G-246 195) Gear } a 24 354 422 4H S820-3 7 G-167 . Bz. Worm Gear } 16 Halves 16 Halves Fig. 1.—The Combination Shop Order and Route Sheet (the upper form) Prepared the Production Order Depart- ment. printed and filled with hectograph ink and becomes the standard form from which all other instruction cards and forms are impressed Fig. 3.—Hectograph Copies the Shop Order Are partment, the order, prints and bill material then being sent the production department. The latter department does all the paper work, including preparation the shop order sheets, route tags, time cards and other forms used connection with the various regular and special production orders. Shop orders, the form the combination shop order and route sheet shown Fig. are prepared the produc- tion department from standard bills material, stock requi- sitions and sales orders. Department numbers, symbols and other routing information then added the route clerk from the master route card shown Fig. There also indicated, the extreme right-hand side the shop order sheet, the “number forms required” the casting issue cards, route tags, transfer slips, time cards and other forms required for the particular part order. 2—July 1928, The Iron Age Shown the Insert. possibility errors retyping The hectographing eliminates the tions are hectographed, eliminates the possibility errors copying. Before leaving the production department, copy the shop order, with its package cards, sent the rate set- ter, who writes the piece rates and other related information the time cards. The shop order then ready for sched- uling. Dispatch Racks Used Shop Departments Departmental control order work and other steps the production processes facilitated “material- not-in” file and route board, dispatch rack, each shop When the shop ready for additional work, the order sheet and package cards are sent the time- keeper the department which the parts covered the order first into production. Until work the order department. | } | j | = T > x — | | Part Name Fig. 2.—Master Route Card Used the Pro- duction Order Depart- OPERATIONS | Seq. Symbol ment Making the Combination Shop Order and Route Sheet Shown Fig. The production partment does all the paper work, including preparation the route tags, time cards and other forms used connection with regu- lar and special produc- tion orders actually started, the order and cards are kept the depart- ment’s “material-not-in” When the work started, the time, stores issue, transfer slips and route tags are removed from the package and sent the stockroom for the material. The material then delivered the stockroom the machine bench which the first opera- tion performed, the exact place delivery being indicated the route tag, which remains with the mate- rial part process until the part reaches its final destination the plant. Transfer slips are made out duplicate that both the sender and receiver have receipt for the movement the material. These slips also serve notification the timekeeper the department that the material hand ready for the first operation. MACHINES Number Hours 7 eportments | | ~ | | \Zofa/ lurnmber of Hours VU \.| A// Departments | Work start here The Graph Indicates the Progress Reduction Labor Hours Which Followed Systematic Shop Scheduling. May, 1927, piece-work rates were established some machining operations DESCRIPTION AND OPERATION FACTORY ROUTING CARD Pc. or Part No. Dwg. No. Matl. Weight Fdry. Tickets Fdry. Pcs. Per Day Upon arrival the material his department the timekeeper removes the package cards from his “mate- rial-not-in” file and places the third back pocket the route board dispatch rack, which has section three pockets for each machine bench the depart- ment. When ready begin operations part order, the foreman takes the package cards from the third back pocket assigned the particular machine, bench man performing the first operation and places the next, middle, pocket the same section the route board. The packages cards the middle pocket are ar- ranged the order which they are used, thus con- stituting order-of-work file for given machine, bench man. Blueprints Issued with Operation Time Cards When work given order started, the time- keeper takes the front package cards from the second pocket the route board, removes the first operation time card and stamps for The remainder the pack- age cards then put the first pocket the board, which shows that this machine working the job cov- ered the card. The first pocket, should noted, con- tains only the time cards and transfer slips for the part being worked the machine bench which the pocket assigned. With the time card, the blueprint the part machined issued, the blueprint being returned the timekeeper the completion the job, the time stamping “out” the time that particular operation. The timekeeper then takes the front package cards from the second pocket the same section the route board, removes the top time card and stamps the starting time it; this manner each machine the department kept supplied with work. The first operation having been completed, the time- keeper advances the package cards the third rear pocket the section the route board assigned the machine which the second operation the piece. Thus each operation given part completed the remainder the cards the production order are moved another section the route board, the sequence operations. For special orders that through the shop single job lot number, route tags similar form that shown Fig. are issued the production order department. These tags are printed eight colors. white tag signi- The Iron Age, July = | | =) | 6| } | WEN K 7 | | Se ‘ 10 | | | > SANS Remarks \ \ i | | | | | ~ | further ‘| [Reduction in . | | o+ 7 | | } Structural Shop Hours | Erecting Shop Hours | no on | LOT No. ane (TEM |) CES fies that the material going through the shop replenish stock. Dark red tags indicate that the parts which they are attached are rush special order. Various other colors are used designate the parts certain models standard machines. Costs Compiled Main Office Timekeeping, far shop costs are concerned, done the shop office. The main office cost department figures and compiles each day the cost all completed jobs. the following day sheet showing total time and money for each operation performed the various jobs, prepared and sent the foreman, who has his BAN'S NO. MACH NO. SEQ'CE OMPANY | THE COMPANY NAME AND DE AND desk file former costs similar jobs. This affords him the opportunity comparing present with past per- formances. the same time the main office gets copy the report detail and total cost. Two days after lot machines has been completed the general manager has all the cost data before him. Savings made the adoption systematic routing and scheduling, and other changes noted above, are shown the chart page November, 1926, machine shop hours the model “A” machine were 3640 and September, 1927, they had dropped 1950. the same year structural shop hours had been cut 1625 and erecting shop hours had been reduced from 1950 IG. 4.—When the Shop Order Sheet Duplicated Fig. Complete Set Castings Issue, Time and Other Cards Shown This and the Opposite Page Are Hectographed from Shop Order Sheet. These cards are as- sembled together, forming package for each part tured, and are arranged the order which the shop will use them The shown above are the from the package cards. They are used bring the material the shop. The nine time cards, the left, are for the successive operations per- formed the piece. From the last opera- tion the finished work goes the stockroom, order, the stores credit and two transfer slips, OPERATION BAD 1928, The Iron Age | i Sones | | shown the opposite page, are required RATE | CHARGE EARNINGS | UNFIN, CHARGE pare’ Order No or No. = = 2 — kee Rowe Sheet | Prog. Rec'd Pie Tesen from “Deirrered to 200 PERATION CHARSE TO | STARTED g Lo Tem PCE. OR PART NO DWG. N MAT. NAME AND DESCRIPT Sy < — LAKE ANY CHARS mu wo. | orn SEC ce ES t sToPPED MAN'S NO 4 4= = STOPPED MAN'S NO, | MACH.NO. SEQ’CE OPTRATION CHARGE TO | STARTED /! 7 | 3 0 7 — N | ow mat. NAME AND DESCRIPTION Z, ER NO OR 4 ER PCE] TOTAL MAN DAY W PREV. FIN) FIN A | | 950. November, 1926, machine shop hours were 3640 and this had dropped 2500 hours May, 1927, due almost entirely the new method scheduling work through the shop. the fifth month 1927 piece work was installed and September, 1927, machine hours had dropped 1950. The top curve shows the combined hours the machine shop, structural shop and the erecting department re- quired the model “A” machine. noted that total hours September, 1926, were 7424, while 1927 the figure had dropped 4597. The dotted curve, marked model “B” machine, represents total for departments pre- viously listed and indicates that similar economies are being effected regardless the type machine that regular TES GE company TES company production through the shop. Similar methods procedure the structural layout department have resulted per cent reduction labor hours. Working System Requires Small Increase Payroll addition increased production and lower costs, the following advantages have been derived from this system: Position Industry ISCUSSING how the growth plants and questions costs have put engineering the purchase me- supplies and equipment, Carleton Reynell, McClel- lan Junkersfeld, New York, told the position indus- try the purchasing engineeer paper presented the recent Kansas City convention the National Associa- tion Purchasing Agents. “Practically every manufacturer equipment and sup- plies,” said he, “today employs sales engineers either handle direct sales missionaries. constant stream salesmen and sales engineers flow through the office the purchasing engineer daily and describe detail the equipment they have offer. Through them the purchas- ing engineer learns the latest developments various mechanical fields, selects those ideas which seem apply his problems and investigates them thoroughly con- junction with the chief operating engineer. “In short, acts the preliminary commercial re- search man always the lookout for something new. brings the attention the operating engineer only the ideas which would ultimately economical, and while Order No. or Lot No. and Item The shop order, card and tag system complete and designed that all instructions are hectographed from one typed sheet, thus elim- inating errors resulting from copying. Drawings are kept date and they are the hands workmen only long the various jobs are the machines. The foreman again has become visor, free direct and plan that each machine continuously provided with work. Machines are kept good repair and they are operated capacity. Foremen and the time study man train operators work the best advantage all. TRANSFER SLIP BIN NO. TRANSFER SLIP Inepector Foreman Continuous compilation time and cost data effect. keep this system working there are required the payroll five additional people whose salaries total about $500 month. They are typist, time study man, cost girl, extra timekeeper and boy who operates the hectograph machine. the Purchasing Engineer course many these are discarded conference, the best are selected for trial. “That purchasing has long been function engineer- ing evidenced some the ideas borrowed from the engineering profession purchasing and other commercial departments. All the curves picturing business conditions, and now used illustrate nearly every phase business, base their origin the analytical geometry and graphic statics developed years ago for engineering use. The pur- chasing engineering departments our largest companies have, you know, gone far the development these curves, combining market prices, production costs, freight overhead, profit and all other factors which enter into the ultimate cost. approach more nearly perfect balance ideas mechanical purchases many large corporations have wisely decided that best consider each purchase sep- arately from two angles, the commercial and the technical, and then agree final decision, after which the com- mercial man with technical knowledge can best handle the business end the problem.” The Iron Age, July | | | 4 nce scr! NS S name Ano Of i} 1S . or ORDER DATE BIN NO. 3 pect DATE } | | LINCOLN, the author president the Lincoln Elec- | tric Co., Cle veland. He joined the Lincoln organization 1907, upon leaving Ohio State University, and took over the management the company 1914. has been active the applications electric welding for several years and pron nently identified with the indus- a cry. OME the developments the Lincoln company since Mr. Lincoln’s connection with are: Variable voltage weld- er; use are welding place cast and riveted parts, in- cluding buildings development the automatic carbon arc welder and the “electronic tornado” automatic welder described THE IRON AGE June 28. Expect Minimum Cost Reduction are not sure that setting this ing this standard tions are that the tendency always not beyond the mark set, spite the fact that may pos- sible so, and therefore this per cent may acting limit rather than goal. Cost reduction has been rapid the past few years nearly all lines that reduction per cent now seems inder, rather than over, the proper standard. think safe say that when value, wage rates, and cost raw materials are taken into consideration, that the automobile industry has reduced its cost more than per cent per year for the last ten years. Three Fundamental Principles Cost Reduction getting this reduction have adopted, three fundamental + our plant, principles which believe are accomplishing the result: The first these accurate knowledge costs. The second attitude mind which regards all processes and methods only temporary makeshifts and holds that there always better method doing any job one only had the vision and ingenuity find it. The third essential the adoption one more manu- facturing development principles. These three principles are actually applied follows: one our plant can tell from the total cost finished product whether not too high; all can tell fairly accurately whether not single operation too high. The only way know appreciating these differ- ences determining all costs their last detail that are dealing with individual operations individual parts. After this has been done comparatively simple deal with each operation and with each individual piece raw material and see whether new method doing that particular operation can devised. Very few cost systems give this information the detail, accuracy and 6—July 1928, The Iron Age recency which necessary make the picture plain enough that the management can, from the picture, see what the next step should be. The accompanying chart shows the cost certain line equipment over period years. The broken line the normal cost referred standard rate overhead; the red line the actual cost including the actual rate over- head. Data this kind are interesting and are undoubted- valuable indication what the entire organization doing, and from curve this kind the management can see whether progress being made not. But value whatever pointing out what management should order correct the situation and reduce the cost. only the detail cost each operation and each piece that would any value indicating the actual steps that should taken. Every Process Method Temporary The second fundamental principle the definite belief that every process, every manufacturing method, always temporary makeshift. The only reason that better method not used because the management and engi- neers have not the vision and ingenuity see what that new method is. long that attitude mind main- tained management the continual lookout for different methods, different machines for manufacture, and different designs which will better the product and reduce its cost. illustrate how this point view works out will cite the following recent occurrence our plant: intendent came the chief engineer with rotor spider, saying that was sure the manufacturing method was wrong because the records showed had been manufac- this part exactly the same way for five years. The fact that everyone else was making these spiders the same way did not make any difference. turing Investigation this particular part showed that change design and construction very much better spider could made less than one-third the previous cost and without many the handicaps which the old part had. may perhaps seem rather radical point view take that all processes and methods are wrong. glance back the history manufacturing, however, would prove this There doubt that history will prove that any process average antiquated within five years. going antiquated within five years, why wait the five years? only had the vision could antiquate immediately and not wait for develop- ment. The organization that can beat obsolescence and ar- rive the new method before its competition does the successful organization. The locomotive 1823 was thought that time marvel efficiency, power and speed. Economically absolutely useless today, and was absolutely useless within very short time after was built. The same develop- ment antiquating nearly every mechanical device. This what call progress. Since history shows that nearly every device which mankind has ever used has been dis- carded for better and cheaper device within short time, there any reason why should think that the nished satisfactory equipment even furnished previous time the best equipment obtainable, is, say the least, dangerous. seems that the very foundation intelligent buying must the idea that conditions are continuously changing and that because this essential that all types any product continually investigated and bought the results that investigation. Blind buying nameplates and buying from friends are two the most insidious wastes that industry now supports. general the raw material, supplies ana machinery are from three ten times the cost labor the cost any product, hence the chance for saving buying very great approached the same “show me” attitude mind that adopted judging manufacturing methods. This the gospel which the manufacturing methods, designs, and points view our whole organization are based. Modern Manufacturing Principles Must Adopted The third fundamental principle which have adopted the application modern manufacturing methods. Broken Line the Normal Cost Referred Standard Rate Overhead and the Color- Line the Actual Cost Actual Over- head Ww =x < ax w < MAcHINES UILT present methods, machinery, designs, construction, have any more worth than those which have been discarding continuously throughout our lives? there any proof all that have arrived the millennium, are even approaching it? The big manufacturing job, then, becomes the forecast- ing development and doing before anyone else. Any concern that can this will enormously successful; the concerns who are not successful are those who not it. “Show Me” Attitude Needed Buying Very closely connected with this matter forecasting manufacturing methods, intelligent buying. The Shaw Publishing Co., Chicago, investigated the buying habits large number representative manufacturing com- panies and found that purchasing machinery least half the companies bought after making inquiry only one supplier the type machine wanted. may be, course, that thorough investigation had been made before- hand, but from own experience this doubtful. Since manufacturing methods and designs are scrapped least once every five years, probable that manu- facturer remains the lead his product continuously. buy without investigation what the market affords from concern because previous occasion has fur- our own case one these principles, which our com- pany has originated and developed, consists the substi- tution welded steel for cast iron, and have been able within the last years make almost clean sweep the iron casting used previously. Since steel five times strong, two and one-half times stiff, and one-third costly per pound casting, the marked advantage made possible this substitution self-evident. That have practically all cases been able accomplish this purpose, making the saving raw material the pur- chased steel more than compensate for the additional labor and overhead cost fabrication and welding, evidenced the fact that throughout the entire line where this sub- stitution has been made have been able reduce our cost more than per cent the previous cast iron cost. This entirely aside from any cost reduction which has been made more efficient manufacturing operations. From this substitution other advantages flow. The first that eliminates patterns, pattern manufacture, pattern storage, and pattern repair; the second that greatly reduces inventories. This steady decrease costs and the consequent steady decrease selling prices has been looked askance (Concluded page The Iron Age, July Bessemer Production Drop? Not Inherent Advantages Process and Properties Steel Are Exploited WATERHOUSE* HIS short discussion takes acid Bessemer steel, because the only Bessemer process carried out the American continent. The process most spectacular, beautiful the simplicity its conception and capable turning out large tonnages steel. tonnage, the second steel-making process our coun- try, coming next the basic open-hearth. The process making ordinary Bessemer steel may briefly described. carried out refractory-lined vessel converter, ranging capacity tons. Such vessel lies its side receive its charge molten pig iron. most steel plants the molten iron used comes from the blast furnaces, being stored mixers mixer-ladles. some foundries making steel castings small converters, cold iron melted cupolas. The proper amount iron brought the converter ladle and poured in. This operation charging shown the photograph the head this page, taken the Steel Co. The blast then turned and the vessel turned up, the air generally passing through hol- low trunnion the blast box under the converter, through large number small tuyeres and then through the metal. The blow heat lasts for from min. The silicon and manganese the pig iron are oxidized and pass into the slag, although some manganese volatilized. Con- siderable iron also oxidized, mostly entering the slag. Carbon burns, giving rise the large carbon flame. Such blow taken the Lackawanna plant the Bethlehem Steel Co. and reproduced the full page engraving. Toward the end the blow the flame drops, showing that the carbon has almost all been removed, the vessel again turned its side and the blast shut off. This operation also spectacular and well shown the view the bottom this page, also taken the Illinois Steel Co. The vessel now holds “blown metal,” which contains very low percentages carbon, manganese and silicon, but all the phosphorus the original iron and almost all the *Professor metallurgy, Massachusetts Institut nolory and M: Tech- nsulting engineer and metallurgist, Cambridge. 8—July 1928, The Iron Age sulphur. also contains fairly large amounts dis- solved oxide iron. order made into steel, certain final additions are needed deoxidize the metal and give the composition required for the desired physical properties. These final ad- ditions vary; they may added either the convérter the ladle, both, but the usual addition ferromanganese added with the stream metal while being poured from the converter into the ladle. pile ferroman- ganese shown the platform near the converter being charged with molten pig iron.) The ladle then usually 4 \ ‘ . q ; bs oot = — a q 7 | | | ~ | | brought into position the pouring platform, the metal poured into ingots and the ingots Bessemer steel are taken the rolling mills for subsequent treatment. large tonnage material handled through the Bessemer converter and then transferred liquid basic open-hearth furnaces for further refining. The product usually called duplex steel and, statistics, included the open-hearth total. The statistical position acid Bessemer steel produc- tion shown Table most the figures which are taken from the bulletins the American Iron and Steel Institute. Without going into exhaustive analysis these figures may pointed out that the Bessemer very important steel-making process, but, with slowly de- clining trend, the percentage the total tonnage has been decreasing until today accounts for about per cent the total tonnage, per cent the duplex steel in- cluded. Duplex tonnage also appears slowly going down, This should really placed different category, because does not handle low-phosphorus pig iron nor make Bessemer steel, but treats higher phosphorus metal which then sent the basic open-hearth. The tonnage made duplex steel depends closely upon economic con- ditions, principally the amount scrap available for the open-hearth, its price and the tonnage requirements the individual open-hearth plants. Confining attention straight Bessemer steel, material that offers advantages over other steels for cer- tain purposes. This particularly true when comes free-machining and welding properties. For high-speed automatic screw stock Bessemer steel has never been sur- passed. The very large tonnage steel used for auto- matic screw machine products seems therefore preempted this process. The demand for such material ing, the steel being either hot rolled or, more usually, cold rolled drawn. comparatively new development the use such material for case-hardened products, with splendid results. Its free-machining, together with its good welding properties, makes Bessemer steel valuable for butt- welded and lap-welded pipe, particularly the smaller sizes which are frequently cut, threaded and fitted the field. short, but rather general, questionnaire would indicate that Bessemer steel holding its own the field skelp, particularly for making the smaller sizes pipe. the other hand, demand for seamless steel pipe certain sizes causing the use open-hearth steel; the speci- fications many the oil companies for open-hearth steel are also lessening the demand for Bessemer steel tubular goods for the petroleum industry. large tonnage Bessemer steel being used for wire products, including wire nails, fencing, and the finer sizes wire, and rolled into sheet bars for making sheets, tin bars and tin plate. Its inherent stiff- ness often advantage wire sheets, but for deep- drawing stock the dead soft open-hearth steel seems preferred. considerable tonnage Bessemer steel still used the form bars, structural shapes and for railroad purposes, such spikes, bolts and nuts. The addition copper the usual amount 0.20 0.30 per cent fairly general for material exposed atmospheric corrosion, such certain wire products, sheets, railroad material and other special shapes. concluding this brief survey the Bessemer steel situation may pointed out that the future promises that this method steel manufacture will not only hold Table I Production and Percentage of Steel Ingots and Castings by Processes Basic Open-Hearth Duplex Bessemer : Total Per Per Per Year Tonnage Cent Tonnage Cent Tonnage Cent 1913 64.9 2,210,718 7.06 9,545,706 30.5 1914 69.2 $35,690 3.55 6,220,846 26.4 1915 69.3 1,781,491 94 8,287,213 25.7 1917 71.2 3,791,830 8.41 10,479,960 23.2 1918 73.0 3,870,017 8.70 21.1 1919 74.1 2,819,785 8.13 7,271,662 20.9 1920 74.4 3,279,119 7.78 8,883,087 21.1 1921 76.2 $40,251 4.24 4,015,938 20. 1922 79.7 1,651,089 4.63 5,919,298 1923 77.1 2,919,286 6.49 8,484,088 18.8 1424 $0.9 2,131,856 5.62 5,899,590 15.5 1925 81.7 2,797,318 6.16 6,723,962 14.8 1926 82.1 2,815,980 5.83 6,934,568 14.3 1927 82.7 2,184,674 4.86 6,191,727 13.7 its own but improve its position. The reserves Bessemer ores are larger than was recently supposed. method steel making capable good control, and for many purposes, indicated, the steel offers advantages. While considerable research being carried order improve the quality and extend the usefulness Besse- mer steel, there need for still more work along these lines. Some the methods used making high-quality steels the open-hearth and electric furnace can ap- plied the Bessemer process, particularly obtaining sound steel ingots and steel more free from non-metallic impurities than usual present. believed that, proper attention paid having the right kind pig iron, proper and some cases improved Bessemer plant and equipment provided, and increased care given the finishing the steel, ladle practice and pouring practice, the Bessemer converter will produce metal perior the ordinary run tonnage steels made today and increased uses can found for such qualities. This, mentioned before, will enable this method not only hold its own the fields now occupied, but will increase the tonnage made and the used other lines now closed it. What the Cost Buying? Who knows today which costs the most—to shop among vendors establish close cooperative relationship with 12? asked Earl Whitehorne, commercial editor the Electrical World, New York, the recent Kansas City convention the National Association Purchasing Agents. “How much more does cost interview sales- men than give the same time representatives six selected suppliers who qualify completely all the other factors value? “There are four things done: the purchaser would demand firm bids, then gen- eral price cutting would soon cease. For firm bid like signed order. It’s the word the house. puts industry the one-price basis just solidly the modern depart- ment store. means that price made the best and final price and the buyer expected place the business selecting the firm bid that offers the best value—not price alone but value. “2. While this practice firm bids crystallizing into custom, whenever bidders are called back purchasing agent and asked for better price, let the bidder demand that the other bids shown him, that will know that not being lied to, and that his price indeed high for equal value. “3. And while the trickery baiting bidders still con- tinues the world business, let bidders hold post mor- tem comparisons bids, submitting their bids closed business their trade associations for comparison and re- port. And let the buyer frankly and publicly proclaim that will thereafter shun the man who cuts his price, because the first price supposed represent the honest value the goods, and the man who cuts stands self-convicted either trickery weakness.” The Iron Age, July = | PEAKING generally, the Ford Motor Co. uses some ten different types steel the new Model clude chromium-vanadium steels, chromium steels with extra manganese, high manganese steels, nickel steels, Bes- semer stock, carbon key stock, low-carbon basic open-hearth steels, special electrical alloys for starters and generators, and pure iron for pole pieces. These in- Taking into consideration all grades and classes used for production and non-produc- tion jobs, the list may extended over varieties. Ford’s practice designate steels colors painted one end the stock. the low side analysis the steel also painted white, the high side, white with green stripe. Men charge inventory may thus see glance what stock available and what its chemical composition is. Furnaces Put Wherever Needed Production Line Since the physical characteristics steel are largely determined the succeeding working and heat treatments, not surprising find heat-treatment furnaces and operations forming inconsiderable part the process lines. Indeed, these departments that some the most interesting automatic machinery, conveyors, electric and gas furnaces are found. such large production there need for handling vast quantity one time and maintaining constant procession parts that minor assembly will there shortage. the installation some This has forced many the bays conveyor furnaces, others intermittent, with methods quenching, tumbling cleaning. continuous, mechanical Tempering drawing also often performed fur- naces automatically controlled and mechanically fed. Where annealing necessary interesting forms apparatus have been devised whereby this slow cooling may occur under conditions travel over baths which, while chilling one part the piece, may allow the other gradually drop temperature, thus producing single part those vari- ations structure and physical characteristics best suited its use. good example this may seen Fig. showing * Me ngineer, New York 1928, The Age Heat Treatment Schedule for Shafts, Axles and Gears—Con- tinuous Gas and Electric Fur- naces Handle Production FAY LEONE FAUROTE* the heat-treatment operations the outer end the rear axle housing. the background the discharge end electric furnace. Stock moves through automatic pusher which feeds five parts time, one each groove. Reaching the required temperature (which, inci- dentally, controlled automatic recording device), the parts are removed one one and placed quenching device which cools only the lower portion, the upper half remaining the higher temperature. This quenching frame holds four parts and fast the workman the center can remove them the conveyor alongside, the work- man the background puts others their place. The device timed that the forging remains the quenching frame only long enough harden the lower section, after which the upper allowed anneal the air while the lower travels along the surface the water the end the bath. Then complete immersion cools the entire piece handling temperature, and removed third workman. Double-Deck Furnace Saves Space sometimes necessary complete the entire heat- treatment cycle very small space the process line. Thus the crankshaft heated, quenched and drawn very limited area. Fig. shows two electric furnaces, one above the other, economical both heat and space. ing them special quenching machine. The crankshaft made hot-rolled steel the follow- ing composition: carbon, 0.35 0.40; manganese, 0.70 0.90; silicon, 0.07 0.15; phosphorus, 0.03 maximum; sul- phur, 0.05 per cent maximum. After forging, normal- ized 1560 deg. Fahr., air cooled, and then machined. The parts are fed from the far end through the lower, hard- ening, furnace shown the view automatic pusher device. The workmen remove each crankshaft appears, heated 1500 deg. Fahr., and place between the jaws rotating quenching machine the right, which im- merses the part caustic solution. After the proper quenching time has elapsed, the machine presents the part the opening again ready for tempering. The workman then drops into the projecting hooks chain conveyor | which carries through the upper furnace. There drawn 650 deg. Fahr. meet Brinell hardness 402 444. The front end then redrawn meet hardness 302 364, and the flange drawn higher still give hardness 228. similar unique electric furnace and quenching device makes the heat treatment the Ford Model camshaft worthy notice. The furnace round like turret and consists rotating hearth table, upon which the cam- shafts are laid one time the table revolves past the door. The speed the hearth timed that when the revolution has been made the shaft heat. After each end given preliminary quench, the shaft hung vertical position rotating quenching bath caustic soda, which automatically completes this portion the heat treatment without further attention. Differential heat treatments—that say, methods whereby one portion part receives one treatment and another second treatment adjusted produce correct properties for the required duties the various portions— are fairly common. The Model rear axle shaft, for in- stance, made piece hot-rolled steel the same chemical composition the crankshaft. heated 1480 deg. Fahr., and withdrawn when has reached tem- perature about 350 400 deg. Fahr. then placed combination gas-electric furnace having longitudinal baffles dividing the hearth into three heat zones. The gear end thus held about 300 deg. Fahr. preserve full hardness for gear wear, the central portion heated 500 deg. meet Brinell hardness 477 512 and the wheel end 800 deg. Fahr., thus giving the latter portion Brinell hardness 302 340, suitable for cutting key- way and threading. Uniform Temperatures Gas Furnaces Gas furnaces are largely used the Highland Park plant. continuous annealing normalizing furnace such unit, from the discharge end, placed line with tumbling barrel for cleaning scale from normalized gear blanks before cutting the teeth. (These rings for differential gears, the way, were originally flat bar, but have been curled edgewise and butt welded into com- plete circle.) shown Fig. the incoming end the furnace heated Surface Combustion burners with in. nozzles, ranged three side, staggered alternate spacings being ft. in. apart. The combustion zone separated from the work false arch, perforated with about 170 holes, in. diameter. After playing upon work sliding through the rails, the hot gases down into the checkerwork below the hearth, and are withdrawn through central slot into series vertical flues in. square, built the side walls and connecting with breeching built above the furnace, into longitudinal flues below the floor level. Passing through this heated portion the hearth, the work enters unheated exten- sion, with descending roof. The hearth this latter portion built three arches, principally economize brick work, and provide ventilation through doors the steel buildings through wide slots each side the hearth. Such furnace has hearth area sq. ft., can heat approximately 2500 steel per hour 1550 deg. Fahr., and consumes 4530 cu. ft. 530-B.t.u. gas per hour. The total flue area 490 sq. ft. Fordson there growing tendency use elec- tricity for heating and heat-treatment operations. Many the new installations use ribbon heating element. Re- sults are justified the more accurate control heat, general cleanliness, quietness operation and simplicity control. There little outside radiation, the work- man can stand close the mouth the furnace without discomfort. The ability various parts stand under road con- Fig. 1.—Machine for Quenching Flange Only Rear Axle Housing Forging (Above) Fig. 2.—Hot Crankshafts Emerge from Lower Furnace, Are Quenched Special Device Left, and Are Drawn Upper Deck The Iron Age, July 1928—13 ditions depends very largely upon the heat treatment. Ford parts are light but unusually strong. Therefore few exact heat-treatment specifications will interest produc- tion and metal-working executives. Many parts, among them the following, are made medium-hard carbon steel with the following chemical com- position: carbon, 0.35 0.40; manganese, 0:70 0.90; silicon, 0.07 0.15; phosphorus, less than 0.03; sulphur, less than 0.05 per cent. The differential gear case heated 1470 deg. quenched water, and drawn 1000 deg. Fahr. Brinell hardness 228 286. The valve push rod made 0.6-in. cold heading wire, upset, counterbored and finished all over. Heat treatment: Heated 1470 deg. Fahr., quenched water, removed from quench 350 400 deg. Fahr. meet specification hardness C-50 C-58. The starter drive pinion made 1.44-in. cold-drawn steel, selected. Its surface practically covered with and ratchet teeth, and the reamed counterbore must maintained smooth and straight for length between the limits 0.788 and 0.792 in. Heat treatment: 1470 deg. Fahr. cynade min., quenched oil. Surface must file-hard. The front brake operating wedge made hot-rolled steel. Heat treatment: Heated 1470 deg. Fahr., quenched water, annealed 450 Fahr. Rockwell hardness C-48 52. The rear spring perch intricate forging made hot-rolled steel. Heat treatment: Normalized after forg- ing meet Brinell hardness 143 196, then machined. ball-shaped projection only heated 1500 deg. Fahr. for min. and quenched water file hardness, The clutch disk forged from 3/16-in. hot-rolled rounds. The drum 3.66 inside diameter, 9/32 in. long, and has gear teeth cut its outer surface. Splines the hub bore are broached, and the whole piece held within two three-thousandths for eccentricity and flat- ness. Heat treatment after forging: Heated 1470 deg. Fahr., quenched water and drawn 1000 deg. Fahr. produce Brinell hardness 255 machining all over, heated 1350 deg. Fahr. cyanide and quenched oil for file-hard surface. Treatment Per Cent Chromium Steel number important transmission parts are cut forged from low-chromium steel the following chemical composition: carbon, 0.35 0.38; manganese, 0.65 0.80; chromium, 0.90 1.10; silicon, 0.10 0.20; phosphorus, 0.03 maximum; sulphur, 0.04 per cent maximum. The transmission main shaft first annealed 1650 deg. Fahr., held hr., cooled furnace 1150 deg. Fahr. LOADING Section Center Line cry, 4. lo, Section B-B With Door Removed Fig. 3.—Construction Details Typical Gas-Fired 1928, The Iron Age End With Door Removed Annealing Normalizing Furnace | | GOR GE VIVA j ane Fig. 4—Normalizing Furnace and Tumbling Barrel for Handling Welded Blanks for Differential Ring and finally cooled air produce Brinell 187 217. then machined. Final heat treatment is: Heated 1500 deg. Fahr. cyanide, quenched oil, drawn oil 400 deg. hr. Brinell hardness 477 The various transmission gears are taken from the low side this chemical specification, and previous machin- ing they are annealed above Brinell hardness 170 196. After machining, they are heated 1500 deg. Fahr. cyanide, quenched oil, and drawn oil 400 deg. Fahr. for hr. Brinell hardness 477 532 (Rock- well hardness C-48 53). Rear axle driving gears are held cyanide somewhat longer and, after quenching and drawing, must file-hard. The differential driving gear steel forging. After forging, brought 1650 deg. Fahr., taking hr. reach heat, and soaked min. and cooled slowly Brinell hardness 170 207. Then, after machining, heated cyanide 1500 deg. Fahr., soaked min., quenched oil 400 deg. Fahr. and left oil hr. Hardness speci- fication: C-50 55. Spindle arms and connecting rods are lower carbon and chromium (carbon, 0.26 0.30 per cent; chromium, 0.80 per cent). The spindle arm normalized 1650 deg. Fahr. before machining, and then given this heat treatment: Heated 1500 deg. Fahr., quenched caustic solution, removed from solution 400 600 deg. and drawn 980 deg. Fahr. Brinell hardness 286 321. Piston pins are still milder steel. The chemical com- position carbon, 0.10 0.15; manganese, 0.25 0.40; chromium, 0.25 0.35; silicon, 0.10 0.20; phosphorus, 0.03 per cent maximum; sulphur, 0.04 per cent maximum. Heat treatment follows: Carbonized 1700 1750 deg. Fahr. (0.025 0.035 in. from finish size), normalized 1650 deg. Fahr., cooled slowly, cleaned necessary, taper-reamed, reheated 1600 deg. Fahr., quenched caus- tic soda solution hardness C-58 minimum. Case-Hardened Chromium-Vanadium Steel Cyanide hardening chromium-vanadium steel makes durable spindle bolt. forged from the following steel: carbon, 0.17 0.22; manganese, 0.60 0.75; chro- mium, 0.65 0.80; vanadium, 0.12 0.15; silicon, 0.10 0.20; phosphorus, 0.03 per cent maximum; sulphur, 0.04 per cent maximum. After cleaning, machining and grinding, heated cyanide 1650 deg. Fahr. for min., quenched oil, test file hard and have cyanide case with minimum thickness. The driving pinion forged the same steel and then annealed 1650 deg. Fahr. Brinell hardness 163 207. machined all over and copper plated. The gear teeth are then cut, and one boss (which must also hard) turned down slightly. carbonized surface 1/32 3/64 in. deep given carbonizing 1750 deg. Fahr. for hr. Pinions are cooled the boxes, removed, heated 1650 deg. Fahr. min. cyanide and quenched oil. After drawing 400 deg. Fahr. oil, the hardened face the gear must have Rockwell hardness C-58 65. Stretching Hot Steel Studied The high temperatures and pressures associated with de- velopments power plant equipment, oil cracking proc- esses, and the chemical industries generally, have shown the need for added information the behavior metals high temperatures. This applies variety proper- ties but particular the elongation with time, so- called creep metals, when subjected fixed loads for long periods. Technologic Paper No. 362 just issued the United States Bureau Standards are given the results so- called “creep tests” which the elongation metal speci- mens was observed when subjected fixed loads for long periods extending some cases for more than year. Tests were made low-carbon structural steel, high-chromium “stain-resisting” steel, chromium-molyb- denum structural steel, high-speed tool steel, and one high-chromium high-nickel “heat and corrosion resisting” steels temperatures between and 1350 deg. Fahr. So- called “creep charts” are given, that the allowable stresses, the steel last for some approximate length time and with certain deformation, may determined. The Age, July q ‘ : | | 7 | | 7 | | | 7 Unite Cut Distribution Costs Manufacturers and Jo