The Iron Age 1928-08-09: Vol 122 Iss 6

THE IRON AGE New York, August 1928 ESTABLISHED 1855 122, No. Manufacturing Expense Control Motor Plant BARON Motor Car Co. America, has used general budget plan. Ex- penses are divided into differ- ent schedules, one which “direct manufacturing ex- penses.” Under this arrange- ment department heads are held responsible for the amount expenses each schedule, while the production manager accountable for all the operating costs the entire plant. The tying actual manufacturing expenses with the budget gave more trouble than all other schedules com- bined. found necessary dig into history find the reasons why our expenses were over under the budgeted amount. Previous the adoption our present plan sev- eral methods trying hold foremen responsible for the expenses their departments had proved unsuccessful, be- cause each was lacking the proper scale measuring expenses compared with departmental production. Budget, Applied Jan. 1928, —Standard-Time Wage Incen- tive Plan Employed Place Piece Rates Our presert plan, put into effect Jan. 1928, adminis- tered the production man- working through the comptroller. developing the plan was thought that fore- men were sold the idea spending only certain amount for each item expense, they would able keep costs within limit set the man- agement. The main problem was determine the limit, which should flexible allow foremen lee- way operate their departments the best advantage the plant whole. Budget Rates Based $100 Payroll Throughout 1926 and 1927 our cost department kept accurate individual expense accounts with each manufactur- ing department. had manufacturing expense ledger divided into departments and under each department was separate account for each expense that department. BARON, author this article, comptroller the Stutz Motor Car Co. America, Inc., Indianapolis, position which was appointed April, 1928, after having served budget comp- has been identified with the industry years, first the employ the Searchlight Gas Co., which supplied acetylene gas for automobile lighting purposes, and then, after serving the United States Army during the war first lieutenant field artillery and aviation, with the Tymann Re-Manu- Later was associated with the Marmon Motor Car Co. cost accountant and December, 1925, was made director charge the cost, timekeeping and pay roll troller since June, 1927. facturing Motors Co. auditor. department the Stutz company. Accountants. Mr. Baron the present secretary the Indianapolis chapter the National Association Cost 4 q | 4 | 7 | | | | | 7 é 4 = 333 sTuTz OF AMERICA. INC Weekly Budget Performance UNIT BASIS 3100.00 FOR WK. | FOR MO FOR WK. | FOR MO || roTaL CONTROLLABLE || | EXPENSES TAN SAVED OR ¥ MAINT. MCHKY. AND PROCESSING EQUIPMENT MaInT. STOCK HANDLING AND Assem Eouir CL, TOTAL MAINT WU EXPENSES BUDGET CONTROLLER TOTAL SAVINGS OR LOSS FOR YEAR TO DATE “Weekly Budget Performance” Report Enables Each Foreman Correct Abnormal Expense Conditions Promptly. The budget rates the report shown, which only representative, are based $100 payroll. Savings are typewritten black and losses (marked the above report) are recorded red From these records were able compare the expenses each department months and quarters. The ratio expense payroll was determined and expense the department. This study gave our scale, flexible amount, which was reduced rates meas- ured $100 department payroll. some departments discovered that comparison expense payroll was not the best unit measure, and those particular cases were compelled use other units gage for expenses. When made the comparison expenses total pay- roll, also made comparison expenses productive labor and the units produced each department. For the initial rates took that yearly quarter which showed the best performance, and happened that the quarter ended Sept. 30, 1927, gave the smallest ratio expense payroll for the entire plant for the period from Jan. 1926, Sept. 30, 1927. Having determined the ratio expenses payroll, other units measure, for each department, decided that the next step was sell the foremen the rates and the budget plan whole. The writer personally talked with each foreman and explained him how the budget would administered, and how the management had arrived the expenses which would allowed his de- partment. The majority the foremen regarded the plan good one and recognized the proposed scheme pos- sible means measuring their own efficiency. means stimulating the foremen’s interest the budget, the management appropriated $100 month awarded prizes for budget performance. the fore- 1928, The Iron Age man saving the greatest percentage possible expenses was given first prize $25, while second, third, fourth and fifth prizes $20, $15, $10 and respectively were offered. addition, the foreman rendering the greatest service the company during the month, regardless his budget performance, was receive general prize $25. The entire plan, finally prepared, was put before the foremen special budget meeting. detailed explana- tion was given and examples were worked out black- board. When vote was taken, the foremen unanimously expressed desire put the plan into effect and abide the rulings budget committee consisting the pro- duction manager, assistant production manager and comp- troller. This committee was empowered revise rates comply with existing conditions with changes manu- facturing procedure, and propose names for the special monthly prize $25. Every foreman responsible for the administration factory departments was formally notified the outcome the meeting, was given copies the rates expenses for his department and the rules under which prizes would awarded. Rates adopted and put into effect Jan. 1928, were car- ried through January and February with few changes. The surprising thing was that the foreman who received first prize for saving the greatest percentage expenses January was fifth February. Furthermore, many other changes occurred the standings for the first two months. For the benefit those departments which were tail-enders both months and which doubt were working under the handicap inadequate rates, decided that, commencing John poe Pre [r= INET — Ge Se INS > | | | | ii | | | | March all rates would revised, the performance for January and February being taken basis. conse- quence, the results March showed considerable change from the two previous Weekly Reports Permit Foremen Correct Conditions Promptly enable foremen correct conditions their depart- ments soon possible the management puts into their hands weekly report their performance. This report, the form which may noted from the accompanying illustration, goes the foreman within ten days after the close the pay period. This “weekly budget performance” sheet contains the budget for the week, the actual expenses, and the savings losses, with the same information cumu- lative for the month. The details the department ex- penses are compiled and condensed report placed before the general manager and the production manager each week. both departmental reports and the condensed report the budget and the savings are inserted black and all losses red. Responsible Total for two months Budget Com- Empowered Re- Dept. No. and Nam achine sho Pursuant agreement this date are submitting herewith re- vised budget rates effective March 1928. These new rates are based your ectual expence for January and " " " Peb. 10,080.52 Material Losses When the weekly reports are sent out the manage- ment, letter covering the performance for the week dispatched all foremen. The letter gives the standing each department for the month date and warns all foremen bear down all expenses which are showing red the condensed report. fact, the foreman any department having net red figure for the month asked report the comptroller and explain the reasons for his failure attain better record. These explanations, gathered each week, are written gen- eral report the comptroller, who submits the man- agement with the monthly operating statements. This method eliminates the necessity digging into past history later date account for the various figures. The plan just outlined has produced valuable results. the best quarter 1927, that ended Sept. 30, manufac- turing expenses were 63.11 per cent the total factory payroll, whereas the quarter ended March 31, 1928, these expenses dropped 51.5 per cent, saving 11.61 per cent thus having been effected. estimate that the experi- ment controlling manufacturing expenses has paid about March 10, 1926. John poe Baron vise Budget Rates Labor Losses 2.21 Comply with Changes Produc- Idle Tine tion Procedure and Other Special Con- ditions. The com- mittee also proposes names for the spe- prize $25 Oilers Grind ing Vendor Defects 4.00 .08 91.36 -40 Assistants 339 .23 45.00 per wk. and 432.00 1.91 76.13 The Iron Age, August 4 STUTZ | EK ES ¢ — ry Wi. =— M4 £23 J 2 2.21 1 | DETAIL ELEMENTS COVERED DESCRIPTION On teble of me cutte finishes clamping othor Parts, place on floor. other part, Place floor with STUTZ MOTOR CAR CO. AMERICA STANDARD TIME ALLOWANCE oarTe Mill Top Bottom Face Size 16-1/4" Over errect DATE OBSERVATION PLUS 25% PREMIUM TIME TOTAL STANDARD TIME ALLOWED s CIAL TOOLS OPERATOR'S 1-10"x2" Cutter VERY Operation Each Department Time Studied and the Result Transferred “Standard Time Allowance” Sheets the Form Shown Above. Total time-study time made the actual operating time plus contin- gency time. this added per cent for bonus and the total the two the “standard with stand- ard time 100 min. and time-study min., the job done min. the operator entitled bonus 9c per cent the Reverse Side the “Standard Time Sheets Recorded Detail Elements the Particular Operation Shown Top Page 336—August 1928, The Iron Age @ . ‘perator picks up (3) Crankceases fram lo ) P { k irom floor (1) each time, place same | sise. t face, end beeri ng locks to “perator throws out feed, and removes = < | & PART hp LSS THIS SPACE FOR USE OF CC TION | [67] COPIES SENT TO TOTAL AVERAGE TIME PER OPERATIO GIN FOREMAN OF DEPT 5 ST PER CAR TIME KPR FOR DEPT. NO. Time HR. RATE | STANDARD < ait TERE NSAB fy q | PA) LAS SIE STANDARD PRODUCTION FOR 9-HOUR D bd iD SPEEDS USED = he DETAIL OF F SCURACY TOOLS USED = LED) = A ESSE FEED FEED Cures REQ ESS | LEMENT SPINDLE | DIAM eT PER REV PE / " "2 TIME OBSERVATION AND RATE APPROVED BY TOOL SUPERVISOR AIRE ACCEPTED BY PROO L.A. Baron ANG | 25/28 DATE DATE Sir « ay q times the investment prizes $100 month. has required less than the full time one clerk keep the records. this method budgeting are controlling the fol- lowing list manufacturing expenses factory depart- ments: Labor and Material Losses: Reoperations account material shortage, salvage expense, material losses, uncon- trollable labor losses, salvaging vendor defects, idle time, day rate guaranty. Shop Supplies: Waste and wiping rags, oils and greases, gasoline and kerosene, perishable tools and abra- sives, electrical supplies, general shop supplies. Indirect Labor: Foremen and assistants, production control clerical, time study, tool design, watchmen and elevator men, clerical, process inspection, re- ceiving inspection, final facilitate payroll accounting have worked out step-rate schedule based savings 2.5 per cent, each saving that amount taking higher rate pay. These jumps are always incentive for operators better past performance. Cost Reductions Credited Against Department Expense per cent saving standard time lessens the cost the product 7.5 per cent, the reduced cost reverting the department credit against department expenses. per cent increase time over standard time increases the cost the product per cent. This increased cost charged the department expense. With the fore- man receiving credit for savings and being charged his budget with losses, constant cooperation seeing that all opera- tors make high daily rate possible. inspection, toolroom at- tendants, storeroom With this article printed chart showing attendants, receiving room labor, department stock handling, car loading labor, firemen, oilers, and janitors, tool grinding and sharpening, layout work, set-up time, time- keeping, cost and pay- roll, payroll variations. Other Indirect: Ath- letic and welfare, and other miscellaneous ex- connection with our budget system, are using productive labor plan, the basis which standard time with bonus for per- formance less than standard time. Every operation each department time studied and the time study added reasonable allow- ance for stock handling, tooling, etc., this allowance being also based time study observation. The allowance and the actual time added together constitute what call “time-study time,” shown the “Standard Time Allow- ance” form reproduced herewith. the time-study time added per cent for bonus, the total the two making “standard time.” Each operation bears standard hourly rate, which the prevailing rate paid this territory for the particular class work being done. Standard time multiplied the standard hourly rate gives our standard cost. Performance paid for the following basis: jobs completed between standard time and time-study time are paid for the standard cost. Worked out per- centage basis, this would figure out the following man- ner: the standard time 100 min., time-study time min. When the job done min., there saving per cent the standard time, which entitles the operator bonus per cent. All operations completed less than time-study time are paid for the following basis: Actual time plus per cent the actual time plus per cent the time saved between the actual time and the time-study time. For example, operator saving per cent standard time would paid 132.16 per cent the standard hourly rate for the job. When the time complete operation more than the standard time, the operator paid the standard hourly rate for the time taken the work. 100 120 160 180 190 200 Minutes lines. HART Showing the Time-Study Time, Actual Cost and Standard Cost Based Standard Time 100 Min. for the Operation and Standard Hourly Rate 60c. This standard-time wage in- centive plan applied individual workers, two-man teams, and gang work the time-study actual cost and stand- ard cost based standard time 100 min. and standard hourly rate This plan pay applied workers, two-man teams and gang work. following rules govern operations paid for gang basis: all assembly all progres- sive lines operation. Where the task requires the labor more than ator. Where labor more than one operator department habitually employed complete all department operations part unit. Where like workers machines are grouped together for the purpose performing like opera- tions different parts units. This method now being introduced and supplanting individual and group piece work. are selling the idea the employees the basis earnings per hour instead price per piece. hire our employees much per hour and find from past experience that new employees coming into the shop are interested primarily their pos- sible hourly earnings, not price per job. the depart- ments where has been installed meeting with success and are receiving the cooperation both the operators and the foremen. Stainless Steel Chain Strengthen London Cathedral stainless steel chain will girdle the dome St. Paul’s Cathedral, London, the base the famous whispering gallery, part the strengthening work now prog- ress. The chain, which now practically completed Brown Bayley’s steel works, Sheffield, England, has length 450 ft. and weighs over tons. Each link the chain composed three four solid bars ft. in. long. Originally much bulkier chain had been designed the contractors, but the steel plant was able economize bulk and weight. The Iron Age, August 7 1.60 | Steel Building Enlarged Welder Floor Area and Height Increased Welding Reinforce- ments and Connecting Beams Old Structure— Minimum Damage Plaster and Interior Trim interesting example how structural welding may used advantage when enlarging remodeling old steel-frame building may drawn from work the Rose Building, Cleveland, done the Forest City Structural Steel Co. This six-story building was erected 1898, and the owners intended not only in- crease its ground area, but carry the old portion four more floors, notwithstanding the fact that the existing col- umns were not designed for this extra load. further ‘ We, Base Plate Old Column Reinforced Dropping Cross Down Open Center and Welding Place with Tie Plates complication rested the fact that the drawings showing the steel details had been lost. would have cost much mouey uncover enough steel enable joints between the existing steel and the new beams detailed and riveted the conventional man- ner. Furthermore, tenants (mostly doctors and dentists) would have been disturbed even temporarily dispossessed. This situation was met uncovering only small area steel each joint, measuring the connection the new frame work, cutting member the field with oxy- acetylene blowpipe, and then welding this connecting mem- ber the exposed face the old steel. Lincoln machines were used for this field welding. Most these connections were made unknown the tenants behind the curtain wall. Reinforcement Placed Inside Columns the old columns was also done with minimum disturbance plaster and interior finish. They are the Gray type, made eight tees held together straps riveted the legs the tees; thus the columns had open center. stiffen them and give them greater load bearing capacity, sections the shape cross made four angles were inserted down this hollow center. The new steel was then joined the old five-foot intervals plates welded the legs the angles and the legs the old tees. cross section the strengthened section shown accompanying drawing. extend this column upward, was cut off square, and in. cap plate welded the supporting steel. This cap plate served base plate for 1928, The Iron Age four-story H-column and the latter attached edge welds. The beams which carried the roof the low section the building were not sufficient size carry floor loads. give them the necessary strength without disturbing the ceiling the sixth floor, track rails were welded the top flange the existing beams shown one the cuts. The flange the rail was trimmed in. wide, the upper flange the I-beam would give the necessary sup- Roof cut away Weld Roof Beams Strengthened Without Disturbing Ceiling Below Welding Rail Top Flange port for the weld metal, and enable the workman weld the “down” position. Welded steel bar joists are used the new addition. These are held position welding the ends each joist the beams. The joists are tied transversely welding half-inch round rod their bottom chords. Operators were required intervals weld samples which were tested satisfy requirements imposed the local building commission. Visual Inspection Each Weld Insured Uniformly Good Work such methods the owners were enabled receive full rentals from the old part the building, and the tenants were discommoded the minimum extent—either hav- ing the interior trim their rooms wrecked, being dis- turbed noisy rivetting operations. 4 q | | | Y a A ANG ths, | | | Mass Production Limited Demand Output Masse Circumscribed Restricted Markets —Relatively Few Businesses Lend Them- selves Mass Manufacture idea that mass production unfailing key wealth mistaken one,” said Charles Piez, chairman Link-Belt Company, Chicago, when inter- viewed staff representative THE IRON AGE. “The fact overlooked that relatively few businesses lend them- selves mass production. large pro- portion the work the Link-Belt Company, for example, jobbing character, i.e., the building equip- ment meet special specifications. “Even industries where mass pro- duction methods can employed, out- put definitely limited demand. sure, some fields markets can further expanded without great ex- create demand for automobiles. Every normal person wants own motor car, and only necessary build one that can afford buy. Lower Costs Not Guarantee Larger Sales “But, because the automotive indus- try can cut costs and expand its market producing masse, does not fol- low that other manufacturing lines can increase sales following reduction costs. the materials-handling field, for instance, would absurd as- sume that price cut few hundred dollars would enlarge the demand for steam shovels conveyors. Even long established mass production indus- tries, such flour milling and beef packing, there are distinct limits the per capita consumption flour and ited beef only about four-fifths large before the war. The habits the public have changed; mixed diets, in- cluding more fruit and vegetables, have replaced the former standard fare roast beef, potatoes and bread. The gain demand that would follow further cost reduction milling and packing would doubtless insignificant. “Bituminous coal mining another outstanding example industry that has restricted market. large extent building, together with the industries dependent it, con- fronted with the same condition. The replacement small buildings skyscrapers the Chicago Loop district definitely limited the area available. Granting that such construction will continue outside the present Chicago busi- ness district, doubtful whether the rate replacement will rapid, with the advantages central location lacking. “The fact that output cannot increased libitum often overlooked mass production industries. The econo- mies from large-scale output are constant temptation idea that mass production un- failing key wealth mistaken one. few businesses lend them- selves mass production, where mass methods can employed, market expansion. matter fact, output definitely lim- demand.” CHARLES increase production first and worry about sales afterward. Efforts sell goods excess consumption have added very considerably the costs marketing. most in- dustries, including those outside the mass production field, distribution has become major problem. our own company have been conscious decided increase the cost selling the past few years. “Selling programs the future must encompass more scientific study markets. Merchandising must made more effective. Futile efforts overcome the insurmountable must give way the more intelligent culti- vation markets that can captured. building were declining, would foolish for maker shovels try advertising campaign. advertising expenditures that could make would succeed reversing economic trend. Ineffective Merchandising Sometimes Handicaps Whole Industry “Lack effective merchandising frequently causes manufacturer whole industry lose ground. The steel industry was among the first develop mass production, but now finds its market limited greater extent, all probability, than would have been the case its merchandis- ing problem had received the same at- tention that was given operating technique. now clear that the steel mills permitted the cement industry outgeneral them aggressively pro- moting the use reinforced concrete. “The problem getting products the ultimate users not solved high- pressure selling that merely moves goods from manufacturers’ warehouses secondary hands. Goods must wanted the final buyer. Sales departments should make careful research markets before, and not after, production programs are inaugurated plant expansion undertaken. Relatively Surplus Capacity Dictates Greater Cooperation “While market study can profitably pursued all lines, the fact remains that most industries have surplus capacity and should control their output accordingly. Our own company could build more than can sell, but, did so, would red figures. “There question that the Government must permit greater cooperation among competitors, particularly those industries where excessive production not only wipes out profits but threatens their very integrity. Trade associa- tions have done much distributing information regarding consumption, sales and production. When sales are declin- The Age, August | 1 | 4 ing there less temptation slash prices company knows that holding its customary share the total business done. The leavening effect the trade associa- tion has been supplemented the good work the Depart- ment Commerce promoting economies through stand- ardization and simplification. Consolidation Only Alternative Cooperation “The only alternative greater cooperation consoli- dation. Mergers are desirable among companies making the same closely allied goods, especially products sold the ton. There little doubt that one company owned all the plants this country steel could sold more cheaply. When great number varieties products are made, consolidation less advantageous. Even the case such plants, mergers are sometimes economic. 1906 three companies having much the same owning interests consolidated into the present Link-Belt Co. This merger benefited both ourselves and our customers. One man- agement replaced three, single branch office sufficed where two were formerly needed, and advertising expenditures, although double those any one the three merged com- panies, nevertheless fell below the previous combined out- lay. “The attitude the general public toward mergers and trade associations has changed. longer feared that prices will raised unduly high level. Expansion business can come only with the improvement products and further reduction costs. Extortionate prices would invitation enterprising capitalists and executives enter the field. Moreover, the stamping out competi- tion would probably result Government control, event- uality that industries seek avoid. Nor inter-industry competition forgotten. Excessively high prices cer- tain fields would tend divert business other industries. Dominant Group Stockholders Desirable Large Company “Consolidations, opinion, are well worthwhile the automobile industry. some other fields con- ceivable that mergers might become large unwieldy. Large companies with ownership widely diffused always run the risk supplying insufficient incentive for progressive management. American stockholders are sin- gularly apathetic, and there are distinct disadvantages the impersonal touch hired management. have always believed the responsibility stockholders. large organization desirable have group stock- holders dominating the company, such the DuPont inter- ests the General Motors Corporation. Where there are dominant owning interests well encourage the management acquire real stake the form stock percentage the profits. Profit-sharing criticised because tends foster driving type management that fails build proper reserves keep plant and equipment up-to-date and good working order. similar self-interest manifests itself piece-rate work, but just the piece-rate method wage payment calls for closer- inspection the product, must profit-sharing manage- ment under closer control the board directors. There Fixed Buying Fund “The problem production, course, intimately con- nected with the problem consumption. The development new products and new uses for products brings about additional employment and greater purchasing power. There fixed buying fund. wrong assume that the public has only much spend and that the fight for the buyer’s extra dollar. you can create new demand, the necessary buying power seems there. “While this broadly true, should not lead mis- conception the significance the wage problem. The employer‘s responsibility his workmen consists pro- 340—August 1928, The Iron Age viding them with steady work, under sanitary conditions, the best possible wages. But those who have meet payrolls year, the face keen competitive condi- tions, the responsibility means light one. Rise Wages Has Been Natural “In our industry and industries allied with have not consciously raised wages maintain increase the purchasing power labor. Wages have had natural rise. 1914, when Ford raised wages common labor day, did because had unlimited market and needed greatly expanded production. During the war and the post-war period opportunities for higher wages appeared and, doubt, did much improve the relations between management and labor. became clearer that employers and employees have common stake industry and that their fortunes rise and fall together. Management has generally accepted the view that wage reduction should the last step any business recession. has, there- fore, concentrated its attention reducing labor costs through the increased use labor-saving equipment. Such equipment was not introduced raise the wage level; rather wages rose first and industry then set out beat them—not wage cuts, but indirectly through better methods and improved machinery. Scientific Research Prime Importance “Economies manufacturing have been forced the high labor market and, naturally, have been prompted also desire expand markets. Such great progress has been achieved the development more efficient methods and equipment that manufacturers have come realize the prime importance supporting scientific research effort find new short cuts cost reduction. “The emphasis lower costs has been matched the attention given financing buying. safe say that the time instalment payments automobiles has been doubled the past few years, thereby enabling many sands people with smaller incomes purchase cars. Consumer purchases mass production goods may adversely affected the decline our stock gold and recent advances interest rates. Human nature must considered this connection, however. The check in- stalment buying may like the attempted check brokers’ loans. other words, obstacles are often ineffec- tive when man wants something. “The general effect business the outflow gold cannot appraised this time, but not unrea- sonable assumption that the return the metal coun- tries that have long had deficient supply will bring about steadier and stabler world money market, the ultimate benefit this country.” “Zeolite Water Treatment” the title reprint issued the Department Engineering Research, University Michigan, Ann Arbor. The paper was read before the American Water Works Association. devoted water treatment system used the heating plant the Detroit Edison Co. The conclusion that the system operates satisfactorily under careful supervision and that reasonably safe. The use phosphoric acid gives less carbon dioxide the steam and less caustic alkalinity the boiler. believed that this phosphoric acid will eliminate scale the tubes the boiler. Little History Marking Devices” the title 24-page pamphlet unusual type issued the Noble Westbrook Mfg. Co., Hartford, Conn. The booklet illus- trates large number nationally known trademarks, clas- sifies the types which may registered and tells how they may attached the various articles consumption. Copies this booklet may had undoubtedly { 7 4 Automatic Cadmium Plating After Brake Bands Are Racked and Placed Hangers, Further Passage Through Washing and Plating Baths Entirely Automatic FAY LEONE FAUROTE* EMAND for automatic plating has come naturally the old way doing things this section the manu- with mass production exposed machine parts facturing gamut was usually relegated outside shed needing protective ornamental covering—espe- with dirt, cinder slat floor. The place was often wet, cially from the automotive industry. Here beauty ex- the ground damp, the air full unpleasant fumes. The Semi- Automatic Equip- ment for Plating and Washing Small Parts Below Revolv- ing Telescope Arms Above Con- veyor Lift ers from Tank Tank — ternal appearance vies with long life the mechanism the race for sales supremacy. Stainless steels and pro- tective coatings have been widely used other indus- tries that motor car manufacturers have been forced adopt better and more permanent methods rust preven- tion. Most automobile parts subject oxidation and apt have their efficiency impaired are now being covered with copper, brass, nickel, chromium cadmium. Automatic Equipment Makes for Neatness Among the several interesting machines recently intro- duced into the Ford Motor Co. shops for manufacturing Model battery automatic cadmium plating tanks served combined automatic mechanism and conveyor. Virtually continuous, this new apparatus eliminates large extent the human uncertainties and incidentally the messiness this operation. *Mechanical engineer, New York. The Age, August 1928—341 4 | — a | metal parts were laboriously hung hooks racks and immersed singly groups the various washing and plating solutions. the end the proper time (and that time was apt vary according the trustworthiness the workman) the parts were again laboriously removed, one one, carried dripping the next tank, immersed again, pulled out and finally hung dripping rack where they remained until they were ready for transfer the stockroom the buffing department. Many times there were not enough parts any one batch make worth while for the foreman rig wooden draining, plating washing frame. Bent wires and wooden racks, wooden crossbars and grimy tanks combined with crude switch- board entangling maze wires—such was the old equipment. was also necessary truck parts from the machine shop the polishing, plating and buffing rooms. How different the modern automatic plating department! True, there still remain some the old earmarks, but the job longer messy one. more need segre- gated. more need the floors running sewers, the workmen slushing around rubber boots. Automatic plat- ing tanks and mechanism may put near the process line without greatly interfering with the work going around it. Like heat treating, may become part straight line production. Cadmium Plating Requires Four Tanks The equipment shown has recently been installed the Fordson plant for cadmium plating Model brake shoes. includes four main tanks: the electric cleaning solution; the first water rinse; the cadmium electroplating tank proper; and the hot water cleaning rinsing tank. The parts groups ten are hung the suspension frames, which frames turn are placed conveyor hang- ers pairs. Loading and unloading done when the hangers are down between the tanks the left foreground. Passage through the process thereafter continuous and automatic. get from the loading position and from tank tank, slowly revolving telescopic arm, whose end guided around rectangular path, picks the hanger off the supporting conveyor fingers, lifts straight up, carries forward this elevated position, and then lowers down again the forward-moving conveyor, whereupon the work submerged the next solution. This unique mechanical device eliminates the necessity for manual handling and makes the dipping purely me- chanical movement, performed tempo and definite speed that each operation given just the right amount time for its adequate performance. The first tank, shown the left foreground, which the parts remain suspended min., contains cleaning solution tri-phosphate sodium, soda ash, caustic soda and little sodium cyanide. Electric Bus Bars Overhead When submerged this bath electric potential im- pressed the metal parts facilitate the chemical action. bus bar will observed just below the conveyor. Each hanger has contact brush connected with spring clips, make good contact with the bus bar during this portion its travel. Naturally the hangers are attached the cast- ing top insulated bolts, the passage current will from overhead bus, through hangers work, and thence from work contacts submerged the tank. While the brake shoes are the cleaning tank the con- veyor passes around the end wheel and travels from left right the rear. Reaching the second tank (not clearly shown the rear) the hangers are lifted automatically over the partition and down again into wash solution. This second tank contains circulating water and the rins- ing operation requires min. The third tank, which the parts remain suspended min., the main electroplating bath. wide long tank which the brake shoes re- main submerged during the most the trip from left right (at the rear) and return. During this time the 1928, The Iron Age brushes the hangers are contact with bus bar, im- pressing the required potential the submerged parts. The solution used for cadmium plating composed cad- mium oxide, sodium cyanide, caustic soda and corn syrup. The fourth and last tank hot water rinse, requiring min. The whole process consumes total min. This plating machine has capacity 3080 pieces hour. Three men are required operate and esti- mated that its use the labor fifteen men per day saved. Direct current volts used, amp. per sq. ft. plating surface being required. 5000-amp. generator set located adjoining room. Small Parts Handled Tumbling Barrel For very small parts which cannot readily handled racks different method employed. They are loaded into perforated copper buckets; given “in and out” clean- ing solution; immersed hydrochloric acid for two minutes and then emptied into revolving wooden barrel which, means overhead trolley, brought over the plating bath, immersed, and revolved for min. the plating solution, Finally the parts are emptied into dryer, the cadmium solution washed off and live steam turned for min. drying operation, after which they are dumped into containers for conveyance the stockroom. The cathode placed inside the barrel comes contact with the work plated revolves. The tumbling barrels are made wood, pierced with %-in. holes which allow the flow the electric current and chemical solution from the anodes outside the cathodic parts inside. This method used for plating nuts, bolts and other small arti- cles. estimated that this method costs hardly one- tenth the old method labor and materials. the photograph the centrifugal dryer shown the left foreground, while the middle background workman seen preparing immerse the revolving drum contain- ing the parts into the plating solution. These operations, course, are not continuous nor fully automatic, but are adaptation which efficiently plates small parts. Activities American Engineering Stand- ards Committee According the 1928 Year Book the American En- gineering Standards Committee, costs $41,500 salaries and $20,000 expenses conduct the committee’s activi- ties. This amount raised from dues member or- ganizations and contributions from 340 sustaining mem- berships. These figures represent slight growth from the report for 1927. Work progress 164 projects, which were instituted during the fiscal year. Some new standards were finally approved the months, bringing the grand total American engineering standards 111. Among those approved last year are table preferred numbers scientific basis sizes for series machines), stand- ards for pipe flanges and fittings, for bolts and rivets, and safety codes for prevention dust explosions. Certain changes have been made the procedure committees, designed expedite the work and secure assent all the groups concerned the project under consideration. change name also under contempla- tion, noted THE AGE for July 12, page 84. Laboratory investigation the creep metals high temperature done during the year past England the National Physical Laboratory indicates that increased chromium percentage (40 instead 20) proved advan- tage for high temperature use; 800 deg. failure occurred mainly cracking. the Ni:Cr:Fe alloys the proportions 25:25:50 have far given the best results under prolonged loading 800 deg. | | & Wide Ramifications Shipbuilding Calls for Materials Made Nearly All Industries —Benefits Come with American Merchant Marine ITH practically every indus- try the United States line benefited, building privately owned first-class American merchant marine comes nearer realization under the recently enacted Jones-White law than any previous time during the present gen- eration. Already negotiations look- ing loans private operators are being considered, while contracts have been completed for carrying the United States mails. That the new law means much American industry accepted the highest authorities, who are deeply interested the restoration adequate merchant fleet within the keeping the requirements the nation, for carrying its immense export and import trade. Indicative this fact are the views expressed vice-president Bethlehem Shipbuild- ing Corporation, Ltd., and also vice- president and treasurer the Na- tional Council American Shipbuild- ers. Mr. Smith was one the promi- nent witnesses who appeared before the House Committee Merchant Marine and Fisheries Washington connection with hearings the Jones-White measure. “The Jones-White merchant marine act the most constructive piece merchant marine legislation that has been enacted within recollection,” Mr. Smith told “While the act may not accomplish every- Coppersmiths and Sheet Wood Workers Electricians Workers Machinists HOURLY RATE CENTS STATES thing necessary establish perma- nent American-owned, American-built merchant marine the foreign trade, under private ownership, never- theless very important step that direction. Act Save Shipyards from Stagnation “In the first place, the act reas- serts policy backed large majority vote both houses Con- gress, and further supported provision for long-term mail contracts for speeds knots and upward. The provision, together with liber- alization loans, both the amount the loan and the rate interest, will make possible for the private steamship owner adopt constructive program for operation, and provide for the building new tonnage. That some vessels will built this year the outcome this merchant marine act seems assured, and this assurance necessary save the private shipbuilding indus- try the United States, which now its lowest ebb within the his- tory modern steel ship construc- tion. “The Jones-White act notifica- tion the world that propose carry reasonable proportion our world trade our own vessels, built American shipyards.” show the stimulus which Ameri- can industry will receive from ship- building, Mr. Smith cited the break- BRITAIN ers down cost 10,000-ton freight steamer follows: Per Cent Insurance fees, and depreciation .......... 5.36 4.50 The percentages will about the same for motor vessel the Diesel motors are constructed the ship- yard. The foregoing percentages show that, for every $1,000,000 spent the building new vessel, $502,000 for materials—ordered from prac- tically every industry the United States. Analysis the material dis- tribution vessel built one the large shipyards shows that prac- tically every State the Union par- ticipates the material required. Mr. Smith said that the rolled iron and steel ship probably not more than per cent the total material cost. But, even such basis, the iron and steel $1,000,- 000 ship would reach value $104,- 000, and, with only fair activity shipbuilding, such sums when aggre- gated would reach substantial pro- portions. They certainly would mean much heavy rolled lines, including plates, shapes and bars, well other products, and important influence the market. Other materials would consist copper, tin, zinc, lead, lumber and allied products; textiles and their products, rubber products, leather, OMPARATIVE Wage Rates Three Countries, Show- ing the Handicap under Which American Ship- ping Labors Compe- tition with European Ships Built Lower Costs. may noted particularly that the American laborers are more highly paid than the skilled labor Great Britain and Germany GERMANY The Iron Age, August 1928—343 electrical products, stone, clay and glass products, all the elements entering into auxiliary machinery, running through the entire gamut material down miscellaneous hard- ware and food supplies. The ma- chinery requirements would appre- ciable, stimulating the machinery trade, well iron and steel re- quirements for their manufacture, and, turn, lines entirely out the iron and steel and machinery trade would require this class equipment operating needs. “The provisions the bill,” said Mr. Smith, “are such that new con- struction seems certain. This con- struction will carried out Amer- ican shipyards, and over one-half the stimulus given every ship built stimulus nearly every branch American industry.” How Cost Large Liner Would Distributed Mr. Smith cited assumed cost S15 0 | 00,000 for passenger vessel type necessary supplement George Washington, and other leading vessels the United Stat about per cent States lines. the total cost building such vessel, was explained, will ex- pended within shipyard; 5.6 per cent for taxes, insurance and depre- ciation; 4.6 per cent for freight, and the remainder, 50.8 per cent, for ma- from supply people throughout the Taking the manufacture steel example this distribution, was explained that the shipbuilder pays for this steel finished ma- terial. The steel maker and supplier raw materials, however, produc- ing this steel pay about three-quarters its total cost labor. Involved the manufacture steel the pur- chase ore, limestone, coke, scrap chased from various parts the country, and each these raw ma- terials involves the purchase other materials and employment labor. Also, said Mr. Smith, the manu- facture any one the products any State, further breakdown into labor and material will occur, with still further requisitions other States for raw materials used the manufacture such product. The transportation each these prod- ucts the shipyard requires the services railroads. Ten per cent the total cost construction vessel goes the railroads pay the transportation charges ma- terials ordered directly the ship- yard equipment manufactured independent contractors. Hence, trans- portation charges approximately $1,500,000 would paid the rail- roads the construction vessel the value $15,000,000. Labor Gets Seven-Ninths Total Cost the total cost $15,000,000 for such vessel, was explained, the shipbuilder expends per cent for labor the shipyard, and the steel- maker and the suppliers raw ma- terials used making steel about per cent the total cost steel for Blast Furnace Capacity Declined 1927 Loss 3.4 Per Cent Brought Total 49,605,720 Gross Tons—588,900 Tons Added This Year annual capacity blast furnaces the United States producing coke pig iron decreased 1,773,680 gross tons, 3.4 per cent 1927, according the annual ical report the American Iron and Steel Institute. Total theo- retical capacity, Dec. 31, 1927, stood 49,605,720 gross tons, but hree furnaces then under construc- ion have since been completed, mak- ing the total Aug. 1928, 194,620 gross tons. This figure does not include the capacity coke furnaces “which have long been idle are likely remain long inactive,’ and based the possible output 300 furnaces. This average 165,352 tons annually and indicates average daily capacity per furnace 453 tons. Greatest losses capacity were evidenced Pennsylvania, Ohio and Virginia, the figures having been 254,100, 430,600 and 374,000 tons respectively. New Jersey and Missouri are each shown with ca- pacity the 1927 analysis, but had and 90,000 gross tons respec- 1928, The Iron Age tively the previous year. Large gains were shown Indiana, Alabama and West Virginia, the figures being ANNUAL CAPACITY COMPLETED STATES ON (Does Not Include Number Furnaces 1927 926 New Jersey ...... 2 Pennsylvania ..... 115 123 Maryland West Virginia .... Kentucky Tennessee 10 11 Indiana . 18 1s 4 Wisconsin ...... 5 5 2 2 1 1 Total 351 (c) 363 Total building .... Grand total ...... 354 365 (b) Includes coke furnaces ich active, the Virginia, 11; Kentucky, Tennessee, and Missouri, (c) furnaces long idle New Jersey, Pennsylvania, Wisconsin (d) Does not include annual capacity and other ferroalloys, nor capacity operations in near future Virginia, labor. Railroads expend about per cent the total amount the bill for labor, and every other item material involves the payment correspondingly large percentage its cost for labor. exclusive mate- rial charge does not exist, except for the intrinsic value the ore the mines, lumber the forest, products the field and profits manufacturers. “The net result,” Mr. Smith said, “is that the total cost this 000,000 ship, about per cent goes American labor, composed al- most every known craft, involving total labor cost about $11,700,000, 2,340,000 days work, the employ- ment 7800 workmen day for one year, 2600 workmen for three years, which approximately the time required build this vessel.” Materials Needed Build Freighter The value material required for 10,000-ton steam cargo ship and purchased direct the shipyard was placed $736,500, while the freight charges were fixed $70,000. Among the items listed and their values were the following: Rolled steel and rivets, $201,500; sheet steel, $1,820; sheet brass, $440; sheet lead, $200; cast steel, cast iron, $38,700; cast brass, $37,400; forgings, $36,100; steel and iron pipe, $6,550; brass and copper wire, $15,800; lead pipe, $800; valves, $8,460; pipe fittings, $4,850; hardware, $2,200; wire rope, $5,100; wire and conduit, $4,100; galvanizing (zinc), $13,000; generators, $14,600; boilers, $113,300; engine room auxil- iaries, $60,130; deck machinery, $92,- 000. 291,200, 278,670 and 175,000 tons, re- spectively. Since the first the year two new furnaces have been added Alabama, bringing additional capacity there 413,900 tons. Detailed figures are shown the accompanying table taken from the Institute’s reports for the last two years. AND BUILDING BLAST FURNACES DEC. Charcoal Furnaces) Annual Capacity Net (Gross Tons) Change, 1927 1926 Tons 175,000 140,000 35,000 3,595,800 3,781,000 185,200 300,000 — 300,000 16,728,050 17,982,150 100 1,112,400 1,020,000 92,400 142,000 516,000 374,000 760,000 585,000 + 175,000 240,000 236,000 + 4,000 180, 000 314,000 — 134,000 577, 170 11,299,000 4.399.200 3,298,500 278,670 430,600 4,108,000 291,200 5,171,600 5,048,650 122,950 665,000 444,500 90,000 — 90,000 600,000 130,000 135,000 5,000 (d) 49,605,720 (d) 588,900 302.750 —286,150 50,194,620 51,682,150 have been long idle are likely remain long capacity which included, follows: New Jersey, Pennsylvania, ; Wiscons sin, the capacity which not