The Iron Age 1928-10-25: Vol 122 Iss 17

EIRO AGE New York, October 25, 1928 ESTABLISHED 1855 VOL. 122, No. Profits Close Material Control Timing Deliveries Meet Production Schedules, Based Sales Forecasts, Permits Stutz Company Turn Over Stock Times Yearly BARON* AINTENANCE minimum inventory secure maximum turnover the basic principle the plan for controlling materials which has enabled the Stutz Motor Car Co. America, Inc., turn over its stock times annually the past two years. This done timing deliveries purchased goods meet current pro- duction schedules established result frequent fore- casts sales. fact, stock has been controlled that the physical inventory compared with the book inventory has shown shrinkage less than per cent value. account the factors entering into these ac- complishments involves explanation the system for regulating stocks. About per cent the parts going into direct material costs the Stutz automobile are fashioned from raw ma- terials our plant, the remaining per cent coming *Comptroller, Stutz Motor Car Co. America, Inc., Indi- anapolis. Incoming Materi- als Are Promptly Inspected the Receiving Room the Assembly Floors. The inspection valve springs and timing chains shown rough, semi-finished finished parts. Regardless the state which material received considered “productive material” from the standpoint accounting, and therefore distinction made our books. fact, the designation “productive used for all direct material costs the time that shipments are trans- ferred “cost sales.” Every piece entering into the Stutz car either designed specified the engineering department. The individual pieces parts are given both name and number, which they are identified thereafter. When new part de- signed, blueprint giving the necessary specifications furnished the purchasing department for use ordering the part the material from which manufac- tured. copy the blueprint and “experimental mate- rial release notice,” Fig. sent all other departments This notice states whether the part manufactured the plant purchased and speci- 1009 * | ; ) fies the name and number the part, the material and other details. the design proves satisfactory experi- mental work, the part approved the chief engineer and released for production form designated “engineering release,” Fig. then written into the “bill materials,” the form which may noted from Fig. and becomes part our product thereafter. Changes the design parts production are covered the “engineering change” notice, Fig. and such changes are written into the bill materials. Incidentally, the bill materials important requisite, being used constantly the purchasing department, foremen, inspectors, stock chasers, cost accountants and others. Material Contracts Based Sales Forecasts Near the end the year the management and the sales department together forecast the probable sales volume for ce TOOL TOOL | Toc. care | | INDIANAPOLIS CHIEF INSPECTOR | RECEIVING | «626 STUTZ MOTOR CAR CO. OF AMERICA, me. corms To FACTORY MGR. TOOL DESIGN | CHIEF INSPECTOR | | INSPECTION i = | \ Tech. | service stocx | ‘es tow roru a z < ° 0 < a ° z N LATEST REVISED LAST CHANGE | DATE OF DRAWING eTrrer the following year. When this information released, the purchasing department solicits bids and places contracts for the estimated requirements for the months. The con- tracts, which cover not only probable production needs, but also spoilage and service requirements, generally not designate specific quantities material. Production materials are ordered from vendors the purchase order, shown Fig. This order made from purchase requisition which specifies the shipping date, and gives complete description the part, packing instructions, price and terms. special order form used for service stores, and another for factory supplies and expense items. Before the purchase order released the vendor, study the processing time must made for each part. process time meant the vendor’s time, plus transpor- ENGINEERING RELEASE LATEST REVISED DATE OF ORM AWING PATTERN OR DIE NO AFFECTS MODELS SUPERCEDES MAS PART BEEN USED IN PREVIOUS PRODUCTION’. REMARKS WHEN 1S PART TO GO INTO PRODUCTION?! ENGINEERING CHANGE PATTERN OR DIE No. || AFFECTS MODEL SUPERSEDED BY mar. DETAILS AND REASON FOR CHANGE \ Punch.acent || WHEN 1S CHANGE EFFECTIVE? DISPOSITION OF STOCK ROUGH FINISHED | 18 PATTERN OF DIE TO BE CHANGED? ASSEMBLIES TOA CH Hes | REQUESTED BY Fig. (upper Release Notice Issued Engineering Depart- ment Fig. (upper Engineering Release Notifies All Departments That the New Part Put into Production Fig. (lower Parts Production Are Made the Engineering 1010—October 25, 1928, The Iron Age Change Notice To | Nis Nom Leo | where Use | NED DAT PART NAME : io. th 6 Ince . {Group Radiator and Connections c N Radiator Cap Ornament Washer 41/64 I.D.x 0.D.x Thick own sher - 5/6 I. D.x 1-1/4 0.D.x 1/32 Thick = 20 Bricht Chrom.Plated Finish 4 Rubberised Pabric Sheet Alum. Alloy Polished or Steel Stamp.- No. REMARKS 261-2 z ~ Maxers R Radiator Cap to Filler Neck D m a Ornament to Cap tor Cap Ornament to Cap Smape into Radiator Shell 2500 SERIES BB CARS Tus Supersedes Sweet Daren Fig. 3—Bill Materials. Upon completion experimental work, the new part, approved the chief engi- neer, released for production. the same time, all necessary data are written into the bill materials tation time, plus our time. Thus, when the purchasing de- partment contracts for the purchase part, obtains the vendor’s process and shipping time. Moreover, when the engineering department releases part for production, the material supervisor informs the purchasing department the factory process time, which varies from hr. local pick-up items days such parts bodies and crankshafts. When production being maintained schedule, bodies and crankshafts for cars coming off the assembly line today should have been received not less than days previously. Five copies are made the purchase order, one which sent the vendor, one the cost department and one the receiving department, while two are retained the purchasing department. Materials and Supplies Controlled Material Supervisor soon material enters the plant passes under the control the material supervisor, who has charge all “productive material” and factory supplies within the plant. The receiving room, interior trucking, stock chasers’ mate- rial records and many other activities are under his super- vision. About per cent the parts received are un- packed and counted the receiving room, the remaining per cent, constituting bulky materials such cushion springs, fenders, bodies and frames, being delivered directly the first station along the production line. The receiving department makes out the report shown Fig. for every lot material delivered the plant. Six copies are prepared. The first attached the ven- dor’s invoice and forwarded the accounting department, while the second used the purchasing department complete its record the purchase order. The third re- tained the receiving department, and the fourth sent the material supervisor complete the material record. The fifth and sixth are sent with the material the re- ceiving inspection room, the former being kept the in- spection department and the latter going the point the assembly line where the material used. Incoming Material Inspected All materials are inspected the receiving inspection room the assembly floors rapidly delivered. While the process inspection the materials are tem- porarily out the jurisdiction the material supervisor and are under control the chief inspector, who respon- sible directly the president the company. Parts that not pass the receiving inspection are cov- ered the “defective material receiving inspection report,” shown Fig. which, addition complete descrip- tion the material, records the vendor’s name, purchase order number and the reasons for rejection. case the supplier has failed comply with our specifications, the report stamped “return vendor for replacement.” similar report used for parts having defects that are found later the course production and for which the vendor responsible. The only difference between the two reports that the latter states the department which the material was found and how far had progressed along the line toward completion. Both reports are filled out triplicate, one copy being sent the material supervisor for his records, the second the purchasing department for use making replace- ment purchase requisitions and preparing shipping in- structions for the return vendor; and the third retained the inspection department. The purchasing partment makes out shipping order, and the vendor The Iron Age, October 25, SPnTe: BR — = ~ BARRELS This Copy delivered Purchasing Dept. for attaching Invoice. STUTE MOTOR CAR CO. OF AMERICA INC RECEIVING REPORT CESCRIFTION CHECKED RECORDED BY TOCK RECORD BY Fig. (at left)—Purchase Order for Production Materials Fig. (at right)—Receiving Report, Used for Every Lot Material Delivered the Plant. Six copies are made charged for the defective material debit memorandum. The record then credited the production material in- ventory account, and the purchasing department issues purchase order cover replacement the defective mate- rial, the amount stock thus being kept the predeter- mined level. Parts that have been passed the receiving inspection department again come under the jurisdiction the mate- rial supervisor, although there formal transfer. In- stead system locations used means desig- nating that quantity material has passed inspection. Material delivered the stores department more than 200 stations along the assembly line. While not have storerooms which are designated that term, have four cribs which are stored perishable material such trim, special fittings, paints, Oniy parts that are particularly subject pilfering, such clocks, speedometer heads, trouble lamps and cigar lighters, are kept under lock and key. For the storage items that the instrument boards there special combination storage and assembly room, the instruments leaving this room assembled the board, ready fitted into the body the car. this way theft these parts the majority parts the Stutz automobile are not interchangeable with those other cars, have little trouble with theft. Incidentally, this phase material con- trol common all car manufacturers that long ago was found cheaper put the bulk materials open, accessible place near the assembly line than keep them storerooms where requisitions are necessary cover withdrawals. 1012—October 25, 1928, The Iron Age Damaged, broken and scrapped parts are accounted for daily. These are passed upon the floor inspector and sent the salvage department. the part can re- paired the plant, the salvage some other department makes the repair and charges the labor the department responsible for the damage. the part cannot repaired, covered “defective material process” report, which similar form the “defective material receiving inspection—vendor responsible” report, Fig. and shown just above that report. Copies are sent the purchasing cost department and material supervisor. The report describes the part and the extent defect dam- age and names the department responsible. The face the report stamped with suitable wording cover each case, such “consigned scrap bin” for parts which are com- plete loss, “return for repairs our expense” for parts repaired outside the plant, “deliver obsolete stores” for parts which are discontinued when engineering changes are made. The purchasing department uses its copy the report make out the repair purchase order cover replacement, while the material supervisor com- pletes the material stock records and the cost department charges the department responsible with the loss, and credits the productive material inventory. Although all materials process are under the juris- diction the material supervisor, the inspection depart- ment has authority reject any piece found anywhere the plant that does not meet requirements. Such pieces, with defective material tag, are sent the salvage de- partment, which examines them determine the extent the defect, and then fills out the necessary “defective mate- rial reports.” er gor? {o - rom | | trom Zi LAC ont on == BUNDLES | = further means controlling material, one person each department designated watch the stock. may member the stock department assistant foreman. every part minimum quantity set com- ply with production schedules and when the supply approaches the minimum, report made the material supervisor. The reports, made each department, are compiled each morning into “dangerous shortage report.” This shortage list checked against unfilled purchase or- ders and steps are taken expedite deliveries place orders cover the shortage. When the material supervisor checks his records against the “dangerous shortage report” ascertains the reason for the shortage. the shortage cannot reconciled with the stock records, issues “unaccountable loss” report, “productive material loss” report, Fig. duplicate and corrects his records conform the actual count. One copy this report, which shows the quantity lost and the de- partment responsible, sent the purchasing department Part Name From P.O No. PRODUCTIVE MATERIAL LOSS REPORT ORIGINAL Dat Estmearep Total Quantity on Hand as of Inventory Total Received since Inventory Total Debit Requirements on Shippers since Inv. Scrap Losses Reported Service Withdrawals Net Pieces Account for Actual Count on Hand Today Quantity Short Cost Department is authorized to charge the value of the above shortage as an expense against Dept. No. Supervisor of Materate Supervisor of materials will report all losses of Productive Materials on this form. Duplicate will be forwarded to the Cost Dept. Form No. tes Desicnatz Reparasiz? Yes on No Crarcz Rzpams ro Cost or Rerams for “shortage purchase order” and the other forwarded the cost department for charges against the department responsible and credit inventory. How the Inventory Maintained inventory cars process and finished cars kept both the sales order department and the material supervisor. While try build the cars predetermined production schedules, reality our operations are usually governed the number bodies received. The inventory maintained the following manner. When sales order received, the order department checks over the inventory ascertain what cars are process and what are com- pleted, ready for shipment. cars are available, sales shipping order made out and copy dispatched the material supervisor. soon suitable body received, the order released for production. When bodies arrive for which there shipping order, the material super- STUTZ MOTOR CAR CO. OF AMERICA. INC. DEFECTIVE MATERIAL—RECEIVING INSPECTION VENDOR RESPONSIBLE ORIGINAL—MATERIAL CONTROL DEPT. CA Part No. ow Rec. Rerr. No Quantity Quantiry REeczrvep Reyectep Nature or Derects AND Tuts Space ror Marextat Cowrsot Diter. Dare Der. Mr. Tac No. Fig. (lower right)—The Defective Material Ven- dor Responsible Report Issued for All Parts that Fail Pass Receiving Inspection. similar report made for parts found defective production and for which the vendor responsible The report the upper left used for accounting for and replacing damaged parts for which the pro- duction departments are responsible Fig. (lower left)—Productive Material Loss Re- port Used the Material Supervisor The Iron Age, October 25, 1928—1013 — Cost Per Form 328 Part Name Description — ; visor notifies the sales order department which issues stock order. The sales order department and the material supervisor keep records the bodies received and process, the records being divided into the various body types. Data given include the paint and trim specifications for each body process, which necessary comply with our sales policy “no two cars alike,” the date that the body passed through the paint and trim department, when was mounted the chassis, when the car assembly was com- pleted, when the car passed the final test, the date ship- ment and the shipping order number. This record, which completed daily, the only inventory finished prod- ucts which carry; enables the management tell when any sales order can filled. Incidentally, for ac- counting and cost purposes, all cars are process until they leave the plant for delivery customers. Control and purchase materials for service stores and factory supplies are handled the same manner for productive materials. Service stores charged with the value all purchases for its account and credited with the cost service parts sales, while supply stores charged with the value supply purchases and credited through the medium all requisitions covering withdrawals. always necessary for service stores draw pro- duction for current productive items, such cases being ac- counted for means requisitions whereby productive material stores properly credited and service stores debited. The material supervisor keeps his material rec- ords date from these requisitions before they are passed the cost department for costing and for transfer charges. Material Records Compiled from Receiving and Other Reports The material supervisor compiles his material records from the “receiving reports” covering receipt goods, “de- fective material reports” for vendor defects and depart- mental spoilage, “unaccountable loss reports” for other losses and pilferage, and requisitions for withdrawals the Aging Cold-Drawn Metals the experimental work described Dr. Pfeil, University College, Swansea, paper read before the (British) Iron and Steel Institute the meeting Sep- tember Bilbao, Spain, the tensile test was employed measure the capacity the metal undergo age- hardening after cold-drawing, and shown that the phe- nomenon chiefly due the presence carbon. Carbon- free iron not subject aging, but iron containing little 0.0025 per cent carbon shows well-developed aging. Iron containing ferrous oxide also exhibits the phenomenon. suggested that both carbon and iron oxide are soluble small extent ferrite ordinary temperatures, but that the solubility less distorted crystals, with the result that hardening and strengthening the duralumin type occurs after cold-working. Standard Skid Platforms order further the method shipping goods ultimate destination skid platforms, the Division Simplified Practice the Bureau Standards has recom- mended that the clearance heights fixed in. and the minimum clearance between supports in. estimated that $700,000 expended annually loading and unloading goods which can shipped skid plat- 1014—October 25, 1928, The Age service department. ascertain the amount any given part hand any time figures follows: Quantity last physical inventory, plus receipts, and minus returns, the result being the net total debit; scrap, plus service with- drawals, plus requirements cars produced, gives the credit; net debit, minus total credit, gives the quantity hand. All goods entering the plant are covered receiving report, copy which matched the vendor’s invoice and forwarded the accounting department. The match- ing the receiving reports and the vendor’s invoice done the purchasing department after has checked invoices for price, terms and quantity. Every purchase order shows what account the purchase charged, this infor- mation also being written into the receiving report the receiving department, which obtains the information from its copy the purchase order. When the accounting de- partment gets the invoices with the receiving reports, analyzes the purchases cards. These tabulated data make the “contra account” for the accounts payable journal. Car Sales Analyzed Monthly Analysis productive material made and shows the part number, quantity, price each and the total amount. This information is. posted the material cost records, which are made the form ledger with separate sheets for each part shown the bill materials. Each sheet carries all the information given the bill materials for each part, such the usage per type car and the place where the part used the car. These parts vary price from 0.0001 cents for many small items, $1,800 for custom built bodies. Each month the cost department analyzes car sales, separating the cars into different groups. The material cost each group shipped compiled, using data contained the bill materials and the material cost records. The total cost computed adding the material costs the groups. Cost car sales then debited and produc- tive material inventory credited. forms, and this cost approximately one-half would saved doing. This practice facilitates handling all along the line movement from factory consumer. Goods thus prepared for shipment are loaded into cars, unloaded onto trucks, and finally moved into the customer’s stock rooms without breaking bulk, with minimum physical effort, and with great saving time. Short Drop Lessens Segregation Blast Furnace Burden study the changes taking place porosity the blast furnace burden, and that means get more light the chemical reactions iron smelting, the Minneapolis station the United States Bureau Mines has been ex- perimenting with scale models one and three feet diam- eter. Similar tests have checked quantitatively. Results date show that,. with equivalent big bell clearance ft., greater proportions ore coke are deposited around the periphery. Coke also found have smaller angle repose than ore, while larger pieces ore tend roll the center the furnace. Size segregation may re- duced depositing material the stock line rapidly possible. This may accomplished increasing the bell drop and the angle the bell, and decreasing the distance from the stock line bottom the bell. | Mass Bolts and Nuts Manufacture 3000 Standard Sizes and Types, Addi- tion Special Requirements, Calls for Varied and Ingenious Methods and Machines GEORGE RICHARDSON* ODERN demands for mass production, whenever possible and economical, have resulted the de- velopment distinctive and ingenious methods and equipment for large-scale manufacture bolts, nuts and related products the Lebanon, Pa., plant the Beth- lehem Steel Co., where 3000 sizes and types bolts and nuts are regularly made and carried stock, not including the much larger variety called for special specifications. Plant production sheets show that minimum eight and maximum distinct operations are involved completing single item, the number depending the type and degree finish called for. Each operation re- quires the use special machines various sizes, ranges and capacities. There are two standards for the manufacture nuts common use this country: The Shop Manufacturer’s Standard. Nuts con- this are those placed bolts regularly carried stock and sold off the shelf. These are sometimes known bin nuts, later name which comes from the fact that the nuts are carried stock bins. When nuts alone are ordered the United States Standard usually furnished. *Bethlehem Steel Co., Bethlehem, Pa. United States Standard. Nuts conforming this standard are slightly larger dimensions than Shop Stand- ard nuts. Ultimately, both these standards will done away with favor one sponsored the Government and various societies. fact, the movement effect this simplification making rapid headway, and shortly the Shop Manufacturers’ Standard will thing the past. Owing conditions that have met, will take longer discard the United States Standard entirely. Nuts are also made hot cold. general, all nuts in. and smaller size are made cold, while those in. and larger are made hot. The exception this the case in. United States Standard nuts, which may either hot cold. United States Standard nuts are made different styles and types follows: Hot pressed, blank and tapped. Cold punched (c. and t.), chamfered and trimmed, blank and tapped. Cold punched (c.p.c. and t.), semi-finished. Bethlehem treated nuts, United States dimensions, specially treated. Standard unit lock nut, United States dimensions, made same types above. Each Hot Nut Machine Provided with Heating Furnace The Iron Age, October 25, 1928—1015 thes addition, Bethlehem makes certain nuts, in- cluding the following: Ideal Recessed Nut. This distinctly track bolt nut and usually made special dimensions. thicker and special shape. Tail Nuts. Used chiefly heel bolts plowshares, etc. called because projecting tail which enables the farmer turn them tight hitting with stone hammer. Bolts are also made conform the two standards, although about per cent made with the United States head either square hexagon. too, movement foot eliminate the two old favor the new American standard. Both cold and hot processes are used, the size limit being practically the same for nuts. other words, bolts in. diameter in. long and smaller are made cold. The larger sizes are made hot. All types bolts are made, in- cluding square and hexagon head, car- riage, plow, etc. The problems bolt and nut manu- facturing plant are complicated the in- finite variety sizes and types. further source complication lies the big varia- tions the quantities ealled for. This con- dition has very im- portant bearing the types equipment that can advanta- geously used and di- vides the products into two more groupings. the one hand are certain products ordered used large quantities. cases this kind the manufacturer has 1016—October 25, 1928, The Iron Age opportunity utilize the very latest types automatic machines designed for large-scale mass production. the other hand, large proportion the products are either special nature, ordered quantities which not justify the expense designing and installing spe- cial machinery. this case, equipment the more ordi- nary types must used, and instead the highly ingenious automatic machines, semi-automatic and even hand-oper- ated machines are the most economical. This explains why mass production has not been much employed some departments others. Both Wrought Iron and Steel Used Wrought iron and steel are both used making the finished products. The wrought iron made direct from pig iron the puddling department the Lebanon plant. used for the manufacture boiler staybolts, engine Operated Skip Hoist Dumps the Nuts Riddler, Shown Up- per Picture, Which Jig Motion Separates the Scrap from the Nuts. Tumbling knock off scale and sharp corners the next opera- tion. Lower picture shows tumbling machines and in- spectors separating bad from good nuts | — { 4 | bolts, ete., and handled Al! steel materials are brought the form billets, coils, flats, rounds and wire from other units the Bethlehem organization. Commercial bolts, nuts and related prod- ucts are made from steel, the form which depends large extent the size the finished product. other words, for the bolts and nuts which are made hot, bar stock used, whereas the smaller sizes are made cold from coils cold-drawn sec- tions wire. Large quantities bar stock standard sections are used, and new 10-in. bar mill has recently been put into operation in- sure uniform source supply. present, more than per cent the total require- ments the plant are rolled mill. Odd lots and special sizes are rolled the older type hand mills. The 10-in. mill located separate building, together with auxiliary equipment. the looping type, assuring the latest and best practice. The general procedure this mill follows: Steel standard billets in. in. ft. long, made other Bethlehem plants and stocked special billet yard, are transferred crane and charged electric machine into the upper end gas-fired, 72-ton capacity, continuous heating furnace. The billets are grad- ually moved from the upper end the furnace the dis- charge point, and, they travel, are brought the proper rolling temperature, hr., the time depend- ing upon the size the finished bars. Small sizes takes longer roll, and more heating time required. me- chanically-operated pusher pushes the heated billets out the furnace roller conveyor and thence the first stand rolls the 16-in. continuous mill. Interposed the conveyor are shears which cut the billets into mill The rolling equipment consists six-stand 16-in. con- tinuous mill, two 14-in. pony roughing stands, two 12-in. strand rolls and two 10-in. strand rolls. Either both sets Semi-automat- Tappers, Shown Above, Are Used Tap the Larger Sizes Nuts, While Smaller Sizes Are Tapped Automatic Machines. The operations the cold nut machines (be- low) follow ilar that the hot nut department strand rolls are used, according the finished size bar. Bars Cut and Inspected for Size leaving the finishing rolls, the bars pass the hot bed and the way are cut automatic rotary flying shears into 150-ft. lengths. Squares, rounds and flats are rolled this mill, the range sizes for squares and rounds being 31/64 in. in. diameter. For flats, the size lim- its are 1/64 in. in. wide in. thick. the hot bed, the bars are inspected for size. they cool, they are moved over from one side the other arrangement rockers. There they drop conveyor, which carries them set hand-controlled shears, where they are cut into 30-ft. lengths. These are inspected, bundled and the bundles tagged with metal tags, showing the size, heat number and other information. The bundles are then transferred large storage building immediate- The Iron Age, October 25, 1928—1017 hed 4 Facing Practice with New Hand Fed Ma- chines (Above) Run the Nuts Threaded Mandrel, Thus Obtaining Accurate Face Which Sets Level. Nuts in. and smaller are tapped automatic machines (below), while sizes are taken care hand fed semi- automatic machines adjacent and kept until needed for use the factory department. Operations for Finishing the Products This brief description the rolling facilities and sources supply materials brings the operations involved the manufacture the finished product. With the ex- ception track bolts, rivets, screw spikes, and certain types bolts, all preliminary operations are performed units comprising parts the older division the plant. The most important preliminary operation that form- ing the material, i.e., bolt stock cut length and headed, blanks for nuts cut and punched, etc. All finishing opera- tions are performed the finishing department which the semi-finished products are transferred. The five departments the old division the plant which the actual working the material are: Hot nut de- partment, cold nut department, hot bolt department, cold bolt department and No. threading department. Hot Nut Shop Makes 150,000 Lb. Per Day already mentioned, all nuts from in. upward are made hot. addition, United States nuts the size may made hot. 1018—October 25, 1928, The Iron Age The hot nut shop equipped with both hand fed and automatic machines, and has capacity 150,000 nuts per 10-hr. day. Square hexagon nuts, in. in., can made the hand fed machines. The size range the automatic machines not great, extending only in. square hexagon, either standard. Sizes larger than in. are made either forging machines, or, the modern practice limited extent, from bars lathe. Each hot nut machine provided with heating furnace. Pulverized coal, reduced proper fine- ness central plant, used fuel, and gives very satisfactory results, because close control the feed readily obtained. overhead screw feed brings the coal hoppers located over each furnace and from here fed with the aid two screws and air blast. one two cases the coal sucked out the hopper vacuum. making nuts, flat bar stock used, the length run- ning from ft. the case hand fed center feed type machine. give some idea the size bars re- two typical examples are mentioned below: For bolts in. diameter, the United States size the nuts will 11/16 in. in. 5/16 in. thick, calling for flat 21/32 in. 25/64 in. Normally, bin nuts Manufac- turers’ Standard would supplied bolts this size, and that case the dimensions would somewhat smaller. For 3%-in. diameter bolt, United States nut would always furnished, the dimensions being in. 3/32 in. thick, for which flat in. 15/16 in. the proper size. These examples represent the standard practice for square and hexagon nuts. Bars the proper size are placed the heating fur- nace and about three feet one end brought forging temperature. After this amount worked the bar replaced the furnace and another section heated. result this practice, customary start charging one side the furnace and continue until there full charge, bars, across the entire front. When the first bar has come temperature removed and the practice from then across”; other words, . soon one bar has been cut the end goes back its same position the furnace for reheating. this way the nut maker goes back and forth until time start all over again with new charge. Making Rough Blank Requires Four Operations Four operations are required the machine form rough blank, these being sequence follows: the proper length cut off and shoved the die. The die stationary and fastened the die block. The moving parts are the punch, piercer and crowner. The piece pierced and crowned. The crowner comes forward still further and ejects the nut. “picker” comes down, knocks the blank nut off the crowner, and flight conveyor, which carries container holding about 3000 lb. When full, the container transferred electric truck temporary storage and weighed. the majority machines, the scrap the shape trimmings and punchings goes into the containers with the blanks and separated later described below. few the machines, however, used for square nuts only, from in. in., separate the scrap the machine and not only eliminate the necessity riddling but finish the blanks such manner that burring not required. Storage battery trucks carry the containers tempo- rary storage electrically operated skip hoist, into which the contents are dumped, lifted, and poured down the screen the riddler. This machine the jig type, the screen being rapidly moved back and forth. The scrap drops through the screen into small car and ulti- mately disposed for remelting purposes. The blank nuts slide down into another container and are ready for the next operation, known “burring.” The burr formed the point punching must re- moved machine. Semi-automatic, two-spindle burring machines, which burr two nuts one time, are used. The blank nuts are set hand dies jigs, mounted flat revolving turret. this turret rotates, stops points located that two blanks come under the two spin- dles, each provided with three high-speed steel cutters. These descend and cut the burr off. the same time, the two nuts burred the previous operation are brought over openings through which punches push them that they drop into container. The two operations trimming off the burr and pushing the nuts out the dies are performed simultaneously, while fresh supply nuts being placed the empty jigs; hence, there very little wasted time. The consideration safety has not been overlooked and treadle release brings the machine stop case necessity. Scale Knocked Off Tumbling Tumbling knock off scale and sharp corners the next operation. The nuts are carried the tumblers, long motor-driven cylinders, containers holding about 1400 Ib. All nuts, with the Exception Track Bolt Nuts, Are Cleaned Hot Chemical Solution Which Cuts the Oil. The upper pic- ture shows the “washing” ma- chine. ma- chine for cas- tellating nuts (below) con- sists re- volving drum containing four grooves which jigs chucks are mounted The Iron Age, October 25, = < eat? + each. After tumbling, the nuts pass directly out the far end sorting table, where there thorough inspec- tion and sorting. There has already been partial inspec- tion the burring machines, where operators throw out any half nuts. Inspectors spread out the nuts, turn them over and eliminate those with cracks, poorly formed blanks, and any other imperfections. These men become very expert. The nuts are again dumped into containers and trans- ferred the loading station, thence turn they are de- livered the finishing department. few automatic hot nut machines are use, and for these 30-ft. bars are furnished. The latter are transferred from the storage building racks, the sides which drop, forming table for the approach the bars the oil-fired furnaces. The bars are fed into the furnaces hand and pushed out into the pinch rolls the hot-nut machines. With the exception the automatic features, the oper- ation these machines similar that the hand fed machines. There one slight change practice. the case the hand fed machines, the bars are rotated each cutting-off position offset the bending action the die. This rotation not necessary the automatic ma- chines, because their greater bearing surface offsets the bending action. few production figures help visualize the amount work that can done. One hundred 1-in. hexagon nuts weigh 56.14 About 6000 Ib. these can made day’s run hand fed machine and the capacity in- creased about 8000 Ib. the case square nuts. The scrap loss necessarily quite large, includes the punchings well the portions trimmed off. For hex- agon nuts, the average amount material scrapped per cent. This lowered about per cent the case square nuts. Operations the Cold Nut Department The number operations producing blanks the cold nut department considerably reduced rea- son the fact that when they leave the machine they are ready for transfer direct the finishing department with- out riddling, burring, etc. The stock comes coils usual weights 200, 250 275 Ib. Bin nuts from 3/16 in. and including in. square and all United States sizes, including 9/16 in. hexagon and square, can made these machines, which produce from nuts per min. per machine, according the size. The operations the cold nut machines follow se- quence similar that the hot machines. The stock en- tering the machine cut off, formed with forming punch and punched, after which the blanks the finishing dies. Tumbling, sorting and inspecting follow and the nuts are then ready for transfer the finishing department. The finishing department, where all the various finishing operations bolts and nuts are performed, interest- ing section the Lebanon plant. Here, addition the more commonplace types machines, are automatic ma- chines designed for mass production large scale. This department housed half large steel and brick building, which about 375 ft. wide 1150 ft. long. The other half used warehouse. The exact point which material enters the finishing departments depends upon the amount and kind finish- ing specified. Nuts classified “rough” direct the tapping department, tapping being the only operation be- fore inspection and washing. Semi-finished, the other hand, require number additional operations and enter the west end the building. nuts are chamfered and trimmed and faced the bottom. Finished nuts are.made from cold-drawn steel automatic lathe. The general order work the case semi-finished nuts runs somewhat follows: Flatten, chamfer, trim, 1020—October 25, 1928, The Iron Age tap, face, castellate required, wash and inspect. semi-finished and finished nuts may castellated.) The various operations and machines are grouped bays, which there are three. All nuts are finished the north bay; large bolts the middle bay, and all in. and smaller bolts are handled the south bay. The more important operations their logical sequence without regard individual specifications are follows: Flattening.—Although commonly used term, “press- really better describes this first operation, which for the purpose obtaining more uniform thickness and making the nuts more level. preliminary operation for chamfering and done semi-automatic, hand fed presses. Chamfering.—Chamfering the operation beveling the corners the nuts. Equipment the general descrip- tion mentioned above used, modifications being made ac- cording the nature the work involved. Trimming.—The number operations pends on: (a) The size the nut; 1%-in. nuts are trimmed five times; %-in. are trimmed three times; (b) the quality the stock and the tolerance allowed for irregularities. Inspection.—A thorough inspection made here for both surface and general imperfections. This only one numerous inspections. There inspection each individual operation. Tapping.—One the most interesting parts the nut section the finishing department the division where tapping done. Nuts in. and smaller are tapped auto- matic machines, while the larger sizes are taken care hand fed semi-automatic machines. The semi-auto- matic tapping machines, depending upon the individual de- sign, are fed hand, either directly the tap, into slot leading the tap. The taps are automatically raised and lowered and they come down tap the nuts which have been pushed into position. These nuts remain the taps until the taps are filled. The taps, which fill rota- tion, are lifted out, one time, while the machine oper- ating and the nuts are stripped off hand. The taps are then reset the machines. One group automatic machines used for the smaller nuts; these machines are capable tapping from 1,000,000 1,500,000 per day. Operations are follows: The nuts tapped are delivered containers holding from 1000 2000 each. These are dumped crane into stock bins the top the machine. The nuts feed down from these bins gravity into open hopper. circular disk, the periphery which are small lugs, ro- tates the hopper. The lugs lift pick the nuts and push them into narrow chute track, down which they slide, one time, pusher finger which, moving and out, pushes the nuts the tap. The tap used bent, and thus differs from the ordinary. mounted revolving head and rotates with the head. The nuts, either square hexagon, instead being re- moved after tapping from the tap end, pass off over the shank and drop down into the inspection pan. Inspectors watch for imperfect tapping. When there evidence this, the machine stopped and steps taken correct the cause the trouble. Small pans are used that defect develops only few nuts instead sev- eral thousand need sorted. With machines this character nuts and 5¢-in. nuts are tapped per min. The greater tapping speed the larger nut due its coarser thread. some cases, nuts, aftur tapping, direct nearby sorting benches, where they are inspected and sorted. Other operations may follow, first, however, indicated below: Facing.—Facing, when required, done special ma- (Both chines. the facing operation, the cutter puts washer effect. The older practice facing was simply run the cutter over them, with the result that | | wii good bearing surface was seldom obtained. Facing prac- tice with new hand fed machines run the nuts threaded mandrel, accurate face which sets level. Nuts from in. in. can handled these machines and the facing made accuracy 0.002 in. specifications. The new machines used are comparatively simple but effective their operation. rotating drum contains four grooves which jigs chucks the size and shape necessary are mounted. The nuts are placed these and the drum rotates pass under milling cutters located the top the machine, which cut one slot time. the drum continues rotate, the nuts drop out and are set position again for the cutting the second groove. Any nut from in. may handled this equipment. Washing.—All nuts, with the exception track bolt nuts, are cleaned hot chemical solution which cuts the oil. very slight film oil remains protect the nuts against rust. Nuts washed are dumped into the hop- per the washing machine, and from there drop into drum which holds the cleaning solution. This equipped with steam pipes for keeping the proper temperature. The nuts are agitated the solution and pass ro- tating screen which allows the surplus liquid drain off. short belt conveyor which they dry their own heat carries them container. Belt washing, all cold-punched nuts are sorted, receiving 100 per cent inspection. This so- called “belt inspection” something that the plant people consider especially worth while, and very thorough job. The nuts travel belts passing before number inspectors. After inspection the nuts containers the warehouse. Special nuts direct packing and shipping floors. The procedure described covers the operations involved finishing the different kinds the regular sizes nuts. Large nuts, particularly special ones, are finished the machine shop. division the finishing department given over facilities for doing special cold forming jobs. in- clude punching machines, presses, shears, etc. (In subsequent article, the finishing bolts will described.) Advocates Arc Welded Steel Construction welding for steel construction was discussed the meeting the American Gear Manufacturers Asso- ciation, Buffalo, Oct. 11, and 13, Lincoln, vice- president and general manager Lincoln Electric Co., Cleve- land. What had say was part follows: “Structural steel,” said Mr. Lincoln, “has strength approximately 60,000 lb. per sq. in.; the strength cast iron but little more than one-fifth this. Structural steel has modulus elasticity 30,- 000,000; cast iron modulus elasticity 12,000,000. general, factor safety twice great used for cast iron for steel. “The price per pound structural steel more than one-third that iron castings. Translating this, structure made the efficiency which depends upon tensile strength, the material cost, made from structural steel, will greater than what would made from cast iron. the factor safety were taken into consideration, the ratio instead being its success its stiffness, bases, bridges, etc., the ratio would without the factor safety, and “It evident, therefore, that the ratio between the material cost the same structure, when made from structural steel cast iron, great enough permit great deal welding done the steel structure and still make very considerable saving over cast structure.” Motors, arc welding machinery and other products the company which welded steel parts are used place castings, were shown lantern slides. Redesign many these parts permit the use welded steel, was begun several years ago, and was stated that, general, there has been reduction least per cent the cost the structures. Mental inertia, fear change appearance and the lack information committees and technical bodies were discussed connection with the failure use the welding process possible applications. Sees Wide Use Welded Steel Next Years Within the next years, per cent the castings being made today will replaced welded steel parts, said Mr. Lincoln. “The profound result this industry can well imagined,” said. “Inventories castings will re- placed with inventories structural steel taking about one-fourth the space and one-tenth the cost. Pattern storage and pattern development, which heretofore has been very large item manufacturing cost, will eliminated. Breakage and scrap, heretofore appreciable item, will done away with because any part which wrongly machined will welded Steel does not break handling does cast iron. Hence another great waste will eliminated. “Changes design which heretofore have been difficult will greatly simplified, and instead the same model being manufactured without change over long period time, changes will made continually because the ease, and because the entire elimination pattern equipment. Deliveries special machines will greatly shortened and the weight all machinery will materially decreased. “This change not going revolution, will evolution. does not mean that your present erganiza- tion must replaced; does mean that your designers and your plant officials must become welding-minded that they will see structure not accumulation castings and rivets, but structure built-up joined pieces steel, making much better structure much lower cost.” Use welded steel the manufacture shears, punches, iron workers, fans and bases, was outlined Booth, the Buffalo Forge Co. Gears welded steel plate have been made experimentally. Those made far have been noisy, but they are being redesigned and expected that the noise will eliminated. Rockwell Hardness Tester Compared with Others British comments the value the Rockwell hard- ness testing apparatus were presented before the (British) Institute Metals its autumn meeting Liverpool, England, Sept. and paper, “The Rockwell Hard- ness Test,” Malam, Birmingham, England, the author described work carried out furnish data for con- version between (1) Rockwell and Brinell and (2) Rockwell and scleroscope numbers for 95:5, and 70:30 copper and 63:37 copper-zine and 80:20 alloys. examination these data led the conclusion that the Rockwell ball test its present form yields so-called “hardness numbers” which must considéred quanti- tatively misleading. Similarly was found unscientific results are obtained owing the arbitrary numbering the scleroscope scale. was suggested that tive committee set order consider the subject hardness testing. The Iron Age, October 25, ¥ 4 \ + Selling Maintain Prosperity Margin Control Distribution Costs Requires Better Understanding Among Competitors Curb Professional Buying CONGER* any study sales application, Control Selling Costs should divided into four divisions: first, creation demand; second, establishment outlets; third, influencing markets, and fourth, maintenance sales spirit. Direct returns are possible from capital ex- pended within the second division, while returns for capital invested bring about results within the first and last two divisions are more indirect. Creation Demand Advertising and contact promotional repre- sentatives are the prime means creating demand. Both efforts should used connection with specialty products. For commodity products, constructive advertising alone proves sufficient. Advertising selling mass basis. Its aim the education every possible prospect the product and creating him the desire for it. Mass selling more economically done advertising than salesmen. There it, however, more fertile field for the waste hard earned margins than the blanket acceptance ad- Branch Manager Responsible RANCH representation and distribution through deal- ers are the two main methods establishing outlets. Expenses branch offices are controlled best taki