The Iron Age 1929-10-17: Vol 124 Iss 16

ESTABLISHED 1855 © ITH the is coming the development of terminal facilities rapid at airports and convenience for passenger traffic. It was not long ago that airports with few exceptions were little more than landing fields. It is only two years ago that a wait- ing room and ticket office for airplane pas- which said to be the first to be built in this coun- try, was erected at the Ford Air- port at Dear- born, Mich. Since then, airport building has been going on at a rapid rate and the number of airports in this country is now said to 1500, but sion for adequate sengers, was exceed provi- passenger term- inals is still in its infancy. The tremend- ous increase in the building of commercial air- planes, the large amount of new capital that has been put in this industry during the past year and New York, October 17, 1929 Terminals, Similar to Those Operated by Railroads, Will Provide for Comfort, Safety and Convenience of Air Travelers increase in air transportation that will provide safety, comfort airplane transportation from coast COMBINATION Aijir-Rail-Water Passenger Terminal, as Conceived i by the Austin Co., Cleveland, for Handling Airplane, Rail, Steamboat and Amphibian Plane Traffic VOL. 124, No. 16 the recent tying up of rail and air transportation by some of the larger railroads by providing part rail and part to coast are indi that the carrying of pas cations senger traffic by airplanes is get- ting well beyond its experimental that the general pub stages and lic is learning to accept the air plane as a con venient and safe method of tran Air . how n portation. travel has remarkable growth in this country in the past two or three years, which doubtless is tially due to the building of larger par- and safer planes and the provision of comforts for passengers. The country is now overlaid with a network of air lines from coast to coast. While there have been devel opments in the construction of airports, so far they to do with ments growing out of the opera and main have had largely req ulre tion tenance of. air { KY irport Passenger Depots Planned 7 e necessities of nipani perating planes engineers who have long been engaged in bullding ain These includ ore convenient as well larger hangat ports and hangars, will follow closely the methods of i mmodate the larger planes now being built, repair modern railroad terminals in handling traffic. Passengers shops, rooms for the weather bureau and radio operating will go through the depot to concourses that will tak: vetter lighting facilities. Hangars have been them to waiting planes, which they will enter without ign and in architectural appearance. How leaving cover. Such a depot will consist of artistically tle attention has been given to providing for th designed two-story building units connected by steel ' fet) ( nvenience of air travelers with bridges which will serve as concourses, the buildings late passenger terminals While a few principal themselves serving as piers for the spans of covered ! i passenger depots and comfortable waiting concourse bridges. The space beneath the spans and be- tf ting urports tween the piers will form covered loading areas for thx SECOND FLOOR PLAN ; Pd # S > . aS ' Qe aE ‘O88 - G8 ans 438-943-995. 998- Ser ae a3 197-935-833 -45 LONGITUDINAL SECTION Design _ Depots WX Have Covered Loading Areas Where Passengers Can Board Planes Conveniently in Bad Weather | | | Ample space is provid viewed by the Austin Co. is shown in the accompanying layout g passengers and the covered areas where planes will be loaded thing more than open fields. The lack of terminal planes. When a passenger arrives at the depot, he wil for air travelers, it is pointed out, in sharp enter the waiting room under a marquee at the entrance, ! h t safety features and provision for com- purchase his ticket and go to the passenger concourss the newer types of passenger planes on the mezzanine floor. When the plane is announced, Engineers Planning Passenger Terminals petent ilrport engineer! have piaved an m- int part in the development of airports as they exist re now being consulted to provide more ade t rer terminal fac ities, which. it 1s believed, n a marked increase in airplar passenger Wt TeW a rport depots nave convenient ! few if any have a system of traffic cor ir to that at a large railroad terminal. Pas- n good weather and bad still embark and alight ! tne alr} t neid, vhich not nfrequently s muddy, face the | rd of whirring airplar propellers. Che alr depot of the tuture, as nee qa DY some 1024—The lTron Age. October 17. 1929 he will descend a stairway built in one of the piers and walk across a portable railed-in passageway similar a ship’s gangplank and through the open door of the plane directly to his seat. A variation from this plan to have a passageway in the form of subways unde rround instead of building overhead bridges. In addition to having a waiting room, the main bull ing will have rooms for ticket and other offices, baggag room, restaurant and rooms for various other purposes The small pier buildings will provide room for rad eq lupment light control, dormitories for field pilots an ooms for other uses. This general plan, of course, ibject to various modifications in detail. recently An airplane hangar designed and built uJ a a) iON AW TERMINAL | tia Entrance, as Well as Other Parts of the Air Terminal, Will Closely Resemble That of a Railroad Depot Burts —=—— = > 2 -_— I Sine ole f 4/RPORT anaG covereD \! area ff c —_—_—_— Tr Mes ha eee { ened nD oa MEZZANINE FLOOR PLAN “jy I i 2 a mT ‘ rE i COVERED , AREA bee GE . AN TILEVER Type of Roof Truss Is Used in Cleveland Airport Hangar of Na- tional Air Trans- port, Inc. Because > of the almost com- plete absence of ' t columns, this han- H gar provides large : le ar spans and wide door openings The Iron Age. October 17, 1929—1025 various locations, has a he Austin Co., cantilever type of roof truss. Cleveland, at Because of the almost type provides large Roof trusses are -omplete absence of columns, this i@ar spans and wide door openings. carrie on the structural steel frame which supports the entire load Hangars with this roof design can be unlimited width. with door openings of The hor ntal top and bottom chords for the carrying isses are Dullt H-sections, angles or channels, de- pending on the span, and consequently the stress. They re placed on 30 to 40-ft. centers. The web members al ( f angles, H-sections or channels. Cantilever isses, the outer ends of which are unsupported, are iced at right angles to the carrying trusses They ire fabricated of angles and are placed on 20-ft. centers. The roof purlins span the cantilever trusses and are ( n 8-ft. centers. They are made of 6x12 in. yellow yn which is laid a 2-in. wood deck. In case a steel ate deck is desired, steel channels are used for purlins. In designing this type of hangar, the Austin Co. has ’ ts standard building design to the construction nangars Side " S ré rick ely the Ss né Above tne ntin ! f steel sash extending If any por- up to the roof trusses are usually provided. tion of the hangar is partitioned for small partition walls may be of metal or brick. rooms, the Various Types of Hangar Doors Used Various types of hangar doors are in use. There are different kinds of built in usually with glass in the upper part, steel rolling doors and a cantilever type of door which is a recent develop ment. This type is opened by raising it outward from the bottom and when open provides a canopy sheltering the entrance to the hangar. It is built in sections that are motor-operated independently or together. steel sliding doors sections One, any all the door sections can be operated in approximately one minute. This door is built of tural steel and plates and has large panels of steel sash. The airport depot of the future, if some of the present number of or struc- elaborate plans materialize, will result in considerable increased demand for steel in this field. A passenger terminal of the proposed type, with structural steel require up to 1000 tons or more of steel, depending on the size, and additional steel needed for and various mechanical equipment. bridges for concourses, will will be ornamental stairways, passageways Effect of Scrap on Operating Costs of Open-Hearth Steel XTENSIVE experiments have been made in Germany, | n an actual operating scale, for studying the effect ] prades f scrap it operating costs er th furnac s charged with a grade of I the manganese consumption, hot-metal addi- I ! needed, time of melt, etc., are noted. On the f xed price for pig iron, the prices of the scrap en adjusted to yield a constant operating cost per steel madi Because open-hearth costs depend, t ( nt, on the quality of the scrap, the Association German Iror sters ma the instigation with the ratio sever German plants. The results i reported DY the London I and Coal Trad } e as _ Ir e experiments mac Ernst Kerl at the Ver nig Stahlwerke at Hontroy n x 120-ton tilting I I ving grades of scrap were used Th result he experiments, consisting of eight n the iS¢ scra (1), (2), (3) and (6), and he case of (4) and (5), are shown in Table Table I. _ : 1026—The Iron Age. October 17, 1929 I. The two furnaces were fired with a mixture of coke- oven gas and blast-furnace gas. On the basis of the data, the value of the different grades of scrap was determined, and the prices then fixed The results of such seen in Table II (applied to German Clean unrusted turnings, at a price of 54 marks a metric ton at a pig iron price of 65 m. per ton, are used as the basis for this calculation. With per ton, the cost of the clean to yield a constant operating cost. an evaluation are to be practice). steel a pig iron price of 74 m. scrap was not to exceed 51 m., and with pig iron at 90 m. per ton, the clean scrap had to be as low as 46 m. Table I].—Price of Scrap, Marks per Ton Per Tor 65 M 74 Mks 90 MI ] 1 48 44 ) ) i9 49° 0 ov oe ' } t ( 51.50 44.51 1) Block scrap 8 5¢ 6.00 52.00 The pig iron was, whenever possible, charged into the state, and was of the Mn, 3.77; The scrap was nearly throughout mild about 0.08 per cent carbon, and 0.40 per cent manganese, except the furnace in a molten 1.42: and Cu, 0.15 per cent. open-hearth Si, VU.ol; following average analysis: C P, 0.138; S, 0.03: ’ steel carrying turnings which had a carbon content of 0.25 per cent and 0.68 per cent Mn. Effect of Various Grades of Scrap on Open-Hearth Results i) . > (3) (4) ( ) ct 4 665.68 > 2¢ 74.4( 77.04 70.68 8.701 133.47 6.731 125.527 t ts4 s s/4 ‘ 190 { Llobo9.4 S.¢ 128.67 1¢ ) 177.44 640 } 4% OF $8.2) 14.89 22 0 64 50.4 14.04 t ” 2.4 fe 10.54 ) j ‘ 9502.18 j ] 2469.49 2339.21 0 9 10 4 a 4 4127 ERR 4RR 20) bS 17 054 611 $50 - 10.94 87.87 89.79 RR O77 93.0 a4 6.38 9.64 7.37 9.2¢ 4.54 v l ) 333.0 361.9 $11.4 319.4 5 } 69 74.1 87.2 33.0 t 6_¢ Ff ¢ 26.6 36.6 36.6 I Norma Badly damag Normal Cold-Heading and Thread Rolling Characteristics of Steei Wire Best Suited to These Methods in Making Bolts, Screws and Rivets BY FRED ROWTH of the “cold process” as a means of manu- ( facturing bolts, screws, rivets and other headed : and threaded parts has been due as much to metal lurgical research in steel makimg as to the development of automatic high-speed machinery. It is fully appr ciated by many manufacturers that the process is faste1 than any other method for making bolts, screws and rivets of ordinary commercial sizes, and it t cases superior. Such skepticism as once existed regarding the pra ticability of producing high-quality threaded work, fo1 example, by rolling is now largely dispelled. In fact, thread rolling is generally conceded to be unsurpassed for pr ducing screws of accurate thread form and lead At least one reputable manufacturer employs the process for making the calipering screws of micrometers, which in itself is ample proof of the merits of the process. It is true, however, that difficulty is liable to be ex- perienced in producing both cold-headed blanks and rolled threads, if the physical qualities of the wire best suited for cold forging are not taken into account. It is the purpose of this article to deal briefly with this important subject. Ordinary basic open-hearth steel of low carbon con tent is best adapted for cold heading, because it an b¢ worked extensively without “crystallizing.” Basic Besse- mer steel is suitable also, although it has a comparatively short fibrous structure, which makes it more difficult to head, but easier to drill. Bessemer steel is, therefore, best for hollow rivets. The wire is made from hot-rolled bar stock and cold drawn through dies which finish it to within plus o1 minus 0.002 in. of the desired size. It is furnished in coils up to 200 lb. in weight and should be wrapped in paper, or burlap with a tar paper covering, to prevent oxida- tion and corrosion, and should be stored in a dry place. Importance of Adequate Drawing ' especially Drawing the wire is of utmost importance, : when producing wire that is to be threaded. The hot- rolled stock has an open, fibrous structure which is not suitable for thread rolling and which is liable to cause split threads and rough, irregular edges, particularly when rolling sharp V-threads. If these conditions appear in thread rolling, it quite evident that the wire was not drawn enough; that is, the hot-rolled bar from which the wire was drawn , was too near the wire diameter, to start with. Drawing closes the open, fibrous structure of the rod, thereby re fining the metal. When properly drawn and thoroug! annealed this wire is best suited for thread rolling ‘ Wire Finish for Bolts, Screws and Rivets + The finish of the wire is also important. Bright fin- <A ished wire, which is the product resulting from drawing lime-coated stock that has not been subjected to a *Waterbury, Conr DANIELS ( a ll ‘ ! aching m VO! ind enerally Ss not anneaied I ch wort ‘ Triage S ng irge-« meter nin head il quare corners ups inderneath the head, the wire mu e thor ighly innealed after drawing and eanec | he wire is 1 ead soft these ne ‘ no n heading Liquor-finishe wire é ‘ i pu rk high-quality finist ha ip serew nachine crew ind rivet blank nedium and short length reneral ade I d die heade1 The finish f th wire he noothest obtainabl The liquor 1 copper hate wash which deposit i vating similar to pe harder than copper-coated stock. The mating fills in all seams and pores on the surface of the wire, with the result that the heading dies wear Ie and last a great deal longer Copper-finished wire, also, is used for cold heading ilthough not so extensively as the liquor finish lhe ating is a wash of copper and tin solution Temper a Heavy Factor rempe} hardness of the wire for heading and reaaing equal importance The te mper depends or the number of drafts, or reductions in diameter in draw ng the wire, and it is often right here that the funda mental cause of troubles experienced in cold heading ma It is common practice, when ordering wire for heading, specify not only the analysis of the steel and the finish but also the temper or degree of hardnes Failure to take the various factors mentioned into account when yrdering will result often in difficulties that could be prevented Heat Treatment of Blanks Cold-headed blanks are usually annealed to remove the heading strains Work having heads of unusual ize or shape is annealed before the heads are completed 1 ind then finished in a reheader However, the quantity if reheading work is comparatively small, it being pos ible in most cases to upset practically any head in two or three-blow header. \ heat treatment is recommended, especially for car riage bolts and work having special heads, and consist f thoroughly heating and quenching the blanks in oil procedure depends on the composition of the teel and is defined by the manufacturer. Heat treating necreases the tensile strength of the bolts and refines the tructurs f the metal Quenching in water after heat ng 1 another means of toughening the blanks. Machine bolts of ordinary proportions are not always heat treated after heading, because the heading strains carriage bolt heads, which are shallow and brought down to a thin edge are not Oo severe as tnose Low-carbon steel analyses suitable for small screws, such as used in electrical work and ordinary fixtures, for The Iron Age, October 17, 1929—1027 machine and carriage bolts, follow: Carbon 6.08 to 0.12 per cent Manganese 0.35 to 0.45 per cent Sulphur 0.03 to 0.04 per cent Phosphorus 0.03 to 0.04 per cent Silicon 0.10 per cent For hex-head cap screws used in the automotive in- dustry the steel known as Type G wire is used extensively. A steel of higher carbon content, known as Type E wire, is used also for automobile screws. Their chemical analyses are: Twpe G Type E Carbon 0.08 to 0.15 per cent 0.27 to 0.37 per cent Manganese 0.30 to 0.45 per cent 0.70 to 0.90 per cent Sulphur 0.05 per cent (maximum) 0.05 per cent (maximum) Phosphorus 6.03 per cent (maximum) 0.05 per cent (maximum) Silicon 0.07 to 0.15 per cent 0.07 to 0.15 per cent agricultural machinery bolts (not heat treated) and for Other steels suitable for cold-heading are those in the S.A.E. standard specifications, No. 1010 to 1035 inclusive. In the alloy steel field are numereus analyses suitable for cold-heading and threading. It is difficult, however, to head a nickel steel containing over 3 per cent nickel and over 0.20 per cent carbon. All alloy steels should be heat treated after cold-heading. Following are’ two steels that can be recommended for average heading operations: Carbon 0.30 to 0.40 per cent Manganese 0.50 to 0.70 per cent Phosphorus 0.04 per cent (maximum) 0.10 to 0.14 per cent 0.28 to 0.38 per cent 0.04 per cent (maximum) Sulphur 0.04 per cent (maximum) 0.04 per cent (maximum) Silicon 0.10 to 0.25 per cent 0.10 to 0.15 per cent Nickel NE ee ere eer Chromium 0.50 per cent 0.25 to 0.30 per cént WG ce cieceveten 0.13 to 0.26 per cent Preparing Steels for Forgings Overcoming the Effect of Overheating—Service Not Affected by HREE papers of special interest to forgers were presented at one of the sessions during the National Metal Congress in Cleveland, Sept. 9 to 13. Two of them discussed the protection of furnace walls and the over- heating of steels, while the third considered the matter of fiber and dendritic structure. Albany Slip—A Refractory Glaze for Furnaces William J. Merten, metallurgical engineer, Westing- house Electric & Mfg. Co., East Pittsburgh, finds that the so-called Albany slip (a refractory glaze used in the high- voltage porcelain industry) is an excellent protector of furnace fire brick. The finely ground powder suspended in water is sprayed thoroughly over the cold brick and left to dry. Then the heat is put on and raised grad- ually to 2000 deg. Fahr., when a glaze forms into a con- tinuous protective sheet. This converts the chamber into a heat-reflecting and radiating body of high efficiency, reducing heat losses and the time required to raise the steel to temperature. Cooling causes the glaze to develop small craters but these heal on subsequent heating. Re- glazing is necessary at intervals. Fred G. Frisbie, Duquesne Steel Foundries, Pittsburgh, said he had used the glaze at a temperature of 1700 deg. Fahr., on annealing furnaces for steel castings, and found it to be a good heat reflector and to promote equality of temperature between furnace walls and contents even though the glaze had not been fritted by a preliminary high heat. However, he could not agree with Mr. Merten that the same glaze would protect steel from oxidation in a sharp furnace atmosphere, even if the metal had been dusted with soapstone previous to dipping into the Albany slip. Effect of Overheating Steel for Forging Two papers on the burning and overheating of steel had already been published by W. E. Jominy, University of Michigan, Ann Arbor, Mich., resulting from investiga- tions financed by the American Gas Association. A final summary was presented under the title “Overheating of Steel for Forging.” Temperatures at which steels show evidence of incipient fusion, that is, the burning tempera- tures, were determined by microscopic studies. The ques- tion then arose whether the coarse crystallization, caused by reheatings below the burning heat, would cause dam- age to forgings, or induced any effect which could not be removed by subsequent heat treatment. Mr. Jominy 1028—The Iron Age, October 17, 1929 Dendritic Structure—Protective Glaze for Furnace Walls therefore raised the common carbon and nickel forging steels to various temperatures in a range just below burn- ing, heat treated them (quench, draw, and normalize) and then tested them in tension, performed the McQuaid-Ehn test for carburizing, and examined the microstructure. In general he found no reduction in ductility or other prop- erties when the steels were heated no higher than the fol- lowing temperatures, which he fixed as the maximum safe temperature for heating prior to forging: Deg. Fahr. . As Ti RE re es ee re ene ON owed 2650 ee ee a ere eee eee 2600 ee el ee er ee 2525 ee ae ee NR ee ee 2375 Bk ee PR in ons ss kn do oe che 2450 O. W. Ellis, Mellon Institute, Pittsburgh, pointed out that Mr. Jominy’s determinations of the burning tempera- tures gave figures considerably higher that the solidus line in the iron-carbon equilibrium diagram as at pres- ent accepted, and indicated that some revision would be necessary. The new figures do check those of Carpenter and Keeling who published the earliest precise diagram showing the melting points of steels. Problem of Dendritic Steel Discussed An interesting treatment of the question of “Dendritic Steel” was given by H. G. Keshian, metallurgist, Chase Companies, Waterbury, Conn., since he gave evidence re- garding the physical properties of steels of comparable analysis, some of which were dendritic and others which did not have this structure—at least to an evident de- gree. In the forged and heat-treated condition, no ma- terial difference can be detected in the tensile properties so the author concludes that the microstructure and not the macrostructure is the dominant factor. In fatigue, as denoted by the Stanton repeated impact test, a dendritic one per cent carbon steel had a slightly lower value. Di- rectional properties (specifically, reduction in area) were less favorable in a dendritic chromium-nickel steel but in wearing properties, when made into drawing dies, no difference could be detected. A free discussion followed this paper by Mr. Keshian, but it all had to do with the cause and production of dendritic steels, and did not contest his main conclusion that satisfactory service in a sound steel is not related to its possession of visible dendritic structure or lack of it. bie: eee Production Control in Steel Foundry Sivyer Shop Uses Checks, Frequent Inspections and Daily “Pow-wow” to Meet Specifications and Scheduled Delivery Dates BY ROGERS A. FISKE* rigid inspections at frequent intervals and estab- lishment of channels of informed intelligence are the main factors which have enabled the Sivyer Steel Cast- ing Co., Milwaukee, to keep close control of orders and materials in process, and to forward an unusually high percentage of orders on dates scheduled. This is a jobbing foundry and imposed upon it are the common limitations in the standardization of materials and operations. Special attention, therefore, has been A CCURATE checks on materials and plant methods, *Western editor, THE IRON AGE, Chicago. pyres Tea ed eae a 9 Pei m CC se ie ee dae Pee VERY Afternoon Shop Execu- tives (Right) Study Patterns Which Are to Go Into the Shop. Rec- ords of past difficulties are analyzed, also * + & W ORK Order Cards Are Filed on the Schedule Board (Above) in Accordance with Dates Which Have Been Established by the Foremen given to the control of variables from the standpoint of fundamentals of steel casting production and quality. Con-. trol of the variables which affect quality begin at an early stage of the process, even before a charge of scrap is loaded into the furnace. Incoming scrap and other materials are inspected before being unloaded from the car. A 1000-lb. test heat, which is carefully observed by the melter, is made from each car of scrap before the car is unloaded. An analysis is made of a test piece taken from the furnace as soon as the metal has melted down. This analysis is taken not only to decide acceptance or rejection of the carload, but as a means of placing the scrap in its The Iron Age, October 17, 1929—1029 proper bin, since incoming scrap is segregated according to carbon or sulphur and phosphorus content. Each heat of steel is analyzed for the required elements, immediately after tapping from the furnace, and its anal- ysis is reported to the melter before the next heat is tapped. This practice promotes better analysis control, by giving the melter the analysis of one heat before he taps the next. It also enables the operating department to hold out castings the analysis of which does not conform to required specifications. This latter practice is of mate- rial aid to the production department, for new molds may be made up, without much time lost, to replace castings which do not meet analysis requirements. Melters are paid a bonus to stimulate interest in anal- ysis control. This bonus is based upon a score which is obtained by dividing the total number of points outside the desired analysis range by the total number of heats. As CARBON 0.28 0.22 MANGANESE by issuance of forms and records at strategic points, which are supplemented by organized personal attention of the production department or supervisory force. New orders are entered on Form A in duplicate, one section being a recapitulation of the information given in the order, and the other section is used for entering infor- mation relative to cores needed. At this point, the receipt of the order, careful check is made of previous orders, if any, for the same patterns. Quotations are checked, ques- tions of analyses are settled, and delivery promises pre- viously given are entered for shop information. From the order recapitulation one work order, Form B, consisting of four cards, is issued for each pattern. One copy is sent to the shipping department, one to the pricing department and two to the pattern storage. The form sent to the shipping department provides space for dates, pieces made, pieces shipped, defectives and delivery dates CARBON 0.28 028 Sa errr ar nan MANGANESE 0.80 0.70 SILICON 040 0.30 0.35 045 SILICON LA nana he og Typical Monthly Furnace Control Chart (Left, above) Made Prior to Establishment of Control System. Black areas show heats outside of the desired range. benefits derived from close furnace control the score diminishes, the per cent of bonus, based on monthly salary, is increased in ascending rates. If a heat is scrapped for wrong analysis, a definite percentage of the bonus is subtracted as a penalty. The melter records the analysis of each heat, as well as the amount of alloys used, on an analysis log. He is re- quired also to make a report of materials used for each heat, which is sent to the accounting department. And he makes a report of furnace operations and delays, for the melting foreman. Physical tests are made at regular in- tervals and their data, as well as the chemical analysis, are permanently recorded in the laboratory, the former on a card index file, the latter on a daily analysis report, which is later bound and filed. Of special interest is the method of sand control. In- coming sand is tested for fineness. The sand mill is pro- vided with an indicating and recording time-meter, which regulates the milling time. A control sand laboratory is placed near the sand mill. Here one man devotes his entire time to testing facing and backing sand mixtures, the object being to eliminate variables as much as possible. Control of Work in Process In a jobbing steel foundry the establishment and main- tenance of production and shipping schedules require close and persevering attention. It is difficult to control fully by work tickets the movement of individual castings or orders. Automatic progression cannot readily be obtained by continuous conveyors, due to the varying condition of the product in process, and diverse circumstances govern- ing sequence of operations. However, control is obtained 1030—The Iron Age, October 17, 1929 At right is a chart similar to the other, showing scheduled. The shop cards provide space for specific in- structions needed to put the job in process and to show a record of work performed. Printed on these cards in bold- face type is the warning “Payment will be made for good castings only.” A core order, Form C, is made from the core recap of Form A. Form C is sent to the core department with core boxes at least two days before the molders get their work orders. This allowance of time is considered ample to permit the core-making department to have its part of the work completed well in advance of the beginning of mold- ing operations. Old Patterns Studied Before Again Being Sent into Shop Shop orders, upon leaving the office, are sent direct to the pattern storage and all pattern equipment required is laid out on a bench for inspection. Every afternoon a meeting of the shop executives is held fo. the purpose of carefully studying and examining pattern equipment which is to be used. Accompanying each old pattern are records of any difficulties reported, either by the customer or the foundry, on previous orders. Unusual loss by defectives is also given consideration at this time. Both old and new patterns are individually checked from the standpoint of design, method of casting manu- facture, state of repair, anticipated defects and matters affecting scheduling of the order. In most cases foundry equipment consisting of heads, gates, etc., is inspected with the pattern or is ordered from the pattern shop at this meeting. This insures consistent manufacture of the casting in the approved method on successive orders. Mat- ters requiring communication with the customer are Hours Day Work % ORDER RECAP CUSTOMER DATE RELEASED COR ORD it CREDIT LISTED ACKNOW’'D Pattern CARDS Core Symboi Dept. Order S P.W.R Order No. Date Coremaker At Good Cores made—__ Cores due Broken Cores oe. ee 2 2 2 Customer SS NEW CHANGE D Pattern Order Reco; REPAIR Please get___price end sctudm to Our property Authorized: Place order. Order No... EQUIPMENT DESIRED —_ «a \\ - TRUCTIONS | SPecial INS y 1233: 43 7°92 ORMS Used in C is to be and what Ee cist nineepitinntint OD itonioniel Earned laesseremrengsceose secon job in production. C Payment will be for Good Castings Only | D records orders tor n or shortage; three copit BROKEN MOLDS. G is issued if it is nece Hours Day Work Customer i a Core Symbol Order No. P.W. a Date Coremaker______t. No. I i a) Good Cores made—__ NEE SEE LS Ee ee ee eae, Broken Cores 1 | 1 2 | 2 2 2 2 oe Rae m8 i 2 eB oe ge ORMS Used in Controlling Operations in the Foundry. A and A,, ma is to be and what cores are needed. B and B,, four cards in all, gi job in production. C, the core order, goes to the shop two days before D records orders for new patterns and is made in duplicate. F shows, w or shortage; three copies go to superintendent, chief inspector and patter G is issued if it is necessary to call attention to a difficulty , made out together, show what the piece give specific instructions for putting a ore the molders get their work orders. , when necessary, the high-scrap report tern record. A special instruction card THE IRON AGE, October 17, 1929 cr *) S A pe cs = 2 t 7 ° / s a} / brought to the attention of the production or the sales department. Corrective steps are taken if necessary, and these are noted on the shop orders and permanent records. This meeting is attended by the superintendent or his assistant, the chief inspector, the pattern foreman, the core room foreman and members of the production depart- ment. Each morning all approved orders received at the pat- tern storage on the day before are given to the schedule clerk. The foreman of each molding department is called in and the jobs as a whole are discussed and molders are assigned. Dates on which shop work will begin on the various jobs are set according to work ahead. The work- order cards are then filed on the schedule board in accord- ance with the dates which have been designated. At this time the records of previous difficulties are examined and acknowledged by the molding foreman. The foreman is then held responsible for fulfillment of molding schedules according to orders assigned to individual units, and he makes necessary arrangements for delivery of co.aplete equipment to the molders. A day-by-day record of his schedule efficiency is kept, and is one of the items consid- ered at the daily production meetings. After a job is definitely scheduled, one copy of Form B is sent to the office. From the date recorded thereon a shipping date is determined and the customer is notified when shipment will be made. This copy of the order is the production department’s delivery control record. Both molding and shipping dates are recorded thereon and it is used daily in checking progress of orders so as to insure movement in process and shipment as promised. Shipping Schedules Discussed at Production Meetings At 2 p.m. each day a production meeting is held, at which molding and shipping of scheduled orders are dis- cussed and current and overdue promises, both of molding and finishing departments, are given particular consider- ation. The primary purpose of this meeting is to pry into causes of delays and rectify them before they have been in effect long enough to check production seriously and result in dissatisfaction at a delivery promise not kept. It is the aim of the management squarely to place responsi- bility for all schedules and production work, but it does not want single-handed direction. Cooperation among all per- sons interested is expected, and accordingly the chance for error or omission is greatly lessened. An interesting feature in connection with the pattern shop is that it has been placed on its own merits. A cus- tomer who is in need of a pattern may ask for a bid from the Sivyer shop which often is competitive with outside pattern makers. Blueprints are carefully studied by the superintendent and assistant superintendent and sugges- tions are made for design improvement if difficulty is fore- seen. The most advantageous method of pattern con- struction from the casting quality viewpoint is determined and is used by the pattern shop in making its estimate. Patterns, when ordered, are recorded on Form D. Back of the desire to eliminate difficulties and to rec- tify them quickly when encountered is the thought that every such case is an opportunity to build prestige with a customer, and it can be made an incentive to keep the pat- tern at the Sivyer foundry. Defects are often discovered in the shop. These frequently can readily be rectified without inconvenience to the buyer. However, it is the omission that leaves the plant that nettles the purchaser, and which may be the direct and primary cause of loss of future business. Accordingly special attention is given difficulties which purchasers have experienced with Sivyer products. An expression of trouble may come by letter or by word, or it may be passed along to a salesman. What- ever the source, immediate attention is given it. The detailed report is entered on Form E (not illus- trated), which is headed “Disposition of Difficulty Reported by Customer.” This report shows how the difficulty has been overcome, a reply by the inspector, and finally the question “Have we written customer?” In the upper right-hand corner is a ruled space for the signatures of the superintendent, his assistant, the quality supervisor, chief inspector, and members of the production and sales department. If necessary to call attention to the difficulty reported, when future orders are produced, a “Special Instructions” card is issued. Records Disclose Past Difficulties This sheet (Form E) is attached to the pattern storage record, and goes with the pattern each time it is called out of storage. In this way the foremen familiarize them- selves with past difficulties whenever a pattern is called into the shop. Sample enstings are made on any pattern specified by the customer, from new patterns produced in the Sivyer pattern shop, or when desired by the shop executives. These castings are given personal supervision by the assis- tant superintendent and the quality supervisor. A follow- up method is used, necessitating approval from both the manufacturing and the quality standpoints, to insure re- cording of instructions available for future reference before the original request is filed. Careful watch is kept on the space on Form B which is provided for defective material. If an excessive per- centage of castings on an order is found defective a high- scrap Form F is made out in triplicate by the production department. One copy goes to the superintendent, an- other to the chief inspector, and the third, which is printed on cardboard, is attached to the pattern record. This comes to light again when the pattern ‘is next ‘called into the shop. The information on Form F is studied at the pattern meeting. Checks on general defective control are a daily proced- ure. In a conspicuous place in the main shop are three red lights which are labeled respectively floor molders, jolt machines and squeezers. At the end of each work day the total scrap is computed for each of these three departments. The one with the highest percentage of scrap is known to all the workmen because the red light designating that department burns during the next day. Inspection forms an imvortant link in maintaining qual- ity and in catching errors before they reach the stage where they cannot be readily rectified and shipping sched- ules cannot be maintained. Each inspector has a specific station at which he examines each casting as it passes. It is also his duty, when not pressed with work at his station, to make general inspections. By this arrangement the workmen do not know at what stage of their work a close check will be made. The principal stations for inspectors are on the molding floors, prior to sand blasting, after grinding and chipping, after welding, and the final inspec- tion prior to shipment. Those in charge of responsible work are given full assistance, but, once a course is determined, then responsi- bility is placed squarely where it belongs. All reports made in the shop are written on carefully prepared forms, which always provide ample space for the signatures of the men through whose hands they pass. These reports are kept alive, that is, they are readily available for future use in placing responsibility, and it is known throughout the shop that they will quickly be used for that purpose. At first this system may seem extremely strict in placing the blame for errors and omissions. However, it builds among the men a sense of responsibility and pride. Good work is quickly recognized and bonuses are the re- word. It holds the organization to a sense of obligation to the purchaser, and the results are exceptionally satisfac- tory when it is considered that this jobbing steel,foundry sends its products to 30 major groups of industries in 28 States. The Iron Age, October 17, 1929-—1033 Business Is on a Firm Footing Industry and Trade Are Free From Inflation and Should Not Be Severely Shaken If Bull Stock USINESS continues to display B a higher rate of activity than most observers anticipated a month or two ago, and such slacken- ing as is evident has occurred chiefly in those industries whose pace during the summer was obviously too high to be maintained continuously. Electric power consumption, rail- road freight car loadings, coal pro- duction, employment and the turnover of bank deposits are all reported at high levels. Corporation reports of earnings for the first half of 1929 re- flect an even more favorable condition than was expected on the basis of the high level of productive activity which has been reported throughout the year. The decline in the rate of opera- tions of the steel industry which be- gan early in the summer continued up to the end of September, but re- ports of operation so far in October indicate a turn for the better. Un- filled orders of the United States Steel Corporation for Oct. 1 show an in- crease for the first time since April. The improvement is apparently due chiefly to a good volume of railroad buying, which offset a slackening of orders from the automobile industry. Some relaxation of activity in the automobile industry is not surprising considering that the output for the first nine months of 1929 surpassed that of any previous complete year. Market Comes to An End BY DR. CHARLES 0. HARDY @ Fundamentals of prosperity undisturbed by technical con- dition of securities market. whether business men have overestimated their markets. @ If bull market in stocks is over, major business depres- sion need not be feared. @. In previous bull mar- kets business itself was shot through with speculation and price inflation. @ Higher European bank rates do not necessarily mean tighter money here. @ Federal Reserve’s attempt to restrict speculation is likely to be abandoned if business, rather than the stock market, is choked. @_ A major stock market de- cline would interfere tempo- rarily with financing programs. @ Shift from stocks to bonds might take three to six months, but would facilitate financing of small companies, residence construction, foreign loans The increase in the Bank of England rate, from 5% to 6% per cent, undoubtedly points to the probability of continued high money rates. Ever since the Federal Reserve System abandoned its cheap money policy and began selling se- curities at the end of 1927, New York has been a magnet for European, and especially for British, gold. European funds in increasing volume have been placed in the New York call loan market and acceptance markets, while at the same time the amount of for- eign bonds placed here has shrunk to a small fraction of the amounts placed a year or two ago. With more Euro- pean money loaned here on short- term accounts and less borrowed on long-term accounts, pressure has been exerted on the European exchanges, the gold outflow from this country has stopped and since then over 200 mil- lion dollars of gold has come in. This inflow has enabled our banks to replenish their reserves, offsetting the effects of the sale of securities by the reserve banks and to that extent reducing the need for rediscounts. If the higher rates in Great Britain should result in a renewed eastward movement of gold, the pressure on our money markets will be intensified. This does not necessarily mean, however, that business will be so pinched by money shortage as to make impossible the continuance of the The slack in the low-priced car market, which arose from the long interruption of Ford production, is apparently noW substantially taken up, so that further sales may be expected to be more representative of replace- ment demand and the normal growth of the business. Bad crop conditions in the West and in the South give rise to apprehension of restricted farm buying, but reports of both wholesale and retail trade are very favorable. Gold Loss Forced Rise in English Rate Money market conditions and the stock exchange have continued to hold the center of the stage throughout the month, the “big news” being, first, the increase of the dis- count rate of the Bank of England, followed by advances by the Scandinavian central banks, and, second, several spectacular breaks in prices on the New York Stock Ex- change. Does either of these developments suggest the probability of a change for the worse in the level of busi- ness activity ? 1034—The Iron Age, October 17, 1929 and Government enterprises. present era of prosperity. Several alternatives suggest themselves. First, the pull of the New York call loan market may be sufficient to overcome the influence of the new higher rates. If so, it seems unlikely that the British public opinion (which since the war has been extremely sensitive on the subject of money rates and their supposed cramping effect on business) would tolerate further ad- vances in the rate. Rather it seems likely that indirect means would be found to replenish the gold reserve and restrictions would be placed on foreign lending of British funds in order to make possible the financing of domestic business at rates no higher than those now in effect. As a second possibility, the stock market liquidation which has been under way for the past few weeks may proceed so far as to release funds now tied up in brokers’ and speculators’ balances, with the result of easing the market for all types of loans. This has obviously been the objective of Federal Reserve policy for months. While the policy has so far been unsuccessful, it may yet succeed, or may seem to succeed, because the speculative fever has run its course. Third, considerable relief may still be found through a change in the composition of the credit structure. A shift of a large volume of deposits from demand to the time form would lessen the required reserve and furnish slack to offset the tightening effect of the withdrawal of European funds. This process went on at a great rate for several years prior to 1929, though it has ceased for the past 12 months. More probably, and in greater degree, the market pressure may be relieved by the shift of funds from the bank loan accounts to direct loans by individuals and non-banking institutions (of which the conspicuous case is “brokers loans on account of others”). Federal Reserve Policy May Change Fourth, and most likely, the Federal Reserve authori- ties may elect to put additional credit into the market to offset the effect of such gold withdrawals as may result from the recent advances in European bank rates. There can be little doubt that such action would be taken as soon as it became evident that the movement of goods in com- ENGLISH RATE eee meee cere cee seers osees merce and the rate of industrial production were being restricted on account of the tightness of the money mar- ket. The objective of the Federal Reserve policy in recent months has been to force a contraction of speculative credit, not because of immediate need but as a safeguard against an anticipated deficiency of commercial and indus- trial credit. Because both business and speculation have shown such unexpected indifference to the level of money rates the restriction of Reserve credit has gone much further than any one anticipated when the policy was initiated. If it should presently appear that business, rather than the stock market, is being choked off by this restrictive policy, we may confidently expect it to be abandoned. In- deed, the softening of money rates over the past two weeks in the face of higher rates abroad seems to indicate that Reserve Bank purchases of acceptances have already gone beyond the amount necessary to accomplish the nominal purpose of providing credit for the autumn seasonal excess of demand for currency and for export credits. It does not appear, therefore, that increase in the English bank rate is an alarming adverse development in our own business situation. British rates have long been obviously too low in the light of world-wide demand for credit for speculative purposes, and this attempt to bring them into line with world markets needs occasion neither surprise nor alarm. The second adverse development of the past month is found in the behavior of the stock market, where prices have broken very sharply on several occasions, the break in each case being followed by a strong upward reaction. Many market observers are of the opinion that we have finally reached the top of the bull market which began in 1924, and there has been widespread uneasiness lest the anticipated decline in stock prices may operate to under- mine confidence and lead to a curtailment of the scale of business operations. We are not disposed to offer a prediction as to the im- mediate future of the stock market. Appearances certainly indicate that quotations are out of line with present and prospective earnings and are being sustained by buyers who hope to resell presently at still higher prices. Com- petent observers have been deceived so often, however, by the vitality of this bull market that confidence in all fore- casts is at a low ebb. Inflation Localized in Stock Exchange What, however, is the probable effect on business if the stock market has actually reversed its trend? In the past a major downward turn in stock prices has often been the HANGES in Dis- count Rates of New York Federal Bank and Reserve Bank of England (Above) Net American Im- ports and Exports of Gold (Below) immediate forerunner of a wave of business liquidation. This was true in 1890, in 1903, in 1907, and in 1919-20. Such experience, however, is of doubtful application to our present situation. These peaks of stock speculation which were forerunners of business collapse occurred at times when the whole business world was itself shot through with speculation and price inflation; indeed, those stock market booms were only indexes of a general excess of optimism which expressed itself in overborrowing, over- expansion of plants, and overaccumulation of inventories. Today apparently inflation is pretty well localized in the stock exchange. If this is true, we cannot safely use stock price trends as mechanical forecasters of business changes. May there not be a more direct causal relationship? Would not the mere psychological effect of