The Iron Age 1930-06-26: Vol 125 Iss 26

ACE New York, June 26, 1930 ESTABLISHED 1855 VOL. 125, No. Keystone the Industrial Arch RODRICK* HERE factor industrial management the importance which not yet fully realized, al- though some attention has been given the subject literature and practice. That factor not ele- ment, but man. not the president the cor- poration nor member the board directors. His position not spectacular; indicated small block far down the organization chart. has been referred the “top-sergeant industry” and the “spark plug” the industrial machine. the foreman. Foremanship training increasing popularity, because modern industrial management emphasizes the recognition recent years the importance the foreman’s job. The schooling foremen depar- ture from the older order management. Its advent encouraged. One writer predicts that training schools for foremen will con- stitute outstand- ing feature Ameri- and economic training course, how- ever, which does not take into account the importance the foreman’s position will fall short ac- complishing its chief purpose, namely, make the foreman asset. Where such courses are use men. departments. *Industrial engineer, Washington. ployment. foreman the key lower costs. can stop wastes and promote salvage. can much cut down the greatest single industria! waste—preventable accidents. should see that equipment properly oper- ated and maintained. What even more impor- tant, should bring out the latent ability his must have forethought, tact, patience, im- partiality. must cooperate closely with other exerts important influence stabilization employment. The best way keep workman contented free him from the fear unem- COORDINATION contemplated, the subject the foreman’s position should given conspicuous place the What the Foreman Controls facture are reduced, planning schedules are met, the foreman the one man who can bring about the desired results. economies can ef- fected salvage and waste elimination, the foreman the one who position detect them. These are but two major possibilities inherent the fore- man. carries his work simply because paid it, fails realize the potentialities his po- sition. does realize them and acts accordingly asset. The importance the foreman’s po- sition manifest distinct func- tions management production and lower costs, person- nel, safety, and coor- dination and cooper- ation. manufacturer’s most important prob- lem producing the required quan- tity, low cost possible consistent with quality. This not new problem —it has been with him ever since the in- ception industry for profit. But its 1877 real importance being felt more industrial establishments grow size and operating conditions change. High Wages and Low Costs For long time economists well laymen contended that industries could not produce cheaply and maintain high wages. This would seem economi- cally true, but, since the reverse has been proved, the economic theory has been lost the actual fact demon- stration. Any concerted effort, therefore, effect reduction the cost manufacture, either increasing pro- duction eliminating waste human motion material, must have the full support, approval and en- thusiasm the foreman. the one who can further retard any such attempt. the key man, and unless reckoned with the carrying out any such plan reasonably safe predict advance that complete success will not obtained. Foremen, aggregation shop individuals, are jealous their quasi-executive prerogatives. Fre- quently the management required cater some- secured the prosecution any general scheme improvement retrenchment which indirectly affects the particular work they supervise. addition being the key man any general scheme improvement which, put into effect, would benefit the factory whole, the foreman also the key man his own shop, the matter economical operation. business and industry expedient that econ- omy insisted upon, because the life both depends upon profits. And profits are wastes there can “net” profit from which divi- dends are declared. Waste, notwithstanding present knowledge and improved equipment and machinery, still exists industries. And indirect costs arising from uneconomical operation are making figures the debit side industrial ledgers. These costs should receive the same consideration given labor and material promoting economy. Maximum production minimum cost the chief object every- where. The foreman the one man who po- sition not only detect waste when exists, but prevent means reducing costs. Salvage Means Reducing Waste The foreman also distinct position effect further economies through the medium salvage. Waste and salvage, while not dissimilar, are somewhat analogous industries. Certain kinds waste, though not unavoidable, have potential uses, and therefore must regarded actual loss. the other hand, certain waste materials have potential value, because they can used for other purposes, reclaimed sold. The method which this ac- complished called salvage. EMPLOVMEW OFFICE the latter case the foreman’s duty see that nothing discarded 1878—The Iron Age, June 26, 1930 entirely which may used any part the factory, either its present changed condition. Small pieces material can used other jobs, oil can reclaimed, and borings and turn- ings can sold. When the foreman looking for waste endeavoring find something salvage. And when looking for something salvage preventing waste. The question whether the fore- man should know costs still debatable. The writer the affirmative side, because has found from experience that unless the foreman knows what costs operate his shop, cannot ex- pected know where how effect saving, either the cost production maintenance. knowl- edge shop expense impels desire economize. longer merely boss men when has this knowledge, but part the management. must understand his relation the business whole and his responsibility for judiciously using the capital invested his department. the best position observe and detect weakness methods and recommend constructive changes, because nearest the work being done. His chief duty getting work done with such speed, accuracy and economy will result product maximum quality low cost. Looking After Machine Tools and Other Equipment The foreman factor the care and operation machine equipment. must have knowledge its cost, condition, suitability and normal capacity. must know the rate speed which those under him can work, that the flow production may kept regulated. should see that the ma- chinery properly lubricated, kept proper running order, properly operated, not overloaded and not abused. must cooperate with the repair department, save expense and avoid interruption having repairs made before breakdowns. should also carefully supervise the use machine tools and see that they, too, are not damaged when use, and that they are given the proper care while the tool room. The life any machine machine tool will depend the care receives. Norris Brisco, his book, “Economics Busi- ness,” says: “Men who know how get maximum results out machines are common, but men who know how get cooperation and the greatest effi- ciency from the human element industry, are rare.” key man, the foreman supervisor and director shop personnel. trans- lates the policies the company into understandable words the workers. many not only represents the company, but the employer. their boss, and some cases the only boss they know. Not infrequently one hears man say that works for Mr. So-and-So, rather than for the John Doe Manufacturing Corporation. (Continued page 1940) A | 4 / " | ODERN systems shop management most cases advocate taking executives, key men and foremen into the confidence the company giving them certain statements and schedules fig- ures pertaining shop operations. Statements pro- ductive hours, indirect labor, comparative earnings, departmental overhead rates and their composition and like information are the usual statements given shop executives. Some companies give their de- partment heads complete statements departmental expense. This all very good, tends place more less responsibility the shoulders those shop executives for the control the expenses un- der their immediate supervision. But this does not seem sufficient accomplish the desired results cost reduction. Most cost systems are designed, should be, accumulate cost data, direct and indirect, not only for labor and materials, but for all overhead expenses, from the historical standpoint and for the forecast future standpoint well. Both fixed overhead expenses (such depreciation and interest) and con- trollable expense (such supplies, power, mainte- nance) are tabulated upon cost records, presumably for the use plant managers effort attain control those expenses, well for the furnish- ing data for financial statements. How About the Man the Job? These compilations expense data will never used their maximum long such data reach only the key men executives. true that those men should have that data and actually need them they are carry out their mission effectively. However, distribution and use the data should not stop there. How about the worker, the man the job, who actually uses the items comprising the bulk controllable expenditures? should have, and entitled to, information intended bring about the reduction expenses. has been said that present only about per cent all employees involved are informed the results studies cut costs minimum. other words, the men who use the supplies and perform the indirect labor and consume the items controllable expense plant production, and who are the only ones who have their power reduce these items *Treasurer, Cincinnati Planer Co., Cincinnati. “Man the Needs Data Costs More Than “Key THOMAS FRANK* minimum, are the very ones who present are given information regarding expenses, informa- tion how accomplish cost reduction. Better results cost reduction would immedi- ately become apparent the workmen were informed and educated become “expense conscious.” Industry has devoted many hours study and development labor and material standards, but very little the study expense standards. Elaborate incentive systems have been built encourage workers meeting the labor standards, and some cases for maintaining material stand- ards. Why not system incentives the worker for meeting bettering expense standards and cost reduction way controllable expenses? seems very logical “next step” toward the effective control costs. Incentive Plan Offers Best Possibilities entirely within the province real cost department establish expense standards and work out incentive plan encourage workers par- ticipate cost reduction programs. The best results would obtained this manner. cost department that cannot develop these standards from their pres- ent records sadly deficient one its most valu- able elements. Expense information regarding controllable penses, given the men who are directly responsible, backed incentive plan, certainly would prove valuable and much more effective than most methods current use, which reach such small percentage the employees, and then not the ones who could the most cut expense. Waste elimination campaigns, held periodically, and other campaigns directed other cost over- head factors have usually proved profit makers. Why not plan that would assure continual day- by-day, year-in and year-out drive cost reduction through the elimination excessive controllable ex- penses One dollar each 400 dollars, our national in- come, spent for research, according Hard- ing, writing Atlantic Monthly. But only ten cents that dollar goes for fundamental research pure science—for the acquisition information which civilization builds. The rest used for “practical” investigations. The Age, June 26, Gas for Lead Hardening Shovels Lead Pot Fired with Gas Used Regular Production, with Electrically Heated Pot Take Peak Loads GEORGE DVANTAGES lead hardening for the heat treatment shovels are almost self-evident. The high specific gravity the lead permits the shovels floated the bath. the use heavy layer powdered coke, the shovel blades can maintained the proper level without any other means holding them down. the Baldwin Tool Works, Parkersburg, lead baths had been fired for long time with natural gas, but the progressive policy the company investigat- Electricaily Heated Pot Foreground Working the Small Round-Pointed ing every possible improvement process urged them install electrically heated lead pot, which was put operation April, 1929.+ Although the electrically heated pot still available for use, the practice the works use electricity only when the press business goes beyond the capacity the gas-heated pots. such times the electricially heated pot put into service, but this occurs rarely. new gas pot has been installed, manufac- tured Strong, Carlisle Hammond, which Shovels Shown Left. left back- insulated and better de- Asso t Ne Y rHE IRON AGE, De 2 19 ground operator putting clamps brackets larger shovels prevent dis- which were use there. sign than the earlier gas pots tortion heating 1880—The Iron Age, June 26, 1930 a LLL LLL ELL planned control the temperature this new gas pot manually, but automatic controls have been recommended and probably will installed. Comparison Heating Values Feeling that would interest the readers THE IRON AGE learn why gas used rather than electricity for heating the lead baths, some fundamental economic data concerning natural gas have been included this article. Natural gas per thousand cubic feet, served Parkersburg, equivalent purchasing 30,700 B.t.u. for one cent. course, some this heat will lost radiation from the pot, and some the flue gas loss. Nevertheless, when compared with electricity per kwhr., which equiva- lent buying 2740 B.t.u. for one cent, evident that comparison energy equivalents must favor- able natural gas. The only difference efficiency between electric- ally heated and gas-heated pots results from the fact that the gas pot has flue loss. How much this amounts depends, course, the operating tem- perature and the amount over-ventilation. Under reasonable conditions, with temperature 1500 deg. Fahr., the flue loss might amount per cent, but Gas Furnace Foreground and Right, with Sockets Scoops Protruding Above even under those circumstances the cost gas for fuel obviously much less than the cost elec- tricity. This flue loss need not high has been indicated, because very efficient installations can made the use second pot, heated the flue gases the first pot. the conclusion this article recommendation along these lines proposes entirely new method handling the shovels, which might interest, and which would certainly tend most efficient. Equal Labor Cost for Same Product Labor costs for operating lead hardening pots are equal, matter what fuel used, because the gas heated well the electrically heated pot has auto- matic temperature regulation, and requires atten- tion the part the operators. was found, how- ever, during the operation the electrically heated pot, that the labor costs were good deal lower. Regrettably, that analysis depended upon the type shovels being handled, and certain the smaller, round-pointed shovels not require clamp them keep them from distorting when quenched. There- fore, handling the smaller shovels showed labor. When the entire subject was reviewed, the fact the Coke Covering Over the Lead 4 4 4 q q 4 ? The Iron Age, June 26, 1930—1881 vealed that, for identical shovels, identical labor charges exist, matter what fuel used for heating the lead. not possible make accurate and detailed cost comparisons the operations the Baldwin Tool Works, because the wide diversity shovels handled this company prevents from maintaining records the exact cost operation the furnaces, which adds only small proportion the cost the finished product. Character Steel Used Has Bearing Manufacturers shovels employ good many dif- ferent steels, accordance with the strength, tough- ness, resistance wear, and the sales price which established for the finished product. brief survey the significance the various alloys may useful this comparison gas and electricity. the Baldwin Tool Works was found that rapid deterioration the electric heating elements occurs high temperatures, that electric heating not used for the heat treatment alloy steels requiring high temperatures. Among the materials used here and elsewhere are molybdenum alloys, which are noted for their ability retain complex carbides solid solution upon cooling from the critical temperature, resulting tough, resistant and strong steels (a). Chrome- nickel steels can heat treated give great hardness and strength, because double carbide formed the introduction chromium. This steel has the advantage the effect nickel the ferrite matrix and the chromium the carbide constituent, giving better physical properties than either element used itself (b). Manganese steels give excellent results when prop- erly heated treated. The common “Hadfield” steel, with manganese per cent, carbon 1.0 1.3 per cent, frequently used, and gives tough product, with excellent resistance wear. High-carbon steels suitable heat treatment make excellent shovels. These are somewhat less expensive, but are still far superior the so-called “competitive” lines. These different steels, course, require different neat treatment, and that very important con- sider making fuel comparisons. fair every fuel, necessary sure that the com- parisons are made with respect one and the same article. Unless this done, the conditions affecting lead consumption, labor, pot life and the other ele- ments production cost will not identical, and erroneous conclusions might drawn. reference made the pictures the Dec. 26, 1929, article THE IRON AGE, will seen that the shovels indicated the general view the gas- fived lead baths are very much larger than the round, pointed shovels shown the quenching tank front the electric pot. Since the various sizes shovels are immersed different depths and treated dif- ferently, impossible make dollar-and-cent comparison fairness electricity. Leaving aside all reference for the moment the situation the Baldwin Tools Works, entirely new form gas heating beginning develop, which bids fair revolutionize the art heating (a) “Experiments with Rare Transactions American Electrochemical Society, May, 1923. (b) “Nickel and Nickel Steels,” Thomas Wickenden. 1882—The Iron Age, June 26, 1930 lead and salt baths. the immersion heating, using completely premixed air and gas mixtures perfect proportions, that complete combustion will secured under all degrees turn-down the flames. This type gas burning system permits high concentration flames, that the burning may take place the interior submerged pipe under the surface the lead bath. With this method heating, the outside the pot can packed with insulation the space formerly required for firebox and flue passages. result this construction the radiation loss cut down, that there only the radiation from the top surface major item heat loss from this source. Even the latter well protected the bed powdered coke. The flue loss still present, but it, too, cut down the fact that there excess air required for combustion, and that there air movement during the off periods the burner. The pilot burner ad- justed burn enough gas keep the lead molten over night and week-ends. But, since also operates perfect air-and-gas mixture, there will excess air during the time when the main burners are off. This quite different from the operation externally fired pot where atmospheric pilot burners are used. High-Heat and Low-Heat Pots Tandem This look into the future introduces another pos- sibility, namely, lead the flue products from high-heat lead pot low-heat lead pot, and change the heat-treating process. comparatively cheap material which both strong and tough, and capable taking remarkably hard edge, the type steel known Vanadium-G, which averages 0.60 per cent carbon, 0.98 chromium, 0.30 0.40 man- ganese, and 0.35 per cent vanadium. This material good deal less expensive than some the alloys now use, and might make very satisfactory shovel. Research done Guthrie, Chicago, indicates that this steel could heat treated two lead hardening furnaces running series, has just been indicated. The first pot would kept slightly above the upper critical temperature and the other little bit over the Ar, point. The latter, being lower temperature, would ideally suited heating the flue products from immersion heater the high-heat pot. Possibly some additional heat might needed the low-heat pot, but the com- bination would levels efficiency impossible attain any other way. The treatment the type Vanadium-G steel harden two steps: First, heat quickly possible above the Ac,, and then quench plung- ing into the Ar, pot. The length time the steel stays the latter pot immaterial. From that pot quenching into cold water can done desired, quenching into oil, slightly lower hardness wanted. Although this two-step hardening process some- what unusual, seems result much higher physical properties. Ductility higher, and that should give reduction warpage, cracking and forth; and tough structure obtained which will lengthen the life the shovel. Need Standardized Cost Figures Stressed Before Foundrymen EANS enlarging the market for cast- ings, standardization costs that foundries will figure these the same basis, and other problems interest the foundry industry were discussed the third sec- tional conference the Ohio Foundries Association, held the Congress Lake Club near Canton, June 18. There was attendance about members, including repre- sentatives the gray iron, ferrous branches the indus- try. Following the remainder the after- noon was devoted talks and informal discussions. Robert Hopkins, Alliance Brass Bronze Co., Alliance, presided general chairman. foundries today. other better. problems. Use Cost Figures Greatest Problem use cost figures the greatest problem before the gray iron industry day, declared Denison, Fulton Foundry Machine Co., Cleve- land, talk “Evils Using Cost Figures” that aroused great deal interest. cited various cases show that there wide variation esti- mates costs jobs, caused using different well recognized methods computing costs. one job large foundries having cost systems figured their costs all the way from 1.2c. 3.2c. per prove his contention that desired results are not being obtained with the present lack uniformity methods pro-rating costs, the speaker took examples two castings made heavy shops, one weigh- ing 300 lb. and the other counterweight weighing 3000 Ib. Different Values from Five Methods There are five ways, said, figuring costs, all actually used and sponsored good accountants. As- suming that five foundries have the same costs, presented analysis show the cost making these castings based the different methods pro-rating cleaning room and other costs. These figures were based actual costs for making the two castings ONE job, large foundries that use cost systems esti- mated the costs anywhere from 1.2c. casting ranged from per The use cost 14.80c. per difference figures the greatest problem for High-test iron castings have made inroads forgings. Some lost busi- methods ness can recovered more at- costs? the speaker asked. tention alloy castings. Today foundries are melting higher temperatures, thus increas- ing the refractory requirements and the importance solving refractory Cleveland foundries. The cost producing the smaller the method costs. The production cost First step bring about better the larger casting ranged conditions competitive districts from per Ib. for foundrymen know each when computed the same five methods. What likely result from this lack uniformity pro-rating Answering his own question, said that shrewd buyer will shop around and buy one class work from foundry that figures its costs one way other types castings from other foundries that use other methods computing costs. The estimated cost one type casting may lower when figured one method and the cost another casting may lower when figured one the other methods. Purchas- ing agents, said, can “beat foundries death” unless the method handling cost systems stand- ardized. {dvocates Closer Contacts Among Foundries LOSER contacts among foundries the same field, that foundrymen will know their compet- itors, was urged Robert Hoierman, secretary the association, who said that had visited 230 Ohio foundries during the last two months. Outstanding causes the present unsatisfactory situation the foundry industry, his opinion, are lack business, price cutting build volume and lack backbone. The first step for bringing about better conditions, said, for foundrymen know each other better and have confidence each other. Competition from Other Products More important than the competition the foundry industry itself the competition that comes from makers other products, the opinion Mr. Hop- kins. declared, are doing little replace casting business that being diverted other materials and hoped the association could add (Concluded page 1941) The Iron Age, June 26, QUIPMENT unusual size required fabri- cate and erect the members the large bridges now being constructed various parts the world. are used thinking America the home the structures, but far-off Australia shares with the distinction building the largest arch bridge. The total cost this project esti- mated $18,300,000. Steel was manufactured En- gland Dorman, Long Co., but fabrication was done near the site large structural shop the water’s edge. For the iast five years this 1650-ft. arch, together with ap- proaches reaching mile and half either direction, has been construction the main entrance Sydney harbor. Some 50,000 gross tons steel are required. The arch itself con- tains less than 37,000 tons, even though the principal stress- carrying members the latter are normalized silicon-man- ganese steel. Despite the fact traveler which erecting the bridge can lift 122 gross tons, the end panel the lower chord shown the illustrations had erected six parts, divided once lengthwise and into thirds cross- wise. Its overall dimensions are in. deep and ft. broad; its web members are plates in. thick; its flanges are 12x Iron Age, June 26, 1930 Charging Machine Sixty-Foot Plates in. angles, and the biggest rivets are 13/32 in. diameter and grip in. Average analysis and properties the high-strength steel used for these main members are Ultimate 85,000 per sq. in. Elongation in..........22 per cent Reduction area.......... per cent Charging Machine Capable Handling 15-Ton Hot meet the specifications plates for main webs are normalized. Special furnace equipment for handling such pieces, ft. ft. maximum dimensions and weighing tons, was built Gibbons Brothers, Ltd., Dudley, England. This Gibbons-Van Marle fur- nace charger the nature mechanical peel, and patterned after machinery size suitable for fur- naces ft. long and taking load tons. These smaller machines (patented America) are built transfer tables, and can serve battery furnaces; the charger shown the illustration stationary, since one furnace sufficient handle the work for the Sydney bridge. The view shows the charging machine wholly with- drawn, having deposited its load inside the furnace (the door which closed). After the plate has uniformly reached normalizing temperature and soaked for the specified time, the charger enters the furnace, picks the plate and removes it—the whole operation from “door up” “door down” occupying about sec. The hot plate then cools the air, rest- ing undisturbed the charging machine until stiff enough move, when overhead crane replaces with cold plate ready for heat treatment. can seen that the bed the charging machine consists four fingers, something over ft. end end. side elevation would show three long bars and the lower one stationary track, the up- Half Section Through Charger Track Half Section Through Furnace Floor Half Section Through Charger Track and Furnace Floor Finger Bar Construction The Iron Age, June 26, 1930—1885 7 a | Plate, Ft. Long, Ft. Wide, Normalizing Furnace per two may move unit when going into coming out the furnace; the upper one also moves and down when picking depositing its load the furnace hearth. Half cross-sections the charger track and fur- nace bottom are shown line cut. The rails are beams, turned edge, with upstanding flanges tracking the rollers attached fingers the charg- ing machine. These rails butt into the front end the furnace, and match elevation the bottom U-shaped channels heat-resisting castings laid into the furnace floor, shown. These castings therefore form prolongation the track within the furnace. and are wide and deep enough pass fingers and their close nested position. Once the fingers the charging machine are with- the furnace, bar lifted from bar thus pick- ing the plate resting the furnace floor, clearing the latter about in., and this position trun- back out the furnace. In-and-out motions are given pair endless chains geared the 25-hp. motor the pit the extreme left the photograph. Over-run prevented spring bumpers each end the track. interesting device used raise bars from bars Each these four fingers constructed pair bars, properly spaced filler blocks and coun- tersunk-head bolts. close spacing the lower bars have rollers attached, large enough diameter hold bar clear the flange I-beam and also ex- tend between the side bars and keep them defi- nitely place. These are the main rollers which carry the load and out the furnace. longitudinally along electric motor mounted platform across the outer end the movable part the charging machine, effect this motion re- duction gear acting upon rack and pinion. pulled along relative small rollers attached the former roll the inclined tops blocks fixed the latter, which course lifts and any load may contain. The steel shield shown the end the charging machine protect the motor and gearing this lifting mechanism from the heat when the fingers are thrust into the furnace. charge plate into hot furnace the cycle follows:—Bar pulled into its “up” position, and the plate properly placed the charger. The entire assembly then rolls into the furnace; the fingers entering the slots the furnace bottom and the plate clearing the latter about in. When all the plate inside the hot zone, the charging machine stops its forward motion, finger moved forward along lowering its load upon the furnace bottom and sliding further until clears freely. The charging machine then retreats and the door closed. Unloading operations are performed the reverse order. Influence Washing Coal Coke Properties and Yields STUDY the influence washing coal coke properties and gas and by-product yields has been made the United States Bureau Mines. considering the use washed coal, the gas coke plant operator concerned with two classes effects: those due the removal free mineral constituents such slate, shale, bone and pyrite and those due the surface moisture left the coal from the washery. All the first class are desirable, they improve the quality the carbonization products. The second class effects, those due moisture, are complex, partly desirable, but mostly undesirable, especially with material increase moisture the coal. The favorable effects eliminating free mineral impu- rities may summarized follows: Improvement coke quality. Reduction ash and sulphur. Less clinker trouble. Fewer cross fractures coke, resulting greater resistance breakage handling, less small coke and breeze. Greater uniformity chemical composition and physical properties coke. Less sulphur gas. Greater yield gas and by-products per ton dry coal charged. adverse effects moisture are: Reduction oven capacity, due lower charging density moist coal, and longer time required complete coking given temperature. Iron Age, June 26, 1930 Higher fuel consumption per ton coal carbonized. Non-uniform coke, due wet spots charge. Excessive moisture, per cent, causes large- celled, weak coke. Dripping wet coal may cause spalling the brick oven lining. CO the credit side the ledger, moisture increases the ammonia yield and reduces carbon deposits the oven walls. Its effect gas, light oil and tar open question. Other variables, such temperature, coking time and amount moisture, complicate the situation; the absence further data, definite conclusions can made with respect these products. the whole, seems certain that the moisture should kept low (not exceed per cent) for the most economical results. By-product coke engineers have observed that, al- though coals containing excessive amount splint coal may good gas coals, they tend produce weak coke. Sections coke from such coals indicate that the splinty particles not thoroughly fuse and become incorporated with the rest the coal sub- stance. Work the coke and gas-making properties coal, now progress the Pittsburgh experiment station the Bureau Mines, indicates that weak coke produced from splinty coals high carboniz- ing temperatures (corresponding with coke and gas works practice). When made lower temperatures, the coke not inferior that from coals similar rank containing splint coal. | 7 7 7 | 7 7 q How Ford Forms and Polishes Rustless Steel Radiator Shells steel exposed metal parts the Ford tated the installation new machinery the Ford plants and the de- velopment new meth- ods drawing opera- tions. and stronger. More Ductile Than Ordinary Steel Ford radiator shell. Rustless steel, al- loy chromium, nickel and iron, about per cent more ductile than ordinary steel but the ductility decreases faster during the drawing stages. Therefore the various operations must continuous. Furthermore, rustless steel much stronger and stiffer than ordinary steel and, while the dies are the same design those used the forming or- dinary steel, greater allowance must made for spring back. the Ford car, rustless steel used for the ra- diator shell, cowl strip, head lamps, tail lamp, hub caps, gasoline tank cap. radiator cap and the cowl lamps those models having cowl lights. The metal pur- chased the Ford Motor Co. from several producers. How the draw- ing operations are accomplished with- out annealing il- lustrated the manufacture ra- diator shells the company’s Rouge plant Dearborn. The metal comes sheets gage, 7834 in. long and in. wide. From each sheet two oval- shaped pieces are stamped, each which radiator shell. The drawing solution, which Drawing the Ford Rustless Steel Radiator Shell the Rouge Plant the Ford Motor Co. applied before the than ordinary steel. also much stiffer More pressure necessary the draw rings for rustless steel than ordinary steel. chrome-nickel alloy cast iron, heat treated, used for the draw dies and rings. metal, after passing Best results draw dies follow drawing surfaces are finished with stone instead emery polishing wheel. Seventeen operations are required form Shells are polished the Ford plant groups five and not made polished metal. first drawing operation, quantity cup grease, sulphur, tal- cum powder and paraffin oil, thoroughly mixed. through this solution, drawn into the shape ordinary toggle press about 250 tons, using the same drawing speed that required for or- dinary steel. There air attachment adjusted the knockout pad, which also locks the blank the drawing punch prevent the metal skidding while be- ing drawn into the die. prevent scratches and score marks, the space between the walls the die and the punch the thickness the rustless steel plus 0.007 in. drawing rustless steel more pressuré required the draw rings than the case with ordinary steel, order lessen this pressure, necessary have double draw beads the die. The edge thus left the “pan,” after the drawing opera- tion, subsequent- trimmed off. Special Heat-Treated Cast Iron for Dies The draw die and rings are made special cast iron close grain, follows: Carbon, 0.45; chrome, 0.70; nickel, 2.00; silicon, 1.25 per cent. This special cast iron, after being cast and machined shape, treated follows: Heat 1550 deg. Fahr. and cool air; then heat 900 deg. Fahr. and again cool air. Brinell hardness should The Iron Age, June 26, 1930—1887 | 4 7 7 | — 7 7 7 7 7 7 get the best results draw dies, all drawing surfaces are finished with stone instead emery polishing wheel. The space between the die and draw ring very smooth and constant, small indenta- tions the surface will pick and cause scratches. The draw punch made chrome non-shrink air- hardening steel sections, seated cast iron punch shoe. These punch sections are hardened follows: They are heated 1350 deg. Fahr., then transferred furnace 1900 deg., allowed soak 1900 deg., and then hung wire and allowed cool air, after which they are heat treated 980 deg. Fahr. hour for each inch thickness section. UFFING the Sides the Rustless Steel Radia- tor Shells. The shells are locked frames groups five and travel through the battery buffing machines slowly moving conveyor Polishing Rustless Steel Radiator Shells for the Ford Car (Below) There are operations the forming the ra- diator shell. After the oval piece rustless steel has been drawn into the shape pan in. deep, the edge trimmed off and the pan goes into another press where the decorative pattern pressed into it. The next operation indents the edge which the hood tape placed, the next cuts out the end the pan that forms the bottom the radiator shell and the next cuts out the pan’s bottom, thus making the opening the front the shell into which the radiator fitted. subsequent operations hole cut the top for the radiator inflow pipe, another cut the front for the crank and small strip spot welded the top the shell for re- inforcement. After the 7 1888—The Iron Age, June 26, 1930 the shell placed overhead conveyor, going the polishers. “The shells, arranged groups polishing machines, are given rough buff with 180- mesh abrasive, fol- lowed 200-mesh emery and then buff 244-mesh emery, which brings out the luster. The shell then gets its final polishing. Surplus pieces from the bottom and end the pan are utilized for making smaller parts. There enough meta! from each radiator shell make one crank hole cover, one lamp tail light body, one tail light door, two cowl lamp bodies and other smaller parts. q { » 7 Open-Hearth urnace Control Discussed Symposium Buffalo BOUT dozen men participated last week open discussion the general subject open- hearth furnace control, one the sessions Buffalo the Association Iron and Steel Elec- trical Engineers. This was started three papers, one Simpson, American Heat Economy Bureau, Pittsburgh, one Mr. Bradley, Leeds Northrup Co., Philadelphia, and one Joseph Shadgen, Smoot Engineering Co., New York. Fol- lowing those speakers were discussions repre- sentatives various control and recording appar- atus manufacturers and number operating men. For best results with furnace control, Mr. Simp- son said, deeper checkers are needed than usual open-hearth practice. fan then used supply sufficient quantity cold air. happens that the least amount natural draft available the time when draft most needed; that is, the start heat cold stock. Great skill needed the part the operator when has maintain manual control fur- nace. With machine control, however, this task made easy. The port construction the furnace must adjusted meet the average conditions, regardless the variation velocity the gases, coming from difference the character gases used. the use combustion control, have elim- inated one the variables which make furnaces act differently. This provides greater uniformity op- eration, better quality product, increase the output and less repairs. Looking Temperature Control Basis Temperature one the most important factors the operation furnace, according Mr. Brad- ley. All the chemical reactions are directly in- fluenced the temperature. also the slag con- trol and the matter getting the heat fluidity which can poured. high degree preheat speeds all the operations. The difficulty usually experienced not reach- ing the necessary high temperature, but the con- trol the high temperature and avoiding burning the roof, etc. Usually the preheat regulated time basis, with reversals the furnace about 15-min. schedule, whereas some years ago min. was more usual. result, there frequently unbalance the two ends, with bad conditions. Flame temperature essentially function the speed combustion. The most efficient reversal method, said, control means the variation temperature the system itself. This may done putting two thermocouples similar positions, one each end the furnace. must remembered, how- ever, that the temperature differential method does not avoid overheating. difference 150 deg. works the same, whether 1800 deg. 2400 deg. Fahr. Great Advantages Obtainable from Proper Control Combustion control the dynamic end the fur- nace, where the furnace design itself the static end, said Mr. Shadgen. The dynamic end the most important part the furnace, despite claims the furnace makers the contrary. Its main control advantages are increase production, decrease fuel, longer life and better metallur- gical operation. Control now installed pays for itself about year. is, however, still the experi- mental transitional state. want more instal- lations, that can study the question more widely and learn more about what they will do. Fundamentals along this line include the fact that (1) Complete machine control essential. (2) Engineering adaptation necessary; that is, the machines must adapted the furnaces. (3) Edu- The Age, June 26, cation the personnel will overcome the initial sus- picion with which machine control regarded; first the service man finds acceptance, then the equip- ment, then the operation. (4) Supplementing the man machines requires regulator; this dynamic job, designed keep moving elements balance. (5) The machine control system must line with placing responsibility where belongs. must work the flow gases, rather than mere temperatures. Temperature result the conditions the furnace and the work must applied the cause. this means, have been able reduce the fuel consumption from per cent, with increase production. Suggests Abandoning Reversal Flow Air and Fuel complete control system divides itself into control combustion and control reversals, ac- cording Mr. Higgins the Shallcross Control Systems Corporation, Milwaukee. control com- bustion—that is, the ratio air fuel—by measur- the excess oxygen the waste gases. may also adjust the ratio air fuel balancing the differentials their respective flows. Furnace atmosphere most important factor. With excessive draft there will air infiltration through the doors. With good control, can bet- ter regulate the amount air drawn in. this point the speaker expressed the view that the time might, perhaps, near when can con- sider and design the open-hearth furnace one- way furnace. favorable heat balance hard get now. The temperature requirements the open- hearth will not permit the use the ordinary air and fuel reheater. But the speaker believes that the future will give improvement over the present two-way method open-hearth practice. a 1890—The Iron Age, June 26, 1930 Carbon monoxide recorders the stack are not very satisfactory measure combustion for open- hearth furnaces, one man reported, because the variable emission CO, from the bath. Neverthe- less, they indicate measure the efficiency combustion. For example, within limits, high reading registers good combustion, and vice versa. Control Keeps Furnaces Running Evenly Air supplied the open-hearth furnace, the opinion Mr. Greenburg, the Bailey Meter Co., Cleveland, care not only for the needs the fuel, but also for the combustible coming off from the bath. The meters either tell the operators what adjustments make, or, with automatic control, themselves actuate the control devices. open-hearth man reported having five fur- naces orerating with automatic reversal based temperature control. said that the best running furnaces were those running most evenly. Occasion- ally all furnaces will get into condition un- balance, and the operator will complain cold end. The control helps the combustion providing constant supply preheated air. Mr. Shadgen told studies made the element conversion costs per ton between pig iron and steel. These have been widely variant, but general average around was cited. this amount fuel represents about $1, direct labor $1, and ma- terials (for maintenance, etc.), $1. Thus, there only about ton the fuel costs, which work with any control system. closing the discussion, Leahy, combus- tion engineer, Youngstown Sheet Tube Co., Youngs- town, who presided this session, remarked that control systems are designed essentially aid the first helper, and not substitute for him. the Field Museum, Chicago, there have been constructed four figures typical native iron workers the Tinguian tribe the Philippines, one them woman. The forge was obtained the village which means the town many maidens. one the communities noted for fine heads and spear points. 7 | ! 7 q ‘ y r | 4 | | 4 > Closing Markets Results Excess Capacity Consumer Goods HAY HEN competitive advan- tages represented vari- ous formsand modifications monopoly have, large extent, become equalized industry producing consumer goods, highly probable that the market may closing already lim- ited. Modern methods mass pro- duction and mass distribution have resulted the rapid saturation new markets and the early clos- ing parts such markets, not the whole. Rapidly expanding markets attract more and more manufacturers and the potential production all tends equalize the advantages low manufactur- ing costs. The cumulative effect rapid increases plant facilities devoted the mass satisfaction markets over-capacity for the available market. natural for industry ex- pand its potential ability pro- duce more goods, and the progres- sive manufacturer must provide ex- cess plant capacity order keep ahead the actual demand for his goods and preclude the possibility shortages. When sufficient number manufacturers the same industry expand this way, any recession demand finds each with excess capacity unless produc- tion continues. This what hap- pened the radio receiving set industry last winter and resulted the withdrawal many companies because financial difficulties. dustry”) Until Generally speaking, markets remain “open” long consumption continues expand, but when the rate increase diminishes small percentage, when the additions the volume goods “in become approximately equal from year year, the market may said This observation holds true for entire industries and particularly true the case individual corporations, two sam- ples which are presented—one manufacturer washing machines, the other motor car builder. both illustrations, the industry first became limited and afterward the market for the particular manu- facturer was satisfied. consequence, neither has Closing Market for Washing Machines ALES Single Washing Ma- Increased Much More Rapidly Than Production for the Entire Industry In- 1927, When Com- petition From Other Manufacturers Forced Retrenchment. the individual manufacturer was keeping with its sales, but rate increase much sharper than that for the industry whole could not maintained all chine Maker been able make advance re- cent years. Expand After Their Markets Close spite the closing their markets, each these highly pro- gressive manufacturers continued expand their plant facilities for some time after consumption their own article ceased gain. rational increase plant facilities would have been the same rate the growth demand measured the actual consumption their markets. Thus, the potential pro- duction facilities the motor car manufacturer might have been ex- panded, after 1926, the same rate registration was expanding. Additional capacity have been secured, not new buildings and more tools, but improving methods, thereby secur- ing further reduction manufac- turing costs. the contrary, there has been actual decline plant efficiency because this management, having excess capacity, has not yet felt any necessity improve meth- ods order secure needed pro- duction increases. manufacturer not protected patents processes can surpass competitors for extended period. Low manufacturing costs may secure temporary advantage, skill merchandising may enable manufacturer forge ahead all competitors for while. But the passing time, competitors will appropriate the ideas and adopt successful methods until these tem- porary advantages are equalized. the case the washing machine manufacturer, the management either planned secure much larger share the market than was entitled to, else grossly overesti- mated the actual consumption its market. any event, there has been steady decline nearly per cent annually the dollar volume sales per dollar value net plant investment. The excess capacity this manufacturer now real burden the busi- ness. Capacity After all, the measure any manufacturing suc- cess the ability the business continue earn The Iron Age, June 26, | 7 regular and increasing profits for the real owners,— e., the holders the common stock. Neither the corporations discussed has made any increases earn- ings since 1926, nor likely recover any ground this year. Pressure Surplus Capacity Intensifies Competition The pressure excess capacity closed markets, coming usually times lessened activity, leads the intense competition frequently prevailing. Those manufacturers who have survived usual- are financially strong and are able attempt secure production more giving greater value for the same price, and But most increase other means. the secured one manufacturer necessarily must the expense his com- petitors’ business and this leads the con- stant shifts within the industry that are char- acteristic limited markets. The most not- course, the withd