The Iron Age 1930-09-04: Vol 126 Iss 10

W. W. Macon, Editor Cc. E. Wrieut, News Editor E. F. Koon R, E. MILLER G. 8. Herrick F. L. PRENTISS Cleveland Chicago Pittsburgh BURNHAM FINNEY Detroit L. W. MOFFETT Washington GERARD FRAZAR Boston R. G. McInNtTosu Cincinnati IRON AGE PUBLISHING Co. 239 West 39th Street, New York, N. Y. Cable Address: ‘‘Ironage, N. Y.’’ F. J. Frank, President G. H. GrirritHs, Secretary Baur, General Advertising Manager Division UNITED BUSINESS PUBLISHERS, INC. New York, N. Y. District Offices: Cuicaco, Otis Building 1319 Park Building CLEVELAND, 1362 Hanna Building PHILADELPHIA, 1402 Widener Bldg. Detroit, 7338 Woodward Avenue WASHINGTON, 536 Investment Bldg. CINCINNATI, 409 Traction Building 616 Ellicott Square tosToNn, Room 230, 80 Federal St. San Francisco, 703 Market Street Copyright, 1930, by AGE PUBLISHING Co. Member, Audit Bureau of Circulations Member, Associated Business Papers Published every Thursday. 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Contents for September 1930 Plans The Iron Age 605 Executives Discuss Cost Reductions 606 Waste and Safety Campaign 611 Heat Treating Tractor Parts 615 Rubber Coated Plating Equipment 618 Scientific Control Steel Making 620 Reducing Costs with Electric Trucks 624 Hardening Large Forgings 626 Machinery Exports Depressions 628 Selecting Abrasive Wheels 630 Dr. Haney’s Page 637 August Pig Iron Production 661 Export Statistics 673 New Equipment 632 Editorials 638 Markets and News 641 Personals and Obituaries 663 Business Others See 676 & Reader Service Man Investigates UST dropped into the sanctorum Cone, our metallurgical editor, find what has the fire for next week’s issue, the convention number. recited list high spots yard long; Sergeson nitriding, Dr. Anderson heat treating alu- minum alloys, Bornstein heat-treating gray iron castings, Lorenz heat-treating steel castings, Herbert Boylston recent progress heat-treat- ing, Robert Keeney heat-treating furnaces, Moore heat-treating airplane engine parts. And that isn’t all. all-star cast. there any im- portant development the heat-treating field that isn’t discussed next week’s issue, will have develop between now and next Wednesday.—A. ; AT EP G ‘ THE IRON AGE September 1930 Millholland devises this novel use for New Departure Ball Bearings connection with the combination tool spindles this new Millholland machine, New Departure Ball Bearings support sleeves which turn give rigid and accurate support the spindles which reciprocate through them. These sleeves are located closely possible the tools that all tendency deflection from side thrust overcome. Rotary motion communicated the sleeves key and keyway con- nections with the spindles. Twenty-four New Departure Ball Bearings support these and all other vital shafts machine which 300 pistons per hour are bored, faced the open end, centered the closed end, and their wrist pin holes drilled. New Departures simplify the lubrication problem, prevent vibration and chatter the high speeds necessary, carry thrust and all other ioads with the least possible loss power. New Departure-equipped machines are better from the start and cheaper the end. The New Departure Manufacturing Co., Bristol, Connecticut. q q wil your budget keeping with present reduced production vol- ume and narrower profit mar- gins? Saturday afternoon meetings department heads economies are decided upon. Pay- roll deadwood eliminated; tory expense budget cut; general labor for each department budg- eted basis direct labor.— Page 606. Factory expense waste elimination campaign. formed its standing. dis- play boards each department are fastened broken tools, parts and supplies. President’s cup awarded for best record.—Page 614, * * * Warpage heat-treated parts allowed for machining. Mill- ing wearing surfaces motive cross heads with slight concavity results such straight surface after quenching that less than 1/64 in. metal needs ground off.—Page 626. * * * Electroplates rubber metal racks provide acid-resisting surface. Excellent for plating use, the rublier insula- tor and prevents current losses. —Page 618. Steel seldom injured the finish rolling, steel maker finds. Practice has abnormal harm the quality the steel. Open-hearth and blooming de- partments are properties are made.—Page 623. Why will two grinding wheels the same specifications give different results? Cause: Va- riation the amount abrasive the wheel relation other factors, abrasive manufacturer finds. This factor can now controlled within one per cent.— Page 630. Saves space department mounting switch- board transformer equipment top furnace.- Page 616. * * Carburizing pots made cast iron water pipe. Long pieces are made from pipe, ft. long. plate forms bot- tom.—Page 627. * » Heat loss charging carbur- duced using electric truck. Work that formerly took nearly tion the time six men saved per shift. Direct labor saving alone 624. Export market huge volume metal-working equipment, says Department Commerce executive. Proper cul- tivation should result tinued heavy exports.—Page 628. * Cuts accidents per cent safety campaign. Every depart- ment inspected each month chief safety committee, com- posed three general foremen executive. weekly meetings recent accidents are discussed.—Page 611. * a Heat loss heat treating trac- tor parts reduced mini- mum use conveyor which operates entirely within the fur- nace. Chain belt acts hearth.—Page 615. Foremen submit service card record every six months every employee. Employees are rated various qualifications, one which “Co-operation Waste Elimination.” Employee given copy. poor record, con- tinued, reason for dismissal— Page 614. Tensile strength drive shaft raised more than per cent using chrome-nickel-molybdenum steel instead chrome-nickel. The addition molybdenum makes appreciable improve- ment the physical properties the steel.—Page 615. * Rubber-coated plating tanks have long life. Rubber sheets cemented metal surface and hand-rolled exclude air, that perfect adhesion will ob- 618. Casting rejects reduced from per cent 2.3 per cent. Waste campaign shows marked results brass foundry opera- tion.—Page 614. * * * Double hardening gears, with first heating 1500 deg., and second 1375-1425 deg., gives best results treating tractor gears.—Page 616. + Free use optical pyrometers educates eyes steel melters judging steel and furnace tem- peratures.—Page Old foundry flasks serve furnace structure for carburizing ft. cross heads.—Page 627. Unintentional variations from recommended times lead the way improve- ment standard practice, steel maker finds.—Page 622. * For the success economy campaign, necessary almost every company these days, try get everyone your organiza- tion act intrepreneur, rather than routine em- ployee. you can this, you will get outstanding results.— Page 606. | THE IRON AGE September 1930 Warner Swasey Turret Lathes are use one department alone having replaced lathes, special machines and other turret lathes WORTHINGTON PUMP AND MACHINERY CORP. Harrison Works, Harrison, Their work would ordinarily require constant tool changes, but they eliminate this with WARNER SWASEY Turret Lathes and standard tool set-ups. The Warner Swasey Company Boston : Buffalo : Dallas: Dayton: Chamber of Commerce Bldg Iroquois Bldg. 618-4 Washingt Blvd 805 Newell 610 Mutual Home Bldg. Detroit: Indianapolis : Los Angeles: Milwaukee : 5928 Second Blwd 4473 College Ave. 1118 Santa Fe Ave. 1143 Wells Bldg. The Warner & Swasey Co. of Calit. New York: Philade|phia : Pittsburgh : St. Lou Singer Bldg. 5143 Spruce St ibe merece Bldg. 527 yracuse : 108 Grant Ave. Cleveland, Ohio, U.S.A. THE IRON AGE New York, September 1930 ESTABLISHED 1855 VOL. 126, No. BROADENED SERVICE For New Industrial Epoch BROADENED editorial service begins with this number The Iron Age. Changes introduced both program and methods presentation are tune with the increasing intensity industrial effort. Some four hundred additional pages year have been allotted the discussion produc- fully rounded schedule publication has been laid out the tion methods and practices. result extensive field studies. The plan covers revised balance and periodicity dealing with the various phases reader interest, while time- liness will remain cardinal principle our policy. Our editorial staff has been enlarged and strengthened and contacts metal working plants have been broadened. Henceforth, the business news the metal- working industry, the market reports, price quotations and other commercial information will appear special section, printed tinted pages for ready reference. new feature this section will weekly survey industrial construction. This will sup- plement the weekly summaries that have long been dependence shaping the plans industry. Three barometers trade will now 605 available: one based raw materials, one machine tools and third expansion industrial plant and equipment. For the busy general executive, who must keep touch with developments all branches the industry, have devised system “half-minute present the salient These, and the summaries the tinted news section, points leading articles glance. will keep this type reader posted with mini- mum expenditure time. The “suggestive executive another new feature calculated enhance the value The Iron Age. Questions which executive might fitably ask respecting his own methods and practice are presented with the articles that suggest them. All these forward steps aim serve the reader with maximum timely aids and thus promote commercial and technical progress the truly majestic industry the making metal products and machinery. Editor. have with today, this IRON AGB Executive Round Table, number gentle- men who are the heads important indus- trial organizations. Each them has faced, during the past months, the necessity making adjustments methods and policies meet new conditions, and placing added emphasis the subject cost and reduction. All us, with few exceptions, are confronted the same problem earning profit through economies instead through increased volumes and turnover. Regardless upturn business conditions, all will face this condition for months come, during the readjustment period. expense The methods that these gentlemen have found effec- tive the solution this problem their own or- ganizations are applicable other organizations all branches the metal-working industry. Briefly put, these methods resolve themselves into inten- sive application the question mark. this informal discussion very timely sub- ject, shall hear from five chief executives diversi- fied branches the industry, who have consented tell something about the ways which they have FRANCIS FARQUHAR 606—The Iron Age, September 1930 CRAWFORD Executive Round Table—conducted John put the question mark work meet present day conditions. hope that the readers THE IRON AGE who are sitting with this round table will join the general discussion the subject, which will presented later issue, submitting constructive suggestions drawn from their own experi- ence. The first gentleman that shall hear from today the chief executive large and well known con- cern which manufactures agricultural implements, presses and wood-working machinery, Mr. Francis Farquhar, president, Farquhar Co., Ltd., York, Pa. Mr. Farquhar: soon realized the serious- ness the situation, arranged for meetings Saturday afternoons with our various heads depart- ments. The first object was over the payroll, and eliminate such deadwood might found. But this object soon broadened out considerably. our intensive use the question mark, had thought that had very good budget system. Evidently, however, thought knew more about this than actually did, for when got going into the matter and actually began budgeting the various KRAMER | NIG the ES (0) IN| { Van Deventer, Industrial Consultant, THE IRON AGE Half-Minute Summary ARNING profit reduced production volumes the problem good management now solving. done through the intelligent and systematic questioning operating costs and expenses. this Age Executive Round Table, number heads important companies tell how they are applying the question mark their work, and with what results. departments, the situation became quite illuminating. “First, took the features common all depart- ments, such repairs equipment, repairs machinery, small tools and buildings. found that were spending entirely too much these items comparison with the business being done, and that during 1928 and 1929 the figures covering them had been literally running away. planning our new budget, however, did not forget that decidedly unwise allow machinery equipment deteriorate. But could and did arrive budgets for the various repair items each department. “Next, took the subject general labor RYAN being each department, and tried arrive ratio one general laborer for many mechanics. course this figure varied among departments be- cause the nature the work, but finally were able fix upon ratios. Following this step, took the matter determining budgets for such items crane operation, minor supervision, trucking and handling, oiling, lumber inspection, stock-keepers, yard men, etc. were not always accord these budgets the outset, but finally determined upon them. This resulted our having rather complete set sub- divisions each department, fact have covered some one hundred and fifty separate divisions. Some these have been and are being revised from time time. All these budgets, the way, were finally Participating this Iron Age Conference: FRANCIS FARQUHAR President, CRAWFORD President, McKeesport Tin Plate KRAMER President, Columbian Steel Tank Co. RYAN President, Ryan, Scully € Co. DIAMOND President, Federal Screw Works DIAMOND The Iron Age, September 1930-—607 900 based the productive labor each department, which brings them line with production volumes. the non-productive departments such the pattern making department, the labor new patterns was classified productive. “It very instructive over the budget results each month. having number our leading men this not only know where our expenditures have been excessive, but often see where can make further substantial sav- ings. “While were about it, went ahead with the budget matter tended our sales department. This process conditions and the charac- ter our output change. “We have not reduced wages, nor, far know, has anyone this city. “While this budgeting work has proved extreme- interesting us, even more interesting has been the revision our produc- tive work methods. This has been going with more extensively than before and have succeeded making some striking improvements. Since this also probably going quite universally indus- try whole, the depression will probably not without some wholesome effects. course inefficient production methods should not tolerated any time, but when conditions make necessary ques- tion work-methods from the ground up, seems easier detect inefficiencies and make changes. “Finally, are endeavoring, through changes our output and budgeting methods our sales depart- ment, overcome seasonal unemployment and seasonal rushes work. While this really the hardest task all, believe that are making progress; and, indeed, know that has been very substantial progress compare results with those eight ten years ” ago. Thank you, Mr. Farquhar, for the very helpful comments that you have made, upon the basis your own experience. believe that the depression has thoroughly industry the usefulness budgets, and that many concerns that have not used them heretofore will soon doing so. also believe that many executives have found necessary question their budgets question operating prac- tice, for fixed ideas any kind, even budgeting, are harmful. expected that there will more oppor- tunity for “taking the slack” plants having wide variety more less complicated products than plants making simpler products which are highly standardized, assuming equal grade manage- ment ability present both. Can the executive question mark much for the plant with highly 608—The Iron Age, September 1930 standardized product and highly specialized opera- tions? The manufacture screw products represents extreme case specialization. the question mark can make real progress economies such plant, should able business anywhere. have asked the president the Federal Screw Works, Detroit, Mr. Diamond, tell something about his recent experiences this connection. Mr. Diamond: “Like good many other concerns, prided the past the fact that were constantly striv- ing keep overhead ex- penses line, reduce manufacturing costs and stimulate sales. That was before the industrial depression. Now, the light our experience since that time, must admit that there was still considerable room for im- provement. The depres- sion has forced not only our executive staff but our whole personnel put forth much greater effort. have been really sur- prised the results obtained when concerted effort this sort made for the purpose effecting savings. “We, too, have found that the most important step toward economies the closer scrutiny expenses that obtained through budgetary control. our case, important part this the close executive scrutiny which given purchase requisitions cov- ering raw materials, tools, supplies, etc. have found that many cases requisitions are made out for purchases that are not absolutely necessary. other cases, have found that they raise the ques- tion whether change our methods might eliminate reduce the expenditure. use such things the means starting every one interested the matter thinking constructively for the interest the organization. “We have found particularly helpful encourage the constructive use the question mark throughout the entire organization. This results increased efficiency manufacture for the reason that every- one, from the superintendent down the humblest worker, continually striving eliminate waste helping the other employees their work more efficiently. During economy campaign this sort, belief that the shop foremen, particular, are made some real constructive thinking along the lines efficient manufacturing. “In conclusion, should like leave this thought with you, which summarizes our experience few words. During time like the present, try get everyone the organization act the capacity entrepreneur, rather than routine employee. this spirit can instilled throughout organiza- tion, the results will stand out representing progress.” 7 7 | Mr. Diamond has given idea that should great value every concern that faced with the problem effecting economies. economy program which exists the minds few executives not likely maximum effectiveness. economy program, however, that thoroughly favored approved all the members the organization, will produce the required results through concerted action. Whenever there major change the tide business, industry and its management are faced with new set problems. During the past few years the problem increasing sales and production volumes and quickening turnover occupied the chief part managerial attention. Now, the emphasis laid upon cost and expense reduction. What will the effect this future industrial activities? Having found the new effectiveness the question mark, will management content lay aside when the tide turns again, are entering upon era which will representative higher degree industrial efficiency have asked Mr. Crawford, president, Keesport Tin Plate Co., express his views this phase the subject. Mr. Crawford: “It belief that depressions trade, such have had since last September October, always result good for the future. have found, going over our plant from beginning end, well having combed with fine tooth comb every item expenditure, that have been able effect some considerable economies. fact believe that during the past two three years, have been able effect economies which more than represent the actual net profit are making all the tin plate sell today. opinion also that profits the larger lines manufacture must made economies every direction, such purchasing, manufacturing, marketing, etc. “It also candid opinion that more attention were given things this kind instead laying much stress the matter depression, which many cases psychological rather than real, would have generally better feeling, which would result generally better business.” believe that Mr. Crawford right his opinion that tomorrow’s profits must built out today’s economies. And this true, the lessons that industry now learning the more effective use the question mark, should considerable value future prosperity factor. One attractive and valuable feature the execu- tive question mark its universality. matter where applied, large small organizations; matter what the product services offered may be, applied intelligently and persistently produces results. some cases leads refinement methods reduction costs and expense items. other tases the results may far reaching include complete reorganization. have mind one which the intelligent use the question mark the light existing busi- ness conditions led engineering and sales organiza- tion the industrial heating field expand include manufacturing well. The president that organiza- tion, Mr. Ryan, Ryan, Scully Co., Phila- delphia, will now tell how the use the question mark brought this about. Mr. Ryan: “Although our volume business booked the first this year was large, and there Suggestive Executive Questionnaire 1—Have set proper organization for the purpose applying the question mark? 2—Have instilled the spirit constructive questioning throughout our organization, that its members take nothing for granted? 3—Are utilizing the competitive principle between departments and individuals our search for cost reducing possibilities? 4—Are budgeting indirect labor the basis direct labor hours, make its ratio proportionate production volume? allowing fixed budget handicap the search for progressive cost and ex- pense reductions? other words, have sufficiently questioned the budget? instituted thorough study the possibilities revision productive work methods? 7—Do maintain list the economies that have been made since the change business conditions, and who have suggested and effected them? our inventories been reduced proportion decreased production volumes? Are applying pressure make them still lower? 9—Have effected system thorough executive criticism purchase orders? 10—Are avoiding possible cancellations through the making quick deliveries? 11—Are paying enough attention getting the small orders that our salesmen might ordinarily The Iron Age, September 1930—609 was distinct evidence depression, noticed contact with our sales work that more men were being brought into our prospective customers’ sales dis- cussions. also noticed that the purchasing agent seemed have more power than any time during the past eight years. “This indicated that while there was going business, the buying was going close and the competition keen. That opinion has been definite- borne out, for while have been able keep going 100 per cent basis and have kept incompleted business volume safe margin, have been compelled take business lower fig- ure than ever before. believe that this condition not going improve, but fact, will become intensified. “Unless your profits have been ex- orbitant, when you must take business lower figure, there are but two ways out for you; one increase your vol- ume, the other your cost operation. reduce “It difficult thing increase the volume business poor market, the alternative lies reducing the cost doing business. Possibly you will interested finding out how solved that particular problem. have “Originally functioned engineering or- ganization. Some four and half years ago, however, established small research shop, and by- product, did some our own switchboard and control valve work. Profits seemed accumulate, moved larger location and finally built our present headquarters some three years ago. that time felt that was good for ten years. But when the change business conditions occurred and put the question mark work, decided that the control production many our products, could find the additional profits necessary solve our problem. immediately arranged for the erec- tion new plant. “Among the advantages secured this way are quicker deliveries which will eliminate lost orders, the doing away with trucking charges considerable amount, savings volume purchases and approxi- mate reduction per cent production costs. addition shall make substantial savings increas- ing 100 per cent the volume products which can shipped complete, thus saving erection expense. The establishment research laboratory contain- ing all types apparatus makes possible demon- strate and close sales our own headquarters, rather than make costly trips isolated locations. “The next question was where could increase our output normal products already established standard? determine this, made study every article that were producing. The result that many them are now being pushed new and diversified fields. division, after the There great thrill obtaining large But large order usually involves cut “Putting the question mark our sales found there the quite natural desire big orders. order. 610—The Iron Age, September 1930 price, takes long time sell, and not attractive from profit standpoint group small orders reaching the same volume. patiently showing our salesmen how this attitude affected them adversely well the company, have been able increase materially our volumes small sales nearly every district. This has carried through period that might have looked bad otherwise. “Finally, applied the question mark our accounting and cost divisions. Strange may seem, found many items that were being sold loss. found that our buying was bad spots and that had many unbalanced items our inventory, i.e., items which were carrying large quantities over long periods and others which quick sales made the inventory other items inade- quate. “In connection with inventory sav- ings, you may interested how these are affected the addition plant fa- cilities. Because our previously man- ufacturing only approximately per cent our own products, practically our entire inventory represented finished items, such burners, control valves, blast gates, switchboards, etc. the total value these about per cent productive labor. Our new facilities will enable carry double the inventory products that can finished almost immediately, and yet this will involve total inventory reduction over per cent. “The foregoing represents the high points what have learned through putting the question mark work. would not say that all the deficiencies have been corrected, but least know where they are, and are after them aggressively.” The interesting experiences that Mr. Ryan has just related bring out point that well for all deficiencies eliminate inefficiencies once know where and what they are. The hard thing find them. That where the use the question mark comes in. good times are busy with other things that not find time use properly and result, inefficiencies are bound creep into our plants and hide away. There little doubt that continued prosperity tends decrease industrial efficiency. From the long term view, “technical correction” they say the stock market, good thing for us. Business depressions are bitter pills take, but they produce tonic effect upon the industrial system. would keep the question mark work in- tensively when business good, perhaps would never become bad. Some concerns have found this statement true and have made greater profits during the past year than ever before. One these the Columbian Steel Tank Co. Kansas City, Mo. said that Missouri the original home the question mark, the form the well known expres- (Continued page 676) = Accidents and Waste Greatly Reduced Ohio Brass accidents almost the point elimination has been attained the Ohio Brass Co., Mansfield, Ohio. This has been accomplished arousing the interest the rank and file workers accident prevention. Results indicate that the desired goal accident prevention cannot reached without the hearty cooperation employees. Another outstand- ing feature the management this plant the organized efforts that are being conducted elimi- nate waste, which also are bringing good results. Previous 1927, the company limited its safety work mechanical requirements, giving attention educational work along safety lines. safeguarded its machinery conformity with the State law, and some cases protected workers greater extent than the law re- quired. 1926 the company had 279 lost-time accidents, REMARKABLE record reducing industrial What the Ohio Brass Co. Expects Its Men Co. Campaign work among its men and reduced its lost-time acci- dents 20, which the injured employees were incapacitated for more than one week. Going few steps further 1929, the company effected safety work organization covering the entire plant and succeeded reducing its accidents per cent from the year before. During 1929 had lost-time accidents, six which kept employees away from work for more than one week. Under the operation this plan, the record for the first six months this year indicates that there will further reduc- tion accidents this year. During the six months’ period 1930 there were three lost-time accidents, all for more than one week. Two the injured had previous accidents and were guilty contributory negli- gence. The plant employees the conduct the safety work are divided into three groups and the activities are conducted more than one week the in- largely through these group jured employees. During 1927 good work. organizations. The plant has the safety problem was put departments and these are the foremen. While respon- dependable. grouped that sibility for preventing acci- groups are nearly equal size dents was placed the fore- men’s shoulders, they were not given any direct help this direction the management. However, with certain amount interest aroused among the foremen, lost-time accidents were reduced 1927 more than one week lay-off. Educational Work Among Employees 1928 the management ex- tended its accident preven- careful. Take good care property and materials. clean and orderly. punctual and industrious. Follow instructions willingly and intelligently. agreeable and cooperative. numerically. The guiding body the safe- organization general safety committee four, which member the staff the director personnel chairman, the other three be- ing general foremen, one whom serves supervisor for each group, team chair- man. The group chairman appointed the director personnel. Each group chair- man has safety committee each department his group that works with the depart- The Iron Age, September | \ \ > ‘ SAFETY TEAM RECORDS » ACCIDENTS One the safety boards. the center light for each day the month. White lights indicate the days which there have been accidents and red lights days which accidents have occurred. the left are the records the various teams. the right are the records the various factory departments. ment foreman. The size these department com- mittees depends the number employees the department, committee consisting about per cent the employees the department. ings are held once month and are attended all the workers the group. All safety meetings are held during working hours. The general safety committee four meets once Group Meetings Held Once Month week. these meetings list every accident that occurred during the week reviewed and later each group chairman checks back the accidents his group with the foreman the department which the accident occurred and with the employee injured, regardless how slight the accident may have been. This done the theory that the dif- ference between major and minor accident only one degree and that there might have been much carelessness involved minor accident one that resulted the more serious injury. The general committee also makes complete inspection the plant once month, being accompanied through each department the foreman that department. Each departmental committee also holds meeting When the safety organization was first effected, three group meetings were held, during which the director personnel explained the purpose the organization and gave talks the prevention accidents. Now that the safety organization func- tioning smoothly, the monthly group meetings are conducted the group chairmen. These group meet- Safety Campaign Greatly Decreases Accidents Number Accidents month review its record for the month and fotal Accidents Resulting in Over One Week Lost Time receive any information that the group supervisor may have offer. No safety work bevond oh- servance laws requiring order maintain the greatest amount in- terest safety work three foremen serve group 1927 supervisors for only one year. The next year they Safety work limited super become group chairmen the committee waste. replacing one set with three other foremen after year’s service, there increase each year the number foremen who have served group chair- men, have developed interest safety work, are familiar with safety rules and are inclined offer the heartiest cooperation their successors. The general chairman holds over from year year. Un- der the plan safety organization that the manage- ment regards highly efficient has been set without the additional expense having safety Employees number about 800, the average not showing much director and perhaps assistants that would devote all their time safety work. vision foremen 156 1928 = Cooperation of employees 1929 work carried under plant satety organization Months Continuation safety work 1 1 under plant organization The three group chairmen are sent each year 612—The Iron Age, September 1930 MENTAL i : = | | . the meeting the National Safety Coun- cil the company’s expense and the more members the department committees are sent the annual safety congress held under the auspices the Ohio Industrial Commission. Posters Plant Stress Safety Various methods are maintain interest among the men safe- work. Attractive safety posters made the plant are displayed here and there and, because these their design always have local color, they are regarded much more appealing than standardized safety posters, although few the lat- ter are used. safety board located each the two main entrances. these lights are displayed for every day the month white light denoting accidents for the day and red light accidents. Red and white lights also show the standing group team for the month and year. addition each department listed with the number days that has operated without accident since Jan. 17, 1928, when the plan was put into effect. This chart shows that number departments have not had accident since that date. This display acci- dent records tends maintain interest the work and arouse rivalry between groups and departments. The spirit rivalry also fostered the award each year silver cup safety trophy the one the three groups that has had the fewest accidents during the year. Located the center each department above Ae in, 29 Stop waste display board that won the first prize and was awarded the cup. PROPER LUBRICANT---PROPERLY USED SAVES the main aisle flashlight that flashes bright star suspended metal mounting that bears the words, “Safety Pays.” Waste Elimination Campaign Resultful The waste elimination activities include educa- tional work under the direction the group com- mittee that served the previous year safety com- mittee and headed member the staff the manufacturing superintendent. Standing con- spicuous position each department display board, attractive appearance, that visually presents message waste elimination. Many the boards bear the slogan, “Stop Waste—Increase Prosperity.” Each department designed and built its own waste elimination board, and prize cup was awarded the department having the most attractive and ap- pealing board. Attached the boards are displays broken small tools, parts and supplies, and adjoin ing are figures which show graphically the loss caused the breaking tools, the breaking parts han the upkeep machinery and other items that can included factory waste. The educational training the men waste elimination, which part the waste elimination program, includes ex- planations the employees regarding the require- ments production and why parts, sometimes seem- ingly satisfactory, have rejected. evidence that this campaign, which was started Jan. 1929, bringing good results, the molding The Iron Age, September MACHINERY loss the brass foundry due rejected castings was reduced from 4.07 per cent 1928 2.3 per cent last year. Deliveries from the factory the warehouse 1929 increased per cent from 1928, but the actual operating factory expense overhead was $65,000 less last year than during the previous year. Included these expenses were tools and other supplies, repairs machinery and equipment and non-produc- tive labor. While analysis the reduction over- head has not been made, the management satisfied that the saving due largely the elimination waste. Two sets rules, one for the foremen and the other for the workmen, designating their duties from waste elimination viewpoint, have been established the waste committee. The foreman’s duties, designated, are listed accompanying box. President’s Cup Awarded for Efficiency incentive the men, president’s cup was awarded last year the departments making the best records for efficiency waste elimination and oper- ation. This cup went three departments, the first, second and third winners. Permanent possession the cup will given the department that wins twice succession, and that event new cup will offered prize. The cost department records will used this year determine the successful con- testant for the cup, which will the department showing the greatest efficiency operations indi- cated these records. feature the company’s system management the keeping the record each employee ser- vice cards that are made out every six months the foreman. While this separate from the waste elim- ination work, the same qualities are listed essential for successful worker are specified for work- man from the waste elimination viewpoint. Conse- quently the purpose the cards indicate whether the man has the same desired qualities that are listed his duties from waste elimination standpoint. addition several questions relating the man’s personal affairs are listed the service record cards. The foreman answers the questions regarding the worker’s record the shop with yes no. The cards are made out triplicate, one going the director personnel, one the foreman and the third the employee. “no” appears after the same question twice man’s card, called the carpet and may discharged. The foreman also held responsible and asked explain why the man has not improved. Perhaps the man better fitted for different class work and can show satisfactory record card transferred different department. The worker knows from his card what his short- comings are the eyes his foreman and has opportunity mend his ways. Sometimes the em- ployee objects the grade given him foreman and threshes the matter out with the foreman and director personnel. The service cards are used spirit helpful- ness and means aiding the men better work. The management finds there only one type man who cannot helped—he the one who will not help himself. Duties Foreman Ohio Brass Co. Plant Have clean and orderly department. receptive frame mind recognize waste when you see when pointed out you. When waste found, analyze for cause and eliminate the cause. Proper supervision of. work and workers and good discipline. Advance planning production, intelligent assignment work, and proper instructions. Use proper machines, tools, materials and methods. Know the product and its service requirements. Show proper appreciation good work and cooperative effort. Develop “shop pride,” “department pride” and “individual pride” workmanship. real friend your people and have return their friendship and helpful cooperation. 614—The Iron Age, September 1930 4 ic ‘Ss Practice Making Tractor temperature control, high quality work, saving floor space and reduction handling labor have been ef- fected the installation continuous electric furnace for heat-treating parts for crawler type tractors the plant the Cleveland Tractor Co., Cleve- production, close land. The furnace new. chain belt conveyor type, built the Electric Furnace Co. This furnace used for hardening transmission gears and the rollers, bushings and EVERAL alloy steels are used the various parts crawler type tractor. These must carefully and accu- rately heat treated bring out maximum physical properties. claimed that larger output, closer control temperature, combined with better quality, are obtained from the use electric furnace for heat treat- ing. Also there pointed out this article the consequent saving floor space and reduc- tion labor for handling. De- tails the furnace and the heat treatment which the va- Parts tion chrome-nickel-molyb- denum steel place chrome- nickel steel, SAE 3145 for the rear axle drive shaft, which subjected very severe strains. The physical properties the steel are improved molybdenum content, the ten- sile strength having been in- creased from 165,000 per sq. in. from 180,000 190,000 lb. Most gears are made per cent nickel, per cent nickel and nickel-chrome steel, SAE Nos. 2315, 2512 and 3310 re- spectively, drive shafts are made nickel pins that, with the shoe, form the track shoe assembly, parts that are subjected very hard and abrasive wear. The sepa- rate track shoe assemblies are joined together pins forming series track as- sembly. also discussed. Rollers Made Steel Tubing The rollers are made seamless steel tubing, SAE. 3120. Tubing, in. outside diameters, used depending the type tractor. This cut lengths, then the outside diameter turned and the inside diameter broached, after which the pieces are carburized, hardened and drawn. The shoes are chrome steel castings that are heat treated the foundry that supplies them. The bushings and pins were formerly made alloy heat-treating steel, but recently this was changed plain low-carbon carburizing steel, SAE 1020, secure parts that, after carburizing and case hardening, have harder surface. While the cost this steel lower than that the alloy steel formerly used, this offset the increased cost carburizing compared with heat treating. Another recent change material was the adop- rious steels are subjected are and nickel-chrome steel. Driv- ing gears and lower truck wheel shafts are made medium hard, plain carbon steel, the former, SAE 1045, and the latter, SAE The continuous conveyor furnace, which 110-kw. capacity, has flexible endless chain belt in. wide with side flanges, the conveyor serving furnace hearth. operates entirely within the furnace, thus reducing the heat loss minimum The work loaded directly this belt, through the furnace and removed through side dis- charge door, the unloading being done with tongs when individual quench desired. alloy steel chute, with water cooled extension, pro- vided permit work discharged directly from the conveyor into water quench, but present pieces are handled from the furnace hand either water-quenching tank special type, oil- quenching machine located the side the fur- nace. The furnace provided with variable speed transmission, giving range 120 min. the heating chamber. With the schedules used the The Iron Age, September 1930—615 | Quenching machine rear furnace and transformer switchboard and con- the work kept the fur- nace. From 500 800 are being heated the furnace per hour. The furnace chamber divided into two zones, one for heating and the other for soaking, and pro- vision made vary the heat input over wide range each zone well the entire furnace. Heavy cast grids are mounted above and below the belt, insuring even heat distribution over the entire charge. The switchboard transformer and control equipment are mounted above the furnace save Oil-Quench Machine Provided With Conveyor oil-quenching machine provided with overhead, intermittently operated, conveyor consist- ing double strand chain with cross bars between the strands, each chain running over four sprockets. The gears other parts oil quenched, be- ing drawn from the furnace, are placed upon hooks the cross bars. When cross bar filled capacity, the operator presses button starting the driving mechanism. After proper travel, switch stops the motor and the conveyor comes rest with the next cross bar position for loading. Three sets cooling coils are provided the bottom the tank. hood located above the tank for carrying away vapors. Rollers and gears are subjected double harden- 616—The Iron Age, September 1930 trol instruments are placed top the furnace ing secure the maximum hardness the case and re- finement the core. They are first heated 1475 1500 deg. Fahr., 1500 deg. being found give the best results. They then are quenched oil and re- heated 1375 1425 deg. and again quenched. Quenching the gears oil instead water assures hard case and minimizes distortion. Plain carbon bushings and pins are heated 1425 1475 deg. Fahr., the lower temperature usually giving the best results. They are quenched water assure the maximum hardness the case, hardness that would not secured oil quenching. The parts are dropped into the quench tank individually, which assures uniform quenching. The rear wheel drive shafts chrome-nickel- molybdenum steel are given one heat treatment salt bath avoid surface decarburizing. All long shafts either alloy carbon steel are heat treated salt pot furnaces which they are kept from one two hours, after which they are quenched, usually oil. While the furnace they are kept perpendicular position assure the minimum amount distortion. All alloy gears and shafts which are not carburized are drawn after hardening Homo-type electric furnaces. After quenching and before drawing they are cleaned cleaning compound. Steel having carbon content above 0.20 per ann — Parts are removed through side door and, oil quenched, are hung the conveyor special oil-quenching ma- chine shown the right cent Work that carburized drawn 250 300 deg. the continuous electric heat-treating furnace. All furnaces are controlled either Homo furnace salt bath. All small parts including bushings and pins are carburized two rotary furnaces, fired with natural gas. Gears and larger parts are carburized boxes three oil-fired batch type furnaces. They are held 1650 1700 deg. Fahr. for hr., depending upon the depth case required and then cooled their boxes until they reach the tem- perature 300 deg. less. Various Hardness Tests Used parts that are heat treated and not carbur- ized Brinell hardness range from 300 600 maintained. Carburized work requiring maximum hardness case given individual file test well the scleroscope test. Other carburized work given only the scleroscope test. All heat-treated work given 100 per cent inspection and only those that come the standards the assem- bly department. All steel, whether forgings, bars, tubing castings, analyzed the laboratory determine whether conforms the S.A.E. spec- ifications. Gears, transmission shaft and other movable parts that come contact with oil are sand blasted after drawing provide clean surface. Two sand- blast machines for this work are located adjacent Leeds Northrup control and recording instruments, which are located separate control room. High-Grade Slags from Manganiferous Iron Ores the importance manganese making steel and because our limited deposits ferro- grade ore requiring simple methods beneficiation, the North Central Experiment Station the United States Bureau Mines, cooperation with the Uni- versity Minnesota, Minneapolis, has been conduct- ing extensive investigation methods whereby will possible produce ferromanganese from our large deposits manganiferous iron ore. tecent tests conducted both small arc electric furnace and small open-hearth furnace have shown that feasible produce slags containing from per cent manganous oxide, per cent silica, under 0.2 per cent phosphorus, and per cent ferrous oxide. Such slags are decided improvement over those produced previous tests. Further work with the electric furnace shows ‘that.it ad- vantages over the open-hearth for producing artificial ferro-grade ore from high-phosphorus spiegel. The Iron Age, September — Ai >... i demand mod- ern industry for ant products increases, there growing use rubber coating for metals resist acids. The rubber-lined and some cases rubber-lined and covered tank for acids has been use for score years, but re- cently German process This rack for suspending has been small objects the plating bath has been coated with mercially posited and then vulcanized. rubber manu- facturers, der which, small and intricate metal articles, rubber electrolytically deposited and thus given highly resistant coating against acids. Among the products being made with electrolytically deposited rubber coatings are racks for plating, one which, manufac- tured the American Hard Rubber Co., New York, shown the accompanying illustration. The rack itself formed square bar bronze, which copper wires are attached, and the entire rack dipped tin. the tinned surface, the rubber electrolytically deposited. The coating shrinking the rubber closely the rack frame. The ends the wires alone are left bare, make electrical contact with the articles plated. claimed the maker that the rubber provides insulation, prevents large loss current the bath, when racks are used that are not coated with non-conductor, and avoids repeated plating the rack. These racks have been manufactured various de- signs, depending upon the types articles plated and the number poss