The Iron Age 1930-12-11: Vol 126 Iss 24

EIRON ACE New York, December 11, 1930 ESTABLISHED 1855 VOL. 126, No. “BARGAIN” BUYING PENNYWISE WALDO HUTCHINSON inventory about $500,000 ported the bal- ance sheet, June 30, 19—, the “A2 Mfg. Co.” About $400,000 this value was rep- resented raw materials. rally this appeared under the classification “current assets” and was observed that the ratio current assets current liabilities was healthy, from bank- ing standpoint. Also the working capital, repre- sented the difference between the current assets and current liabilities, appeared ample from the classification figures shown the company’s statement. This statement was presented the company’s bankers with request for extended line short- term credit. The moneys applied for were used convert the raw material inventory into finished goods. Orders hand also indicated favorable con- dition. From the information submitted appeared, first glance, that the loan was warranted. Inventory Found Unbalanced detailed investigation the inventory brought light peculiar situation and one that upset the inclusion the major part this inventory value current assets, and hence working capital. The raw material was divided into nine major groups. one group there was available sufficient material manufacture corresponding parts for some 8000 product units. This was one extreme. The other extreme consisted group raw material sufficient manufacture corresponding parts for but 800 completed units. Therefore, order make available for completed product manu- facturing all the material the first group, would necessary purchase additional material the second group for 7200 units. The quantities the other seven groups fell somewhere between the two groups mentioned. was calculated that order make per cent the value the raw material inventory $400,000 available for conversion into the finished product that additional expenditure some $40,000 for raw material was necessary, and that order make per cent the value the raw material inventory available, purchases some $300,000 were necessary. was very obvious, therefore, that but small part the inventory its unbalanced condition could correctly classified “current and that the financial needs the company for the con- version its inventory were far greater than had been anticipated and applied for. The apparent healthy condition the company, reflected the balance sheet statement, was changed indicate rather weak and uncertain position. was in- terest determine the reason for this condition. Excessive Purchases Caused “Price Bargains” Upon investigation was found that, about year previous, the purchasing agent discovered “price bargain” this over-purchased item, and purchased all that was available. For number years practically all inventory items were drastically unbalanced 3 4 : | 3 4 q ; ; 1749 j XCESSIVE purchases prices result seriously unbalanced inventories. policy buying the lowest possible figure often leads delays deliveries and losses machine time, not mention the receipt products that fail manufacturing requirements. manufacturer making major part his profit out changes inventory values departs from his main function adding value materials processing and be- comes speculator supplies. Inventories, badly out balance, lack real availability value and cannot clas- tensions credit. cause the general policy the purchasing depart- ment buy any time practically any quantity “price bargains” were found and almost entirely with- out regard production requirements. connection with examinations made for the pur- pose determining the value proposed financial issues whether not large commercial loans extensions credit are warranted, one the many items critically examined the inventory. How Highly Developed System Production Control Failed The “B” company, leader its industrial field, prided itself upon its highly developed systems, statis- tical and control methods. The information gathered and the effective use made this information were remarkable. The company operated quarterly schedule basis. The sales department made elabo- rate analysis the market possibilities for the ap- proaching period. Sales quotas were set and every in- ducement was given the salesmen meet their quotas. From these quotas master schedule manufactur- ing requirements was developed and submitted the production department basis for planning the period’s production. The production department turn analyzed the material requirements and pre- pared purchase requests, each case specifying the date when needed. These were submitted the pur- chasing department. The purchasing department was highly organized from system standpoint. The dominating slogan was “Purchase Goods the Lowest Prices.” Hence, every item cost more than $500 requests for bids were mailed many sources could found. 1750—The Iron Age, December 11, 1930 The writer became interested the machine record charts this organization. These charts graphically indicated the planned operating hours each machine tool and the actual hours. The reason for idle chine time was indicated various symbols. One department showed unusual amount idle machine time and the reason indicated was “waiting for ma- ” terials.” was also found that several other depart- ments were seriously affected the idleness this department. The cause was traced the purchasing department and the reason for the absence the needed item raw material was discovered. appeared that this item raw material re- quests for prices were sent large number sources and many these sources were new. There was nothing unusual about this, but part the rec- ognized routine, especially since the quarterly require- ment for this item was valued about $50,000. The quoted prices from the various sources did not fluctu- ate any great extent, the lowest, however, was some per cent below that former source. accordance with routine the entire order was placed with the lowest bidder apparent saving about $2,500. The usual promise prompt de- liveries according stipulated requirements was made this source also the others. The source, however, new organization and not prepared handle order this size during the allotted time period. Idle Machine Losses Exceed Price Savings order aid the situation frantic search was made for small lots available for immediate delivery and limited quantities were obtained substan- tially higher unit price and express rate charges place freight rates. Records indicated that losses due idle equipment and delays completed assem- blies were excess $1,500, and was estimated that equal amount would probably lost before the situation was brought balanced condition. This occurrence was value this organization for brought very forcibly its attention that other factors besides “lowest prices” were importance purchasing, and that the common sense use system mechanism even more important than the theoretical perfection the mechanism itself. Manufacturing has been described process which increases the economic value materials the application human, mechanical, electrical chemical energies forces. Theoretically, therefore, manufacturing enterprise should obtain its profit result this increased value rather than through any market rise the value the raw material. practice, however, during periods increasing prices, many industrials profit also this rise value their raw material stocks. Occasionally one finds manufacturing enterprises ® whose major profit, and times all their profit, made from appreciation inventories and “fu- tures.” This method becomes more prevalent during periods rapidly increasing commodity prices. such cases the manufacturer reality becomes broker speculator the material market. Close Cooperation Between Buying and Using Departments Needed The Mfg. Co.” produced what termed assembled product; that is, about per cent the parts the completed unit were so-called standard parts and purchased complete from outside sources. The production new model was planned, and order cope with the competitive market situation cost limit was placed these parts. The engi- neering department prepared complete specifications for these parts and some the more important parts actually stipulated the source. one unit difference $40 each the price two manufac- turers was discovered. The one specified the en- gineering department was the higher. From layman’s point view there appeared little difference the two types; the purchasing department, without further consultation with the en- gineering department, contracted for the purchase 1000 the lower-priced units apparent sav- ing $40 each. the dismay the purchasing agent was discovered that although this lower- priced unit could readily used, changes designs other parts were made necessary with added increase some $95. apparent saving $40 reality increased the cost the completed product some $55. Where close cooperation lacking between those who specify and those who procure, cases like the above are not infrequent, especially where the items are somewhat technical nature. the examina- tion inventories one frequently finds items con- siderable value classified obsolete because when de- livered they agreed with the purchasing agent’s or- ders, but were not adaptable the needs. Fre- quently returns the source were difficult, and also times happy optimism prevailed that some fu- ture time use would made these items. Practically all companies made effort dispose non-usable items, but this operation usually substantial loss. Purchasing but one many functions the cycle business. Its effect, however, other functions and activities far-reaching. The purchasing department comes direct contact with the engineering department, specifications depart- ment, for specifications; with the production depart- ment for quantities and time deliveries; with the receiving and inspection department quality and quantity verifications; with the traffic department routing and tracing incoming shipments; with the relationship between inventories and other financial measuring devices needs more careful computation, taking into account the inventory total during various periods the year. The relationship and gross sales evenly balanced bus- iness should fairly stable. Similarly the ratio between inventories and gross profits should steady. Good management warrants the adoption inventory and purchasing control plans and comparative records measurement means maintaining healthy balance. But common sense the use the system even more important than theo- retical perfection the system itself. auditing department verification prices and terms; and with the stores department disposals obsolete unusable material. Operating Carefully Planned Schedules Industrial managers have begun realize that large percentage the waste industry caused the lack effective coordination and control plans for the business whole. The tendency now work basis carefully planned schedules. Natu- rally, production and hence material requirements, should based the market condition the prod- uct, and these requirements should determined well advance, that the production and purchasing departments will have ample time prepare for the fulfillment their schedules. The starting point for these schedules the sales department where careful analysis made the sales possibilities for the subsequent period, and from this analysis the sales quotas are set. The length these schedule periods depends upon the distribution and manufacturing conditions the industry and may vary length from one month year. The sales schedule, when completed, sub- mitted the production department, where prepara- tions are made for the manufacturing the specified number units the specified time. The material requirements for this production program are de- termined and purchase requests written for any neces- sary additions materials, together with time (Concluded page 1821) The Iron Age, December 11, 4 Money Savers Modernized OUNDRIES have been studying their costs closely during the past year and have taken unusual interest new labor-saving equipment and better foundry practice, according William Wright, manager the service department the National Founders’ Association, who has spent most the past years traveling from one foundry another and assisting the association members with their problems. the recent meeting the National Founders’ Association New York, Mr. Wright pre- sented lantern slides some the striking develop- ments has encountered various foundries. few the more interesting views accompany this article. “As general thing,” said Mr. Wright, “our foun- CONVENIENTLY-AR- RANGED storage room for core boxes, with core ovens one end. Room equipped with hand-lift trucks. 1752—The Iron Age, December 11, 1930 dries run along even keel, and then, suddenly, without apparent reason, they begin making more scrap than half dozen foundries ought make. such times, man from the outside who familiar with foundry problems can frequently locate the con- dition that has crept into the work and causing most the trouble. The foremen are close the job that they the problem without even seeing it. outsider, the other hand, takes nothing for granted, and, questioning each step the proc- ess, very likely discover where the practice differs from the standard, and, advising the proper correc- tion, causes the difficulty disappear. “Perhaps new pattern has been put molding machine. When hand molded, the piece gave trouble, but machine job has different gating, dif- ferent sand, different ramming, different pouring, and, owing these differences, the job runs large loss. That condition encountered again and again. Undue Shrinkage Frequent Trouble “Probably the trouble met with most often undue Foundries shrinkage. The pattern, being improperly propor- tioned the first place, has caused loss attend its use from the start. Owing faulty proportions, the foundry has been working against the laws nature and trying make solid castings regardless the design. could only make engineers understand the importance uniform sections, especially where two sections come together, great step forward would made. Often, from one cause another, the design cannot changed. The foundry then must find some other way overcome the shrinkage. Making low phosphorus iron casting from low phosphorus pig iron, malleable pig and steel scrap comes near over- coming the trouble undue shrinkage anything have seen. low phosphorus mean low 0.16 0.18 per cent. Then keep the silicon low machinability will permit. Gating, course, has great influence, also the pouring temperature, but most foundrymen understand these. have helped many foundries out shrinkage trouble advising them use low phosphorus mixture. National Founders’ Association, through its service department, has been studying the methods which mod- ern foundries have adopted the cut- ting production costs. Mechanical charging cupolas, mechanical convey- ing and better methods sand prepara- tion are among the practices that are finding wider favor. “It seems well established those who have gone into synthetic sand that has qualities which make far superior natural molding sand. First, the fineness grain can kept constant. That is, once having determined the size grain best suited the work, silica that fineness can purchased, and, since the sand tested often, the fines they accumu- late can eliminated. SHAKE-OUT grid mod- ern foundry. The flask handled air hoist and dropped the grid. The sand drops 4 The Iron Age, December 11, 1930—1753 j 7 ECHANICAL charging growing factor cutting foundry costs. This view the foundry the Caterpillar Trac- tor Co., Peoria, shows pneu- matic bucket loaded used fill charging buckets. “In natural deposits molding sand, the finest the top the bank just beneath the soil. the men work from the bottom the cut, every little while the bank slides down and more less fine sand be- comes mixed with the coarser and shipped that way; frequently one gets small quantities No. among the No. which can cause lot trouble. “Nearly the same condition true the bond. nature, the bond differs different deposits, and unless one lives close some deposit can never sure the sand receives comes from one bank. synthetic sand you have trouble keeping the clay bond any required standard. Moisture the most important all. Where the molder tempers his sand, where night gang employed, the molder finding his heap too dry stabs over the heap and adds moisture guess. Or, may have cope drop out, and, knowing that the quickest way increase bond add water, does so, while actual fact the heap moist enough is, but lacks the clay bond. synthetic sand, the bond and moisture con- tent can kept easily the right proportion. “There are the market simple machines make 1754—The Iron Age, December 11, 1930 and handle synthetic sand, and question for you study regard your own foundry whether there anything advantageous the proposition for you. not forget that synthetic sand gives better surface the castings, and cleaning costs are lower; also, there less new sand used. Look around your town and see you can find close supply silica which will answer make molding sand from. You may find item which can turned into source profit.” want give you word for word just what member company has say about its experience sand control. Experience Sand Control years ago began the study our mold- ing sand situation. Our city has very unfavor- able freight rate and this naturally imposes addi- tional cost upon the price the sand mined, which quite material. figure our sand per ton, made follows: 4.10 1.40 necessary recognize that many sand con- servation programs, the real cost the sand not only the cost new sands f.o.b. banks, but price f.o.b. plus truckage and dumpage charges. The situa- tion applies equally well sea-coal, where here — have the present price some $15 per ton, $6.10 which actual freight. this there should prop- erly added truckage bin and storage and truckage foundry, and, course, similar charge for dump- age compared sand. This would, therefore, prop- erly fix price approximately $17 per ton for sea- coal. Our early work the testing molding sands was primarily for the purpose obtaining greater knowledge the sand characteristics. That say, new sands purchased and heap sands facings used the foundry. Beginning, course, with the formation the joint committee molding sand research the Amer- ican Foundrymen’s Association 1921, industry was given the tools the way standard methods and technique still further carry sand testing. Our early work until about 1925 consisted primarily endeavor purchase the molding sand best suited for the work hand through means specifications and close cooperation with the producer. Our sand testing likewise was used for the pur- pose developing greater knowledge the physical characteristics the sand actually used the foundry. The tests employed the examination the new sands consisted chiefly the moisture and fineness tests, together with the dye absorption test for determination quality clay contained. The control tests consisted principally the Doty tests for strength, permeability, moisture and mechanical analysis fineness test. The use sand testing naturally developed greater ONVEYORS facilitate rapid handling work when ar- ranged, this plant, carry molds away from each molding machine, knowledge our sand requirements and thus indi- rectly permitted reduce our over-all sand costs the selection the best sand available for the work. was not until about 1925 that our work conservation began earnest. had previously and now the question the quality castings produced paramount and any conservation saving new material entirely secondary. 1925 the study the use clay bond was undertaken. The merit clay bond was soon recog- nized and gradually molding sand was replaced clay bond. recent years the more colloidal type bond from Wyoming has been employed suc- cess. indicative the actual saving that has been accomplished the amount new material employed, there shown comparison the old with the new. This comparison involves typical green and dry sand molding heaps. OLD GREEN SAND MIXTURE Cost per ton mixed sand per cent gravel per ton.............. $1.75 per cent sea-coal $17 per ton............ 0.51 The Iron Age, December 11, ail — | "Sey > | q operations. You will note the case the sand mixtures present date, the relatively small per cent sea-coal. This, course, per cent gravel per ton.............. $0.28 per cent sea-coal $17 per ton............ 0.13 Savings Mechanical Charging per cent Bentonite clay $35 per ton...... 0.17 Another place where many firms are making nice Saving per ton sand mixed............ $1.68 years the emphasis saving has been put mechan- Cost per ton mixed sand per cent Cost 2.4 per cen 0.7 per cent Bentonite $35 per ton 0.25 Total PRESENT MIXTURE Cost per ton mixed sand Dry SAND MIXTURE PRESENT MIXTURE per ton mixed sand lightly faced presents entirely different problem from casting cylindrical shape, poured end high tempera- ture which the job cannot faced, and must therefore employ heap facing quality. conservation and sand saving that has been accomplished has been brought about without the expense elaborate addi- tional sand-handling equipment. The equipment use consists the Simpson muller for certain ‘types work, the Auto-sand cutter and standard mixer for other types. explained the fact that less new sea- coal necessary due the lessened amount that wasted, when only some per cent the total heap placed upon the dump compared per cent. Saving per ton sand mixed. .$1.33 Recognizing that any figure sand conservation saving based upon per ton castings basis would not give the true picture, the above figures are given the relative costs the sand mixture applied the foundry. This should entirely clear when realized that 500-lb. casting made shallow flask MOLDING station the brass foundry the Pittsfield works, General Electric Co., showing three tracks for conveying the molds. 1756—The Iron Age, December 11, 1930 ical molding. Lately, some firms have found possible make considerable saving their non- productive payroll. Getting the iron onto the scaffold and charging into the furnace has always been very laborious job when done hand. Today machines that work well they reduce costs very materially. Another development which has attracted at- tention, and which, far can learn, money saver well having many other features excel- lence, the Barrett fixed carbon fuel process melting bronze red brass. This process, however, not recommended for compositions containing over per cent zinc. That important fact keep mind. The outstanding features that process are noticeable soon one steps into foundry where use. First, there noise. you have been around brass foundry using oil fuel, you will appreciate that change. Second, there are fumes from the melting furnace. Think what that means the men! Third, very rapid melting—a 500 600 heat every min. Fourth, the ease and efficiency with which borings are melted. Fifth, melter required. Sixth, the absence excessive heat from the furnaces. Seventh, the excellence the product. Those holes made the old process are entirely absent from castings made this way. have looked over many piles machined cast- ings made this proc- ess and have never dis- covered gas hole. When you think those ad- vantages, together with LECTRIC tram carries buckets along mate- rial yard foundry. Tracks which tram runs are slight gulley, which facilitates easy loading the charge. SHAKE-OUT station the brass foundry the Pittsfield works, General Elec- tric Co. ton, including metal loss, you can see what the process offers. you are melting much bronze, believe will pay you in- vestigate. Foundry operations consist largely conveying material from place place, when you start cut costs your foun- dry look the conveying pig iron, sand, scrap, the finished castings the mill room, then moving the castings about the cleaning room the grinders and chippers. You are all famil- iar with the gravity roller con- veyor. Many jobbing foundries can use this type conveyor greater less extent and save money. Accuracy Investigations Sorely Needed, Says French Authority addressing the Association Technique Fonde- rie, Paris, recently, Portevin criticized verely some the methods adopted metallurgical analyses and experiments. These methods often — | = } 4 4 4 q ~~ a 4 4 | - The Iron Age, December 11, 1930—1757 a] seo : i q q 4 7 — q show incomplete and inaccurate knowledge what has already been published France. waste time, said, multiply investigations order arrive result already known. When the results experiments are inaccurate, fre- quently the case, positive harm done. cited one two examples. Tests for elongation, for instance, are frequently carried out under conditions which preclude the possibility correct results, and yet these are often published three four decimals. Investigations are often made with iron castings which the elementary fact overlooked that two castings from the same melt may show, under different conditions cooling, much poured from totally different qualities iron. heterogeneity directed solely the perfecting the testing apparatus and the mode ment within the limits techniques and science, indispensable con- form the exigencies scientific ac- refrain from allowing the results in- efficient experimental work find their way into public meetings and the press, for such carelessness and incompetence create doubt the sincerity the investigator. a HIS type charging bucket equipped with cone-shaped bot- tom, making for easy dumping and discharges the material melted the outside walls the cupola. 1758—The Iron Age, December 11, 1930 ONVEYING system Pitts- field brass foundry General Electric switch for transfer- ring molds from storage lines pouring lines. dealing with the work the foundry, Portevin observed that some foundrymen believe that their suc- cess depends the possession recipes, formulas, processes, sleight hand, and other secret and mysterious proceedings. They ex- pect receive from the scientist magic wand which will enable them, without any effort their part, obtain large profits. This and unfair concertion. The object scientific research discover the factors variables each phenomenon, find means measuring them, and attribute them their proper value. There foundry which turns out only bad castings; such enterprise could not continue. { ad . ~ ? Re — j A ~ q q q = = ) How Quenching Media Affect Corrosion Alclad Sheets ESISTANCE du- ralumin sheet greatly the quenching medium used heat treatment, or, more specifically, the rate cooling dur- ing quenching. the other hand the tensile strength, yield point and ORROSION duralumin sheet decidedly influenced the quenching medium used when heat treating it. Other properties are also affected. What the situation regarding Alclad sheets, which are duralumin covered with aluminum? The author this paper answers this sheets are much less af- fected the quenching medium, particularly with reference corrosion resistance. This article part paper “Quenching Alclad Sheets Oil,” Knerr, Philadelphia, fore acts protective coating for the duralu- min. the resistance Alclad sheets depends upon the surface layer the aluminum, and not upon the character the internal duralumin, elongation are only read him the National Metal Congress such difference slightly affected the quenching medium. specify that duralumin quenched water when the parts are exposed the action moisture, naval aircraft. These parts are frequently heated molten bath sodium nitrate, prior quenching. Water readily dissolves any ad- hering salt, whereas oil does not. impracticable heat large parts those bulky irregular shape molten salt bath because the severe distortion which occurs when work lowered into and raised from the bath. Salt baths also have limitations, for other reasons. Therefore, much duralumin heat treated electric furnaces the oven type. Quenching oil, such ordinarily used the heat treatment steel aircraft parts, results much less deformation than quenching water. Moreover, electric furnaces that are used for heat treating steel parts may used for the treatment duralumin, provided temperature regulation and uniformity are satisfactory. Such furnaces are usually provided with tanks for quenching oil, oil considered the preferable medium for quenching steel aircraft parts. The moderately increased susceptibility corrosion following oil quenching compared with cold-water quenching has hitherto been argument against this practice. Alclad sheet has been developed since the date the discovery the variation corrosion, following vari- ous quenching treatments. The sheets consist or- dinary duralumin, carrying its two surfaces thin layer aluminum high purity. This aluminum alloyed with and firmly attached the duralumin. has relatively high resistance corrosion and there- Chicago this fall. sistance corrosion, after treatment vari- ous quenching mediums, would experienced characteristic du- ralumin. Tests have been carried out for the pur- pose obtaining information this point. series standard tensile tests specimens hav- ing gaged section in. wide and in. long were cut from Alclad sheet and from duralumin sheet, both 1/16 in. thick. All were heated 930 deg. Fahr. electric muffle furnace, held for min. and quenched various media. After aging, these speci- mens were exposed corrosion the alternate im- mersion method per cent solution salt water containing small percentage hydrogen peroxide. The specimens were immersed the solution for min. and then raised allow them dry air for min. The peroxide was renewed twice week. Corrosion was continued until bent tests made the butt end duralumin specimens showed pro- nounced embrittlement. This period corrosion, 400 hr., did not greatly affect the tensile strength any the specimens, but did show pronounced influence the elongation. The latter regarded ex- cellent comparative measure this type corrosion. The percentage elongation duralumin was char- acteristically reduced the specimens quenched oil and still air, but the elongation the Alclad specimens varied little with the quenching medium and was fully good for oil quenching, either hot cold, when quenching cold water. Specimens each type were tested without ex- posure corrosion, having been quenched cold water, and showed normal characteristics. These tests page 1821) The Iron Age, December 11, 1930—1759 4 a q Ford Makes Substantial Saving Producing Own Push Rods BURNHAM FINNEY AVING penny, nickel dime the cost making automobile may seem insignificant. Yet when small economies are multiplied the production thousands cars day, the re- sult runs into millions dollars year. the little savings, the daily development some new and better way doing job, that make pos- sible the periodic reductions Ford car prices, the increasing wages and the constant improvement the car itself. Quantity output alone, according Ford officials, could not it. the plants the Ford Motor Co. the em- ployees, from the highest officials the more pro- gressive the machine operators, are always try- ing improve methods manufacture. True the Ford idea that nothing permanent but change, they cast precedent the winds. Because thing this belief put practical use the production push rods. Made two pieces with heads chilled iron, they formerly were purchased from other concerns. However, Ford engineers recently developed new iron and push rods now are manu- factured one piece the Rouge plant, with the result that they give better service cost 1.46c. less per rod. Since there are eight rods car, the total saving for each car amounts 11.68c. Gray iron from which push rod castings are made the following analysis: Silicon, 2.50 2.70 per cent; sulphur, 0.10 per cent maximum; phos- phorus, 0.30 0.40 per cent; manganese, 0.60 0.80 per cent; and carbon, 3.30 3.50 per cent. The dies into which the hot metal poured are made the same material. Push rod castings are produced Ford-built has never been USH rod castings are produced Ford-built rotary die casting ma- fore is no reason why it rotary die casting machines, consisting of 12 chine, which consists of should not done now. dies with eight castings die. Machine has dies with eight cast- good example how two operators, one pouring metal and the other brushing dies and knocking out cooled castings. ings die. The ma- 1760—The Iron Age, December 11, 1930 | the constant development new and better doing job that makes possible periodic reductions Ford car prices, increased wages and improvement the car itself. Quantity output alone could not it, say Ford officials, who add that “because thing has never been done before reason why should not done now.” The manufacture push rods the Rouge plant, described this article, example how Ford has cast precedent the winds order achieve new economies and higher efficiency. chine’s capacity 11,000 castings 8-hr. day. Rotating every min., the machine has two opera- tors, one pouring the metal means hand ladle and the other brushing the dies keep them clean and also knocking out the cooled castings wire belt conveyor. The dies are protected acetylene soot that the hot iron flowing into them does not burn them and castings not stick. Moving the machine distance about ft., the castings are removed workman operat- ing power press, which knocks off the risers and likewise automatically ejects the castings into metal basket. From this point the castings are taken automatic, pusher-type, gas-fired anneal- ing furnace, where they remain for hr. They are temperature 1615 deg. for min., after which they slowly cool 900 deg. This brings down the Brinell hardness from 241 179. Castings then are taken the foundry tumbling department cleaned. This operation fol- lowed general foundry inspection. After the rods have passed the inspector, they move small metal trays motor truck the machining depart- ment. Rods Machined High Production Tools Rods are rough-ground both ends end- grinding machine which turns out about 1200 rods hour. Next rough body grind center- less grinder equipped with special hopper feed. Production this machine 1600 hour. From this point the rods pass special automatic Ford-built machine which chamfers the ends and drills the centering holes. All the operator does feed the rods into the hopper the machine, which has capacity 1600 rods hour. order lighten the weight the rod, hole 5/16 in. diameter drilled through the center from the head the rod within quarter inch the bottom. This work done rotary drill equipped with automatic feed. The next opera- tion drilling hole in. diameter the side wall the push rod near its end. This hole for the insertion pin that the push rod can held clear the camshaft. USH rods are twice given sound test detect cracks. this process inspector drops rods steel block, telling sound impact whether they are cracked. The push rod passes through conveyor-type washing machine and thence pusher-type, gas- fired, heat treating furnace having temperature 1580 deg. After remaining the furnace for min. and heat for min., the push rods are quenched oil dropping from the conveyor they reach the end the furnace into oil tank. the oil tank the push rods fall wire basket conveyor which carries them out the tank approximately 45-deg. angle and dis- charges them through chute into basket. this heat treating process the hardness the push rods Rockwell scale. Rods Are Hammer Tested Push rods are tempered passing through conveyor-type draw furnace, which they remain temperature 400 deg. for hr. They then are checked for hardness Rockwell hardness tester. Moving special Ford machine, they are given hammer test which determines whether any heat cracks have developed the heat treating process. This machine tests 2500 push rods hour. After push rods have been found free from cracks, they are finish ground two centerless grinders, the first taking off 0.003 0.004 in. from the surface and the second machine from 0.001 0.002 in. This followed grinding both ends the push rod special grinding machine. The rods are cleaned passing through conveyor-type washing machine, from which they in- The Iron Age, December 11, 1930—1761 -_ si => \ aa =] fi A W. — q 4 4 q 4 al we v4 1762—The Iron Age, December 11, 1930 oe > spector for drop test. this process the inspector picks the push rods hand and drops them steel block, telling the sound impact whether they are cracked. The manufac- turing process completed with the polishing the rods buffing machine. From the buffing operation they are carried the inspectors nearby, who examine them for length (limit 0.001 in.), diam- eter the body (limit 0.0005 in.) and squareness the head with the body (limit 0.001 in.). final precaution they are given second sound test detect cracks. From the inspec- tion tables they are transported the motor line assem- bled. NDS push rods are cham- fered and centering holes drilled special automatic ma- chine with hopper feed. FTER final machining opera- tion, push rods are inspected for length, diameter body and squareness head with body. 4 i 7 NEW YORK’S CHANGING ARCHITECTURE PHOTOGRAPH taken from the top the new Chrysler Build- ing New York shows the prevalence the set-back type architecture the newer buildings. This conform with New York’s building code which prescribes the height that buildings may built straight according the width the street which they face. The set-back permits taller buildings than would other- wise possible and provides for better light and air. The Iron Age, December 11, EE EEE > AAA af q 3 4 4 TANK DIP TANK Dipping and Baking Three Coats Japan Continuous Unit NEALEY interesting installation for japanning, which are incorporated several unique fea- tures, has been made one the large automobile plants. The setup continuous and automatic operation, three coats being ap- plied and baked three gas ovens, with the use but one conveyor. This installation was made the plant the Hupp Motor Car Corpn., Detroit. includes three bake ovens and three dip tanks, the former housed building erected the roof the main factory and the latter the top floor. The separate units are placed single straight line, that the one 1764—The Iron December 11, 1930 traveling conveyor serves them all without any change direction the horizontal plane. the vertical plane, however, this conveyor travels through the roof the gas ovens, returns below the dip tanks and repeats until the cycle com- pleted. Along the line travel this conveyor and di- rectly beneath the ovens, this section the top floor divided into eight sealed rooms, the partitions be- ing the same construction the building proper, brick and concrete. The first and last rooms are used respectively for loading and unloading the con- veyor, while the second, fourth and fifth contain the ENDERS conveyor emerging from first bake oven, left, and about dipped, for second coat, tank just showing right. TANK \ N V-shaped enamel tank, with fenders conveyor dip- ping for second coat japan. dip tanks. Cleaned and filtered air blown into these rooms and just enough air pressure maintained within them prevent the infiltration outside air containing dust, dirt, etc. This protects the quality the coats japan. Work Gets Three Coats Without Leaving Conveyor LOWERS and air conditioning equipment are lo- cated rooms and Fire prevention appara- tus, consisting batteries carbon-dioxide tanks, placed room No. Piping connects these safety tanks with the various sections the installation. Fusible links are placed key points throughout the system and, should the temperature any section rise above predetermined degree, the carbon di- oxide would released and immediately flow the affected section. Made two paral- lel chains, between which rods are suspended, the motor located close the unloading end. con- trolling the speed this conveyor, through speed- reduction gear train, the baking periods are regu- lated within any time lim- its specified. The work hung the conveyor and never leaves until unloaded; finished. During its travel re- ceives three coats, prim- ing, rubber finish, each coat being baked may achieved. HREE coats japan are put fenders and other parts, with in- termediate baking, without leaving the haust duct. The rest single line conveyor the Hupp plant. The dipping done the top floor the building and the baking struc- ture erected the roof. The tanks and ovens are arranged straight line, the conveyor traveling alternately down into tank and through gas oven until the cycle completed. The entire process under both mechanical and temperature control, that best results separately different oven, and approximately 450 deg. Heating the ovens accomplished indirectly, each being supplied with separate air heater (two, the case the last oven), which are fired with gas. The ovens are the A-type and constructed sheet steel. Each heater consists single sheet steel shell, into one end which fires single gas burner which provided with gas-air proportioning de- vice, that the atmosphere the ovens can regulated. the opposite end the heater motor-driven fan which blows the heated air into the oven. obtain fuel economy about per cent the waste heat the oven blown back the heater, mixed with certain amount the fresh air, and recirculated the oven. This taken off the point greatest volatili- zation, just above the ex- the waste heat the oven vented the outside the building through exhaust duct located the first leg and just be- low the roof line. the hot air for bak- the second leg, the heat flows counterwise the movement work. This principle effects another economy fuel, the cold work preheated The Iron Age, December 11, 1930—1765 iin, some the waste heat which being exhausted. These ovens are equipped with temperature con- trols which work automatically through motor-oper- ated valves the gas supply lines. When the tem- perature rises above predetermined setting the valve closes, but enough gas passes through by- pass keep the pilots going. When the tempera- ture drops the valve reopens. All pilots are sup- plied with spark plugs operating intermittently. Accident prevention devices valves the gas supply lines the heaters, which automatically close and shut off the gas flow if, for any reason, the blower fan motor should fail, the temperature the oven suddenly rise above the upper limit the control setting. All the motors are operated through central control switch which interconnected with the fire extinguishing appara- tus. This switch automatically pulled when the flow carbon dioxide starts. Entire Equipment 400-Ft. Area HESE ovens and tanks occupy space about 400 ft. length, the first oven being ft. long and the other two ft. each. The approximate width all them ft., while the distance from top bottom about ft. The bottom the upper sections the ovens about ft. above the which the tanks set. The dip tanks are steel and V-shaped, the tops being ft. and the bottoms ft. long. They are ft. deep. The conveyor closed loop. takes the work through the tanks and ovens, returning over the tops the ovens the loading end. Here rides down over two sprockets, one directly below the other and ft. apart, and makes right-angle turn 1766—The Iron Age, December 11, 1930 over the bottom one, third, directly line, hori- zontally, and about ft. distant. This short hori- zontal run the conveyor used for loading, the operator standing beneath and hanging the work the conveyor rods they pass. From this third sprocket requires three turns more traverse the first tank, raising the work over the end, dipping down into the tank and raising out again. The line travel from high sprocket the conveyor rises out the tank over the enameling line. Fenders have just emerged from last bake oven and are about taken off for inspection. sixth sprocket descends another the mouth the first oven, then the first leg, across the top section and down the other leg. the work emerges the first coat has been thoroughly baked and the parts then pass similarly into the second tank for the second coat, and on, until the third and last coat has been applied and baked, when the finished pieces are unloaded. Commerce Yearbook for 1930 the series annual yearbooks, the De- partment Commerce has published volume for 1930. includes 678 pages, which the last eight pages are index. heretofore, this volume mainly statis- tical survey the progress the United States every material sense. covers not only foreign commerce, but domestic commerce well, the general economic posi- tion, employment, wages, prices, fuel and power, con- struction, iron and steel and non-ferrous metals, machin- ery, automobiles, transportation and communication, banking and finance, and number other topics. Diagrams have been used considerable extent throughout the text, show more clearly than possible through the scanning table just what the relative positions various things have been. The tables, course, are relied upon for the precise information. — Many Factors Determine Cost Using Welding OST welding was the ing paper presented the fall meeting the Amer- ican Welding Society Kinkead, consulting engineer, Cleveland. declared that the use labor, material and overhead cost indicator inadequate and, while that in- dicator cannot there needed additional cost indicator which based upon the economic value the product. This, said, MPORTANT cost reductions welding work are possible, says Mr. Kinkead. Usual cost indicators, based labor, material and over- head, are not dependable. Service behavior welded structures products determines the economic value the welded product. additional cost indicator, related the economic value the product, needed. ucts made other manufac- turers, but the maker the long-life product basing his selling price labor, ma- terial and overhead and com- paring with the price es- timates his competitor able reach, although pro- ducing something that has ten times the economic value his competitor’s product. Un- der these conditions the man- ufacturer who has put eco- nomic value his product probably has one blame particularly true welding. Welding, the opinion the author, holds out promise important cost reductions. Determination welding costs would comparatively simple there were only one weld- ing process instead ten well-defined processes which produce different results the phys- ical behavior the welded product. The ation further complicated claims sellers welding equipment and supplies. bring out the fundamental problems con- nection with cost estimates and prove his conten- tion that the usual cost indicator fallacious, the author took typical example pressure vessel that costs the fabricator $4,800 labor, material and overhead. Adding per cent for sales cost and per cent for profit brought the sales price $6,000. The vessel failed six months and the fabricator spent $800 repairing it. Later again failed and replaced it. However, the fabricator lost good customer. this case the cost the vessel was unknowable, because the loss the cus- tomer’s good will could not estimated dollars. the other hand, the cost the buyer was prob- ably far excess $6,000 because loss pro- duction. Labor, material and overhead failed cost indicator both the manufacturer and buyer. Too Much Confidence Cost Indicator Many manufacturers, the speaker held, are driv- ing themselves out business placing too much confidence cost indicator based labor, mate- rial and overhead. Some products are being made that have ten times the service life similar prod- but himself cannot earn profits. The author said that seems likely that indus- try will operate under different conditions the decade starting with 1930. Production capacity per cent greater than needed. The buyer’s attitude changed. Buyers more and more are requiring information that will establish the economic value the product. The initial cost becoming less im- portant than the economic value and there ten- dency toward consideration the latter rather than the former. Life Tests Machinery Establish Economic Values Economic values products are being deter- mined tests under approximating service con- ditions. Life tests are being run many kinds machinery equipment establish economic values and discourage the competitor who quotes lower price inferior product. When manufacturer the welding field makes 1000 welds that are stronger than the parts joined, shows the quality product not dependent the skill good will the welder. People are be- ginning realize that resistance tension loading only one service requirement met the case welded joints. Other requirements such resistance corrosion, fatigue and too high temperatures are equally important. The service behavior welded structures products respect these conditions determines the economic value the welded product. Tests Professor Moore the University Illinois showed (Concluded page 1822) The Iron Age, December 11, : P panels for mounting instruments have taken the place slate and marble all standard equipment manufactured the Re- public Flow Meters Co., Chicago. These steel panels, often made large ft. wide ft. high, offer many advantages the manufacturer, the shipper and the user. They also enhance the appearance the completed panel, for the reason that flush mounting steel practical and sat- isfactory job. Slate and marble panels are subject breakage during shipment from producer instrument maker. These panels are easily chipped and cracked when being drilled and prepared for instrument mount- ing. Furthermore, slate and marble panels offer the disadvantage producing abrasive dust when being worked, which detrimental delicate in- struments. Finally, they are unnecessarily heavy, thereby adding shipping cost. Steel panels take entirely satisfactory finish and are practically indestructible when service and when being shipped. They are simple manu- facture and comparatively light weight. Most