The Iron Age 1930-12-25: Vol 126 Iss 26

THE IRON AGE New York, December 25, 1930 ESTABLISHED 1855 VOL. 126, No. PIPE MILLS INSTALL NEW MANAGEMENT PROGRAM JACOB recognized fact that iron and steel manu- facturers have pleaded when ap- proached upon industrial and management en- gineering. Their belief that “it won’t work our business” gradually changing, with the result that constructive work now being done and for those industries. The Page Hersey Tubes, Ltd., manufacturer iron and steel pipe and casings, operating plants Welland and Guelph, Ont., and Cohoes, Y., with main offices Toronto, has enjoyed successful growth and, insure steady future expansion, has turned management engineering. This company, the request THE IRON AGE, consented permit the writer present general résumé just what was done its plants in- crease operating efficiency. Survey and Installation Made Cohoes The program was started the president the company when authorized the works manager Cohoes call management engineer deter- mine what could done that plant. The writer was engaged make detailed survey the plant, which covered equipment, plant layout, operations, methods, general routine, man-power, supervision, costs and distribution. This survey, presented the management about six weeks’ time, pointed out that operations could carried out much more profitably cer- Rolling narrow skelp Page Hersey plant. 4 oud Page Hersey plan established costs making pipe 100 ft. per size basis. The older practice keep “100 lb. product produced cost,” which, how- ever, makes impossible arrive in- dividual size costs except general esti- mate. Wage incentives for workmen and bonuses for supervisory staff were based standard production 100-ft. lengths per size. tain changes were made the plant. The sugges- tions, part, were revision the methods processing pipe, change the manner handling raw material and finished product, redistribution man-power the plant and other specific items. The complete schedule existing costs, compared with those that would effect after the changes were made, briefly tells the story. installation new and improved equipment made possible substantially reduce the employees that plant. wage incentive plan for the workers, primarily designed for this type of p permitted further reductions number Man-power and resulted average increase production more than per cent. insure the continuance program installed, all foremen and super- The Ul itendents were placed uron performan I ‘e bonus basis, the details which appear later this arti- cle. The success any installation this type de- pends somewhat upon maintaining uniform mill operations. This was assured the revised method obtaining costs, which permitted the establish- costs sizes per 100 ft. pipe and enabled the company bid successfully against com- petitors for business. Survey Welland Plant Following the success this installation the Cohoes plant, the writer was again engaged con- duct similar survey the company’s main plant Welland. The problems encountered here were entirely different from those found Cohoes. The Welland plant was using very efficient methods its manufacturing processes, equipment was mod- ern type, the plant was operating good capacity and sales were excess production. The survey, however, brought out the fact that production could stepped meet sales re- quirements without installing additional equipment. further disclosed that, introducing the same wage incentive plan for the workers that was in- talled the Cohoes plant and the performance bonus plan for the supervisory staff, substantial re- ductions could made the labor force Welland. addition, was brought the attention the management that export and domestic business could materially increased establishing costs per size per 100 ft. product basis, which would enable the company successfully outbid competi- tors. Establishing costs this basis essential, the product sold 100 ft. per size basis. The customary practice mills this type keep “100 lb. product produced cost.” This, course, makes impossible arrive individual size costs any way except general estimate. Preparatory Work Necessary Upon beginning the installation all foremen and superintendents were called together for general meeting, which time the complete details were presented them. The benefits that would accrue the supervisory staff were pointed out and what the management expected them was mentioned. The staff was much interested and asked numerous SCHEDULE NO. Time Study Observation Sheet Page Hersey Tubes, Ltd., Welland Plant Date: 12/17/29 Operation: Thread Size H-In. Reg. Black Pipe Operati Ind. Cont. Ind. Cont. Ind. Cont. Ind. Total Average Allowed Min. threading machine 0.06 0.07 0.05 0.05 0.06 0.29 0.058 0.06 Thread one end 0.21 0.15 0.22 0.15 0.20 0.15 0.25 0.20 0.20 0.14 0.79 0.158 0.15 Remove from machine 0.29 0.08 0.30 0.08 0.28 0.08 0.32 0.07 0.27 0.38 0.076 0.08 Machine No. 223 Type Landis lathe Drive Motor Total actual time 0.290 Operators No. 416-351 Observations made Cutting speed O.K. Mach. allowance 10% 0.029- Group No. No. operators studied Cutting feed Personal allowance 0.014 Men group Total allowed time 0.333 Standard time per man 0.0055 hr. Production per hour 180 lengths Standard time per group 0.0110 1 1 Remarks Operator working—average Base rates $0.35 per hour Old piece price $0.29/100 Rate made effective 12/18/29 Approved JSW Bonus starts 125 lengths (Std. time 0.80/100 lengths) Bonus $0.28/100 over 125 lengths per hour 1904—The Iron December 25, 1930 7 7 7 4iik 7 JACOB industrial engineer associated with the engineering firm Aires, Stone, Pettay Jacob, 335 Boulevard the Allies, Pittsburgh. was graduated from Pennsylvania State College with the degree B.S. and has been actively engaged management engi- neering for the past ten years. Following period three years the automotive industry, became identified with the accounting firm Charles Hecht Co., New York, and organized and developed their indus- trial engineering department. Before leaving this organization short time ago, had charge the installation standardization programs number plants, including the National Foundry Co., Brooklyn; the Mohawk Conduit Co., Cohoes, Y., and the Sheldon Spring Axle Co., Wilkes- Barre, Pa. member the Society Industrial Engineers, associate the American Society Mechanical Engineers and has written extensively for the trade and business press. pointed questions concerning fundamental details, which were promptly answered. this installation three tough problems had suc- cessfully solved: The plant was operating piece work and tonnage plan which seemed satis- factory. The plant had been operating success- fully the plan use for more than years with- out any material changes being made. The rank and file the workers were foreign birth and were banded together sort local union. Needless state, careful handling was neces- sary put the installation over without creating any friction. The full cooperation the manage- ment helped greatly making this difficult task simpler. the illustrations that are follow figures ap- plicable both plants have been chosen. protect the interest the writer’s client, actual sizes pipe have been supplanted letters. These have been arbitrarily chosen not disclose vital information, but still serve the purpose the writer presenting the details the plan. The actual installation started when the writer began take time studies the buttwelding de- partment. Considerable time was spent checking the production the various sizes the several furnaces, before preparing any figures. The re- sults the actual time studies copy shown for the buttweld finishing department, schedule No. were compared with the previous records, and SCHEDULE NO. the production standards were set for the various sizes pipe made the buttwelding department. (See schedule No. 2). Following the setting the standards, which were terms production per hour, they were con- verted hours per length, shown schedule No. this time revised set hourly rates for the various jobs the furnace was established which the management approved. The information contained schedule No. was not presented the men this form, had tendency confuse them. Schedule No. show- ing the actual bonuses that they would earn for their production the different sizes was pre- pared and given the men. They had difficulty understanding this chart, all workers are in- terested their day’s pay, and not the details how that pay figured. 9) = Before the bonus rates were put into effect the buttwelding department set standards was pre- pared for the foremen and superintendents, which represented the time allowed man-hours complete- process length pipe that department. Schedule No. shows those figures. Operators Work New Incentive Plan The buttwelding department was now ready start work the new incentive plan. Production records continued come the payroll depart- ment before. The paymaster applied the proper standard time against each pipe size, made the prop- > Production Standards Set for the Buttwelding Department Minimum Standard Pipe Size Production Time per per Hour, Length, Lengths Hours 410 0.0024 316 0.0032 394 0.0026 287 0.0035 344 0.0028 206 0.0049 287 0.0035 200 0.0050 Minimum Standard Pipe Size Production Time per per Hour, Length, Lengths Hours 240 0.0042 157 0.0064 189 0.0053 126 0.0079 124 0.0081 101 0.0099 0.0114 0.0146 The Iron Age, December 25, 1930—1905 q q . extensions, and the total represented the standard hours the work accomplished the group that shift. The standard hours, when multiplied the proper hourly rate for the job, resulted the day’s pay for the worker. typical run for shift fol- lows, and calculated detail permit the reader follow the method. Briefly speaking, hr. work was done reg- ular 10-hr. shift and the earnings the various workers for that shift follow: the event that the total standard hours for the shift did not total hr., representing the period the shift, the various operators were paid only their base earnings, and bonus. instances where the payroll department was not interested the bonuses earned, and only the day’s pay, yne calculation was necessary. The standard hours the hourly rate the job, the case the ler above, $9, the day’s pay. Supervisory Bonuses + set standards, which represented the total man-hours required produce one length good pipe the furnace, was used the basis for de- termining the foreman’s and superintendent’s bonus. This, for the buttwelding department, follows, Schedule No. illustrate how the foreman’s bonus was ap- plied, three typical runs were taken random from the production records. The actual hours were those The reported the timekeeper for that shift standard hours were obtained applying the prop- SCHEDULE standard time against each size, listed schedule No. Lengths Standard Time Total Standard Pipe Size Produced per Length Time FIRST Day \ 2 500 0.0757 190 LD 1,000 0.1080 108 l 237 0.1225 29 Total tandard hours 327 Actual hours reported 300 Performance for the day 327 109 per cent SECOND Day \ctual hours reported 290 I r the day $2 118 per cent THIRD Day A 3,060 0.0757 939 1.665 0.090] 150 iY \ orted 305 125 per cent The foreman was informed his performance each day and also his performance date for the month. bonus was paid for every per cent his performance was above 100 per cent, based upon the cumulative average for the period one month. That cumulative figure was arrived through main- taining chart somewhat follows: Total Performance Stand Stand- Total to Date ! \ctual Performance ard Actual for Month ly Hours Hour for Day Hours Hours of January | ri 109 per cent 109 pe r cent 12 290 118 per cent 669 113 per cent The final performance figure date for the month the end the month represents the cumulative average performance for that month. was paid bonus for his percentage over 100 per cent, i.e., 119 per cent shown above the last day the month’s figure, per cent the bonus due the foreman for that month. The actual amount the bonus was calculated taking per cent his month’s salary. Superintendents were paid bonus based upon the cumulative average performance the fore- men under their supervision, the total standard and actual hours each department being used ar- NO. Minimum Hourly Production and Bonuses Paid (Buttwelding Department) B Pa i tor Bonus S1Z Starts We Picker \ +10 $0.18 $0.144 16 0.24 0.191 ( 0.19 0.15¢ 0.262 0.210 | 34 0.210 0.168 I 206 0.368 0.294 0.262 | 00 0.375 0.300 +0 0.31 0.252 0.480 0.384 189 0.397 0.318 ] 0,593 0.473 124 0.607 0.485 N 101 0 4] 0.594 O 0.85 0.685 P 1.09 0.877 1906—The Iron December 25, 1930 100 Lengths Over Base Furnace Shearmen Chargers Hands $0.132 $0.120 $0.084 0.176 0.160 0.112 0.143 0.130 0.091 0.193 0.175 0.123 0.154 0.140 0.098 0.270 0.245 0.172 0.192 0.175 0.122 0.250 0.175 0.231 0.210 0.147 0.352 0.320 0.224 0.291 0.265 0.185 0.435 0.395 0.276 0.445 0.405 0.283 0.495 0.346 0.570 0.400 0.804 0.731 0.512 i Siz dara Total of Pipe Number of Time ay lard = P ced G i Lengt er Lengt Time 300 | L500 4.9 | e for the da | T 7 7 | i very | a on The rive the superintendent’s amount the bonus calculated the same that for the foreman, percentage the month’s salary equal the percentage above 100 per cent. performance. Establishing Costs Sizes Continuing use the buttwelding department illustration, the method obtaining costs sizes per 100 ft. pipe produced will shown. the general scheme establishing costs sizes important that all the direct and overhead ex- penses for the plant charged into operating de- partments. insure this distribution all ex- penses, not directly chargeable against any one de- partment, such overhead and general and ad- ministrative expenses, was made and the proper amounts allocated the various operating depart- ments, prorated basis. doing this all the expenses incidental the manufacture pipe found their way into the costs. simplify the pro- cedure sales expenses, cash discounts and other nor- mal sales disbursements were not included the manufacturing costs, but were added the final costs direct percentage cost basis. One the several buttweld furnaces was used the following illustration. The figures are not those record. The method handling the figures used actual practice. short period was chosen and the expenses for the furnace for that period are follow: Buttweld Furnace Expenses for the Period Items An ount Producing labor $52,372.40 Gas and supplies Machinery repairs Heat, light and power Water 195.00 Skelp handling and yard expense 2,210.70 Works expense 1,296.00 General and administrative expens: »,9 30.70 Total $106,315.80 The production the furnace for this period shown schedule No. The first step arriving costs sizes the determination the skelp yield and the net material cost per size per 100 ft. good pipe produced the furnace. The method simple. The actual weight and value the skelp charged into the furnace are matters record. From the gross charge the proper deductions are made for losses, seconds and scrap, both weight and value, resulting the net weight and value good pipe produced. The total hundred feet pipe welded, when divided into the total value the net SCHEDULE NO. Standard Time per Length for Foremen’s Bonuses Total Standard Total Standard Pipe Size Time per Pipe Size Time per Length Length 0.0757 0.1225 0.0984 0.1970 0.0788 0.1640 0.1080 0.2530 0.0901 0.2490 0.1080 0.3060 0.1550 0.3880 skelp, which reality the value plain-end pipe the furnace, the net material cost per 100 ft. per size. this added the welding cost, cal- culated schedule No. and the finishing cost, arrive total manufacturing cost per 100 ft. pipe per size. Attention called the fact that the standard time per length, used schedule No. the same standard time that was used calculating the fore- man’s bonus. calculating the total welding cost per size, standard hour cost first obtained dividing the total expenses for the period, $106,- 315.80, the total standard hours for the period, 64,428, which amounts $1.65. This standard hour cost multiplied the standard hours for each size pipe arrive the welding cost per size. The welding cost per 100 ft. per size obtained dividing the welding cost the hundred feet welded. Procedure Repeated All Departments The procedure described for the buttwelding department was repeated all the other pro- duction departments. They included the rolling mill, buttweld finishing, lapwelding, lapweld finishing, galvanizing, coupling forge, coupling finishing and nipple departments. each department standards were set for the operators shown earlier this paper. some instances standards were set for individual operators, group standards would not have given the proper incentive, which prime importance installation this kind. Standards for foremen, representing the total man-hour time process pipe that department, (Concluded page 1977) SCHEDULE NO. Calculating Welding Cost per Size per 100 Ft. Pipe Pipe Lengths Standard Time Standard Size Produced per Length Hours 380,750 0.0757 28,801 12,508 0.0984 1,230 140,609 0.0788 11,062 10,502 0.1080 1,137 110,023 0.0901 9,915 25,430 0.1510 3,840 78,147 0.1080 8,443 Totals 64,428 Total Weld- Hundred Feet Welding Cost ing Cost Welded per 100 Fr. 75,550 $0.631 2,032.05 2,416 0.844 18,356.20 27,185 0.676 1,871.16 2,021 0.926 16,350.09 21,213 0.771 6,341.75 4,820 1.315 13,764.37 15,106 0.910 $106,315.80 The Iron Age, December 25, 1930—1907 Spur gear hobs are checked specially-designed lead checking fix- ture. HAT modernizing plant pays dividends the conclusion reached the Michigan Tool Co., Detroit, which recently moved into new one-story factory specially designed for the manu- facture cutting tools. constructing this home, which equipped with new high-production machine tools and other machinery specially built for its operations, the company has reduced operating costs substantially and better position than here- tofore make all kinds special tools short notice. Rigid inspection materials process follow- ing each operation feature. most cases meas- uring instruments designed and built the com- pany are used check the accuracy the work. Likewise, the machinery and tools the grinding room for grinding hobs and cutters, well those another grinding division for grinding gear shaper cutters, gear burnishers, internal gear broaches and gages, were developed the company. Cutters and hobs are form relieved give cutting clearances the back-off department, which num- bers among its equipment special machines the company’s own design and manufacture. Here the range work from the smallest size in. diameter and in. length, the latter represent- ing the largest size now the market. Hob Manufacture Illustrates Precision Methods The procedure making 3-in. hob char- acteristic the work done the company, and 1908—The Iron Age, December 25, 1930 Cutting Tools Manufactured Specially Designed Plant BURNHAM FINNEY illustrates the precision with which manufactures its products. The hob made from high-speed steel forging, having sufficient stock for machining purposes. After inspection for size, surface cracks and seams, goes turret lathe for chucking operation. Here 15/64-in. hole drilled and re- cessed. The hole then broached broaching machine and the forging inspected internally. The next operation turning the hob proper length and outside diameter lathe specially tooled for all these operations simultaneously. Passing the milling department, where the gashes are milled and the blank keywayed, then goes the inspection room for inspection; record made its location the follow-up sheet, and passes the back-off department where the thread rough milled. order remove strains and stress the steel, the hob next placed nor- malizing oven. soon thoroughly nor- malized, the hole rebroached and the ends the blank refaced. The hob then put back-off machine have the form and relief work done. the hob unground form hob, the form hob, there enough stock left the teeth for grinding the form all over after hardening. After the hardening operation, again checked for hardness, which, except for special jobs, held approximately Rockwell reading. then passed the general grinding department, where the hole ground true the form produced the — 4 : | : 4 | | ‘ back-off machine. hole, which held 0.0002 in. The ends are faced true with the Hob Grinder Incorporates Sine Bar The hob again inspected and sent the hob grinding department, the equipment which in- cludes specially designed and built machines for grinding the form the hob. Some years have been spent developing this grinding machine. The old method grinding hobs was use master lead- screw. today’s requirements, where the lead must held very close limits, has been found im- possible produce lead-screws accurate enough produce hob the limits required. Michigan ground hobs are made limit 0.0002 spacing from tooth tooth. The lead checked Michigan lead checking fixture, the limits ground form hobs being 0.0005 in. one turn and 0.0002 in. from tooth tooth, runout outside di- ameter 0.0005 in., and runout hubs for indicating purposes the machine 0.0002 in. With the new Michigan hob grinding machine, not necessary use lead-screw. This machine built with sine bar feature, whereby change the angle the sine bar produces lead which perfect the sine bar itself. the sine bar made round, can therefore easily made and checked for its accuracy. The range this machine from zero 2.6 in. the tool spline-shaft hob, sample piece cut and shipped with the hob. Spur gear hobs are checked close limits specially-de- signed lead checking fixture and contour checking fixture. Special Instrument Checks Involute Profile the grinding department there are many spe- cial fixtures for checking gear shaper cutters, gear burnishers, internal broaches, cutters and gages. special instrument has been set for determining the accuracy the involute profile any these items. consists base-plate and disk the Michigan Tool Co., Detroit, has sub- stantially reduced operating costs con- structing one-story plant specially designed for the manufacture cutting tools and equipped with high-production machine tools and other machinery built for its operations. The story how has geared production make cutting tools short notice told this article. edge are held contact with the base circle disk means steel tape 0.010 in. thick. the straight- edge mounted five-to-one lever, the short arm which contact with the tooth form, and the long arm with the plunger the dial indicator. The lever multiplies the reading that each division the indicator equivalent 10-in. straight-edge rolled about the base circle, the short arm follows the tooth form the gear. the tooth true, the pointer the indicator remains sta- tionary. there are errors, the pointer shows the amount. Among other products the company makes tools cut gears for complete transmission, roughing and finishing, using both the hobbing and Fellows Approximately per cent its output manufactured from forged high-speed tool steel. processes. order that parts may properly heat treated, the plant has special department for this purpose. With the exception ground-form tools, all tools are hardened bath solution furnace make sure that distortion the steel will occur during the hardening process. the hardening depart- ment are gas-fired carburizing furnaces, Homo elec- tric drawing furnaces, Surface Combustion gas-fired same diameter, less thickness tape, the base hardening furnaces, and bath electrically-heated circle the gear cutter inspected. plug hardening furnaces. All furnaces, both gas and bushing locate the gear cutter and straight- electric, are controlled automatically. fixture for checking spur gear hobs. Ground 0.0002 in. tooth spacing. J The Iron Age, December 25, 1930—1909 | i | 4 iq Changing modern manufacturing conditions re- quire flexibility operations, including receiving, storing and shipping materials. Equipment and departments must arranged they can moved quickly production changes suddenly become de- sirable. the other hand, accurate work some- times slow work, but the company wanted give its men the best possible facilities for speed and ex- cellence. These factors were carefully considered designing the new one-story plant Plant Arranged for Flexibility manufacturing part the building een from the street, being hidden the office sec- which higher. constructed steel and vith large factory-type windows placed con- tinuously. covers area 190 260 ft. Near ruined when dropped wood. Above the floor the clearance ft. low aisles and ft. high aisles. Plumbing and steam pipes, water mains and wires are placed above the clearance line. Water mains are properly valved order that any section may turned off for repairs without affecting other sections. Daylight and ventilation are provided two parallel monitors ft. wide, extending the full length the shop. The windows are ft. high and set the faces the monitors projecting above the roof. The wide monitor and high sash distribute light evenly over large floor area. The ventilat- ing units the sash are mechanically operated from the floor. The roof deck steel. Because the fact the center the shop glass-inclosed office for that materials the shop are almost all incombus- company. The machine which produces the de- | ¢ the shop superintendent, who can see from every worker and machine. keeping himself informed progress the work, more efficient di- All special tools, such milling cutters, are red the department where they are used within reach machine operators. Standard kept centrally-located caged crib. Lockers and toilet rooms are mezzanine floor, their positions having been selected with respect the number workers near by. Workmen going down the mezzanine steps are full view the iperintendent and foreman. The cost placing these rooms above the main floor slightly greater than building them the old-style way, but the ef- ect the men excellent. the long run, time and money are saved this arrangement, especially does not interfere with work the main floor. Wood Floors Reduce Spoilage The floor the shop has concrete base, rein- forced with steel and finished with 2-in. wide maple flooring laid wood sub-flooring. The wood floor cut down spoilage parts dropping, because fine tempered and accurately finished tools are not 1910—The Iron Age, December 25, 1930 tible, the insurance companies decided that installa- tion sprinkling system was not justified. For the size the building the heating system seems small, but ample view the insulation the steel roof with half-inch layer Celotex, which reduces loss heat radiation. The saving the purchase the smaller heating plant paid the insulation expense. addition, lessened fuel consumption each year will still further economies. Blower Units Used for Heating and Air Circulation The steel stoker-fired boiler enables the company burn low-grade fuel. brick stack, installed due saving maintenance costs, sufficient ca- pacity handle another boiler plant expansion be- comes desirable. The heating plant provides cast- iron radiation for the offices ated blower units for the factory, and easily main- tains uniform temperature deg. Fahr. over the whole factory. Each floor unit thermostatically controlled and the temperature maintained within deg. variation. summer the steam shut off and the blower-unit fans run, giving good circulation air. 7 ig Hardening department. All tools are hardened bath solution the boiler room the steam pipes are insulated. the factory they are overhead and left exposed give heat radiation. The heating system’s conden- sation return lines are underground, and are kept clear means automatic condensation pump, which maintains operation the system under vacuum. The company buys power from the Detroit Edison Co. Set apart from the main shop, the heat-treating department has metal ventilators the louvre type, each sq. ft. size, the sill walls under the win- dows. full sweep air through the room can obtained quickly, smoke and fumes being carried off through rotating ventilators the roof. The switchboard and transmission room con- furnace make sure that distortion steel occurs during hardening process. walls. circuit The switch house equipped complete with breakers, fuses The power flexible and economical machines are moved from one lo- cation another. supplied reflectors. nor tik no bel used. wiring the open-mill type, which Electric lighting the factory ceiling fixtures with enameled iron Numerous doors the factory facilitate handling goods. the receiving and shipping department trucks can driven the floor level. The floor concrete with drains for water and melting snow. monorail used for loading and unloading heavy materials. conserve much space possible, raw materials are stored the receiving department vertical position. structed masonry separated from the shop fire (Concluded on page 1978) Part shop, showing good lighting and comfortable working con- ditions for men. ¥ ~ j a » - | a 4 The Iron Age, December 25, 1930—1911 7 % ; W QUALITY PRODUCTS REQUIRE ACCU- RACY NOT ALONE INDIVIDUAL OPERA- TIONS BUT FROM THE BEGINNING THE END THE MANUFACTURING CYCLE LITY, extrer ind quantity pro prices that will not stifle ifacturers moving picture cameras and illustrate the exacting requirements oducts, which are growing demand nthusiasts, and which also are finding strial and commercial uses, may men- vhen camera starting button pressed, aft in. long, 0.0938 in. diameter, finished | than half When the button released, rotation + thousandth tolerance, rotates almost instantly. This must repeated thousands times. years ago, Bell Howell Co., Chi- entered the field professional moving picture amera manufacture. This sort equipment extreme precision, rugged, either hand-cranked r-driven, and securely mounted when use. The llars. contrast, the amateur movie maker wants only dependability, which means quality and pre ision, but also light weight and automatic operation. because the camera used mostly without support This camera case, pressed from sheet aluminum, held tolerances ranging from 0.0005 in. 0.004 in. 1912—The Iron Age, December 25, 1930 ZIEBARTH Moreover, the retail price must measured few hundreds dollars. These demands impose the manufacturer such conditions press operations small parts which must assembled quantity without fitting; ished turret lathe and automatic screw machine work which tolerances are plus and minus half thou- sandth and less; grinding operations such accu- racy that the machine must kept normal tem- perature used satisfactorily. Also, some parts are assembled and hand-lapped and tolerances are allowed. typical example punch press work the Bell Howell plant offered the production the mechanism case for the design Filmo camera. The case made from 0.125 in. 0.002 in. thick sheet aluminum, 11°, in. wide and in. long. The se- quence the main punch press operation for shaping the case follows: blank and draw, trim, first backset, push stock for sharp corner, final backset, reset bottom and open sides. These operations form case 3.906 in. wide, 8.656 in. long and 1.649 in. high. There recess the sides and bottom (exterior) allow for assembling fabricoid cover- ing between the shoulders the recess. There are two recesses inside, one formed allow for coat flat black lacquer two-thirds the side wall and the other formed for the camera cover. The out- standing feature other than the tolerances that both the outside edges have 5/64 in. radius and the inside corner radius between the bottom and the sides only in. Ninety per cent the dimen- sions this case are held total tolerances ranging from 0.0005 in. 0.004 in. High Speed Shaft Held Close Limits The governor worm shaft, which the design Filmo camera rotates 30,000 r.p.m., offers ex- ample precision production small parts automatic screw machine. This part made from diameter cold-drawn stock and finished, ex- 4* 2 | 4 7 7 a ¥ ~ FIRMLY believe that manufacturing quality product relative precision methods occupy position importance that cannot overestimated. our own products manufac- turing measured large degree tenths thousandths inch. the emphasis which have consistently placed upon such precision attribute much the success our Ziebarth. cept for the two bearing ends, screw machine. The governor spring bearing this shaft in. long. This surface, after turning, roller-burnished 0.0938 in. with tolerance —0.0005 in. The two end bearings are finished bench lathe fitted with turret head form and burnish them diameter 0.0645 in., —0.0005 in., after which the entire shaft hardened and polished. Production the spindle bearing has been doubled through the application transfer arm and fix- ture the screw machine. Formerly the unfinished end was countersunk drill press. The standard operations the screw machine are center, drill, ream, countersink and cut-off. The transfer arm then takes the part the fixture, where the cut-off end countersunk and the final operation cutting slot performed. Another interesting operation problem has been the making winding key hubs. These are made from 1-3/16-in. cold-drawn bars auto- matic screw machine. The first operation rough hollow mill and then finish hollow mill 0.559 in., with tolerance —0.002 in. The outside diameter turned 0.904 in., 0.004 in. The hub then drilled, formed the back shoulder, rough drilled the shoulder, reamed 0.3755 in., 0.001 in., then fed out stop, and while being cut off the machine finishes forming the front sleeve. The hubs are then placed magazine from which they are fed drilled and reamed from the opposite end. This part reamed from opposite ends as- sure that the two drilling operations are center preparatory broaching for the square winding key. Milling machines also play important part production precision parts. The heart-shaped cam PPLICATION transfer arm and fixture screw machine has doubled the output spindle bearings. This spindle bearing (above) now made one machine. The Iron Age, December 25, — which provides the intermittent movement the film cut miller within limits 0.001 in. This high speed part which, when operation camera, completes cycle 1/64 sec. After ma- hining the cam ground snap gage limit 0.0005 total, for all ways around the cam, and the same tolerance for the cam throw and concentricity, inally the hole lapped in. total toler Indicators Are Applied Milling Machines Many millers this shop have been provided with exceptionally fine feeds, and addition indicators index fixture (at right) equipped with oil dash- pot control cator, which shows when correct depth tooth has been reached. Sprocket tooth forming (above) milling ma- chine using shaving at- tachment. hese indicators are calibrated read indths inch and thereby the operators results rather than feel for them. The eight-tooth sprocket for the projector and the tooth sprocket for the camera are made brass blanked size (tolerances 0.001 in.) tomatic screw machine. Teeth are formed Dimensions the teeth are: radius 0.100 0.001 in.; width and depth 0.040 in., 0.001 in.; 0.042 in., 0.001 in., and 0.001 in. the maxi eccentric tolerance the root diameter the ket. The cutters are ground masters and then finished dimensions. The miller which this work performed with feed-in index fixture equipped with control with indicator which shows when the correct depth cut has been reached. Age. December 1930 Not only are some dimensions given part held exact measurements, but some cases parts must assembled and the accumulative error within total limit 0.000! in. example work this kind afforded punches which are used for per- forating film. The completed punch consists four U-shaped parts, the legs which are the punches. The width the punch must exactly 1.220 in. attain this precision the punch machine lapped 1.2204 in. 0.0001 in. and then hand-lapped 1.220 in., The four segments when assembled have total tolerance over all 0.0001 Each tooth, punch, must measure 0.078 in. 0.110 in., and the diameter diagonal must measure 0.1199 0.0001 in. Three sides the four corners each punch are ground cam control bench lathe. Best results are obtained only when normal from deg. Fahr. maintained. Accurate stamping, drilling, reaming and grinding play important part making the shuttle, which actuated the heart- shaped mentioned. The shuttle blanked and formed from special strip steel gage with 0.001 in. against slide surfaces which are the inner edges the sides the shuttle. The distance between these two slides must held 0.50035 in., 0.00015 These surfaces are ground machine espe- ( ially designed and built the Bell Howell Co. These machines are especially heavy construction and the table, which can adjusted down for the size the grinding wheel, graduated the rim. The top the table highly finished, that the fixture which holds the shuttle may freely moved over its surface. This fixture effect double-ended device, that after one slide surface has been ground the fix- ture turned end for end and the other slide. ground. The fixture, which holds shuttle tigidly four points, placed the grinder table and pressed against mechanically operated arm which keeps the { { a — oF ¥ ¢ a" 4 4 3 q id | | EART-SHAPED shuttle cam milling operation, showing how the machine set indi- cator gage for close limit milling. (at right) Milling machine limits this shuttle cam are 0.001 in. (above) fixture motion that wear will evenly dis- dening 0.1251 in., 0.0002 in. The lapping tributed the grinding wheel. these holes must extremely accurate, because they become location points for important dimensions, and Lapping Operation Brings Holes Line also they are used for locating the parts fixtures Holes the lugs the shuttle are reamed used for exacting grinding operations. 0.1237 in., —0.0003 in., and lapped line after har- Throughout this shop are skilled workmen, thor- oughly maintained equipment, and the desire pro- duce quality product. Parts must made separately and quantity, necessity dictates, and interchange- ability parts manufactured the law. ~J (above) before and after forming the teeth. The eight-tooth projector sprocket made the same fixture the five-tooth camera sprocket. (below) inner slide sur- faces the shuttle are ground this special machine. limits are extremely close, actuated the heart- shaped cam. The Iron Age, December 25, This shuttle, which > Cores Baked Continuous Gas-Fired Oven HENRY LANE the summer 1927 the Packard Motor Car could used the core room. the first place Co. experienced considerable increase the the core room was situated between demands its core room, and was evident building one side and reinforced concrete sand that something had done increase the bin ft. high the other. addition this, the First, study the existing ovens was roof construction the core room proper restricted made see what their possibilities were. These were the height any equipment that could placed forced draft auxiliary air ovens, each taking two within the building. racks, and they were arranged batteries from When using the core ovens neces Several schemes were considered and propositions ain sufficient space back each core were made four five manufacturers. Among the iker for the placing rack. addition, between propositions considered first were vertical continuous each pair core makers’ benches there must main- ovens for different baking times. This type oven wide passage for the operation occupies minimum floor space, but introduces the lift trucks handling the racks. This arrange- serious handling problems getting the sand the worked out require between and 100 core makers, the dryers and plates the core makers, building for each core maker, and this the cores from the core makers into the oven and the ‘lusive oven space and general aisles right baked cores away from the oven. rles the core makers’ benches. was found that The height these continuous ovens was deter- increase the output much would require consider- mined the baking time and the amount work increase the area occupied core makers. that could put into each one. Next study was made various types con- All the other ovens considered connection veyor ovens fired with either gas oil. The exist- with the study were arranged with some form ing building limited the type equipment which horizontal loading section, where the loading convey- sists four vertical chambers for Couples baking, horizontal chamber for Burners cooling and horizontal return where cores are unloaded and fresh cores are loaded the racks. Fig. continuous oven con- Speed Conveyor /4.25 inches per oor 1916—The Iron Age, December 25, 1930 | 0 «-- a- : ‘ ~ toy « < Ae J — J j —_—_—4 74--O > Fig. are three burners, one arranged above the other, for each vertical heat- ing chamber. Each set three has its own temperature control. The dials two the recording controls can seen back the piping near the bottom ors baskets passed horizontally across the room for the stripping baked cores and the placing freshly made cores. practically all cases the plates and dryers were returned the makers the car- riages that carry the cores through the oven. The several different baking times were reduced square foot hour basis, and was found that the 5-hr. bake class required the maximum oven space. These cores required 5-hr. baking the rack-type ovens. was believed, however, that the continu- ous ovens would possible reduce the time for several reasons. The rack-type oven filled placing two cold full cores. Even though the temperature the empty oven may have been the required baking temperature just pre- viously introducing the cold racks, the large mass cold material introduced will cause the tempera- ture fall approximately one-half the maximum baking temperature required. For this reason the temperature oven this kind starts rela- tively low, and remains low during the time that most the moisture being driven off and the metal work the racks and plates being heated the baking tempera- ture. change these con- ditions would have neces- sitated some arrangement means which ex- NCREASED core requirements and space limitations caused the Packard Motor Car Co. install continuous gas-fired core oven. The space saved was equal building costing $30,000. The baking time the cores was reduced and saving overall costs was effected. cessive number heat units could introduced into the rack-type oven during the first the bake, and the operator would have very careful the period approached when the moisture would all driven out and the operation hardening and oxi- dizing the binder would progress. this point would have check the amount heat introduced into the oven. continuous oven having series burners the various steps the baking can pro- vided for introducing just the amount heat re- quired each section and also properly controlling the circulation. Saving Space and Baking Time accomplish the desired results oven the general type shown Fig. was decided upon. Dif- ferent makers had different arrangements the passes. One arranged for high vertical pass the entry, with three horizontal baking passes and hori- zontal cooling pass, but the price was much above that the successful bid- der. The oven installed was furnished Holcroft Co., Detroit, and will described detail later. When all the fig- ures were assembled, none the continuous ovens could justify the invest- ment necessary from purely dollars and cents standpoint, based in- The Iron Age, December 25, 1930—1917 Fig. pipes from the vertical heat- ing chambers connect with two headers which join the outside the building. vestment, operating and upkeep expenses, compared with the stationary rack-type ovens use. The operation the continuous oven the 5-hr. bake, however, could arranged reduce the number square feet necessary per operator. fact, the space saved was equal building costing approximately $30,000. When this space saving building investment saving was taken into account the 5-hr. bake continuous oven showed substantial total saving. When the oven was installed and tested, the predicted results entry conditions were realized such ex- tent that the cores formerly requiring 5-hr. bake were baked hr. and this made possible pass through this oven the and 3-hr. bake cores according the former schedule. originally installed, the carriages for conveying the cores through the ovens were equally spaced that the workmen could step between the racks either side stripping off the cores and loading the oven. Later was found that all work could done from one side each rack and the racks were re-spaced place them pairs which provided for seven more racks, total 56. Four Vertical Baking Chambers The oven consists four vertical chambers for baking, horizontal chamber for cooling and horizontal return for the racks, where they travel through the unloading sec- tion and section where the makers put the cores the racks. The oven shell the vertical baking chambers steel construction, with heavy insulation between the metal sheets. The steel frame carrying the shafts with their sprockets and the other equipment the outside and made nearly independent the oven possible. shown Fig. the centers the main sprockets are ft. from the core room floor and the horizontal travel the racks the core room ft. There are three gas burners each vertical baking cham- ber, located shown Fig. Where the cores enter the { Fig. 4.—Arrangement motor and gearing effects sharp re- duction speed sprockets. Fig. the exit end the oven the cores are removed and inspected, and core plates and dryers are returned the racks, later taken from the racks the core makers. Fig. where heavy cores are made. Sand deliv- ered the benches mono- The cores, after being made, are blackened and placed oven racks. j q A 4 4 Iron Age, December 1930 wee The Iron Age, December 25, Fig. cores are placed dryers skids, from which they ferred core makers’ helpers the oven racks. there vestibule (not shown Fig. which fits the racks closely and prevents any rush air into out the oven the entrance point. The horizontal cooling section insulated and there arrangement ducts and fan (not shown Fig. which draw cold air the out- let point and circulate about the advancing cores and racks cool them and the same time preheat the air its way the oven. Burner Temperatures Controlled ‘he general arrangement the burners and con- trol shown Fig. There are three burners Fig. continuous lines represent the temperatures dif- ferent parts the oven, obtained passing two thermo- each vertical section, one arranged above the other, and each set three has its own temperature con- trol. The gas reduced zero pressure the burner, and the amount gas entering each burner controlled the amount and pressure the air passing the venturi arrangement the burner. Each set three burners controlled pyrometer point placed the oven, indicated Fig. the tem- perature rises above the point for which the instru- ment set, the gas supply cut off and only the pilot light remains burning. The dials two the recording controls can seen back the piping the center, near the bottom Fig. This illustration also shows four exhaust pipe connections with the bottom the vertical drying chambers. There are four these outlets each side the oven. The pipes connect with header each side, and the two headers join the outside the building, shown Fig. The exhaust stack contains venturi sec- tion, and there fan the base which controls the exhaust blast nozzle be- low the venturi section. The amount exhaust from each section the oven controlled suitable dampers the out- let pipes. Fig. also shows the horizontal cooling section extending the left the main couples through, one being attached each end one the drying racks. The dotted line shows the ideal temperature requirements. 1920—The Iron Age, December 25, 1930 general view the machinery plat- form near the top the oven shown 4 4 Fig. The drive illustrates what reduction speed means the design parts. The small high- speed motor the center connected silent chain with Reeves variable speed limit. This, turn, connected another chain reduction with gear reducer, and beyond this pair gears again reduces the speed the jack shaft. The jack shaft fitted with beveled pinions driving beveled gears, which are connected with short shafts carrying pin- ions for driving the main gears the head sprocket shafts. The large gears the sprocket shafts have surface speed only few inches per minute. The exit end the oven shown Fig. The man the foreground inspecting and surfacing cores takes them from the oven. much this inspection work possible done the imme- diate vicinity the discharge end the oven. Cores are taken from both sides the oven, and the core plates and dryers are returned the racks and later taken from the racks the core makers their assistants. Benches Arranged Both Sides Loading Section Core makers who are turning out the heavy cores for transmission and other large blocks are shown Fig. Sand delivered the core benches from monorail means man-riding trolley equipped with two sand bins with undercut gates. This man delivers the different grades sand required the bins over the core makers’ benches. After the cores are made they are sprayed with blackening, shown the center the illustration. The blackened cores are then placed the racks they pass along beneath the oven. The opposite side the loading section the oven shown Fig. The men the foreground rature,Deq.F Temperature, > Gas Consumption \ v 2 E 100 Fig. couple temperatures for entire run the four baking chambers. are making barrel cores, two time, and placing them dryers. Each core maker has pair skids opposite his core bench, which will hold number these dryers, and the helpers place the cores the ovens dry they find space the advancing racks. Comparative Costs The estimate the performance the oven be- fore was built was that would dry pound sand with gas consumption 0.61 cu. ft. city gas. Several tests have been run different times th