The Iron Age 1931-05-21: Vol 127 Iss 21

W. W. Macon, Lditur A. Il. Funnier, Editor Emeritus BE. Wricut, Newa Fiitor E. F. Cone 8S. G. Koon R. E. Minis G. 8. Herrick F. L. PRreNtTISs Cleveland hk. A. Fiskt Chicago T. H. Gerken Pittsburgh KURNHAM FINNK?Y Detroit L. W. Morrert Washington GERARD FRAZAK Boston hk. G. Cincinnati {kon AGE POBLISHING ( 229 West 89th Street New York, N. Y. Cable Address: ‘‘Ironage, N. Y F. J. Frank, President G. H. Grirriris, Secretary Cc. 8. Baur, General Advertising Manager Division of ONITED Business Purristinns, New York, N. Y. District Officea: CuHicaGco, Otis Building PITTSBURGH, 1319 Park Building CLEVELAND, 1362 Hanna Building PHILADELPHIA, 1402 Widener Bldg Derroit, 7338 Woodward Avenue 536 Investment Cincinnati, 402 Traction Building BuFFALO, 847 Ellicott Square BosTon, Room 230, 80 Federal St San Francisco, 381 Bush Street and 1045 Sansome St. Copyright, 1931, by InoN AGE PUBLISHING Cu Member, Audit Bureau of Circulations Member, Associated Business Papers Published every Thursday. Sub scription Price: United States and Possessions, Mexico, Cuba, $6.00; Canada, $8.50; Foreign, $12.00 year. Single Copy 25 Cents. May Testing with Gamma Rays Wage Incentive Effects Savings Tool Inspection Reo Plant New Units National Tube Co. Tungsten and Tantalum-Carbide Cutters Open-Hearth Operators Exchange Ideas Dr. Haney’s Page New Equipment News Personals and Obituaries Editorials Markets Construction and Equipment Buying 1651 1657 1664 1666 1673 1685 1695 1679 1687 1692 1696 1699 1722 GET BIRD’SEYE VIEW CONDITIONS you want keep reliably informed the state things the industries consuming metals, read the iron and steel market reports, and you will know where business good and where poor. Here are few extracts from last re- ports: Steam shovel makers Ohio continue operations near peak. the Chicago structural field the best far this year. Electric re- frigerator makers have cut down their orders (for sheets) the last fortnight. Steel business from the automotive industry fell off somewhat; seems doubtful present production will main- tained Road scraper manufacturers look forward good volume orders later the season. Makers office furniture and steel shelving are not Conductor pipe manufacturers are taking larger quantities (of sheets). Agricultural implement makers are again scaling down Small con- tainer manufacturers are probably the most active among Chicago sheet users. The market reports this issue begin page 1699. —A. | iB — 4 4 | THE IRON MAY 1931 Page Built the Kempsmith Mfg. Milwaukee, Wisc can work New Departure Ball Bearings all day long without running them into dangerous temperatures. And these days increased speeds, excessive heat and all that indicates thing avoided. Such troubles are guarded against the high-speed milling attachment shown, because every carried New Departures. All are angular contact DEPART URE BALL BEARIN True rolling motion gathers type bearings preloaded for rigidity and lasting accuracy. This unit fine example design compactness, most desirable attribute which New Departures help attain because their own simple compactness and because each one packed full thrust capacity and radial sta- bility. The New Departure Manufacturing Co. Bristol, Conn.; Chicago, Detroit, and San Francisco. less heat | TRIG. SSS O NEXT WEEK EPRESSION leads merci- less pruning ex- penses. The danger that carry economizing the extreme, eliminat- ing expenditures that are really essential from long-time point view. Abandoning ap- prenticeship time like this, but such action short-sighted and harmful tices suffer because interruption their training; the company suffers its “fair weather” policy discourages future en- rollments chills the attitude parents and the general pub- lic. “What About Ap- prentices These Days?” will dis- cussed national authority our next issue. i} Milling Cutter, Inserted Blades Tipped with Tungsten Carbide The small steel blade milled out receive the tip which brazed Blades are then tack-welded aea the body the cutter Page 1673 Tungsten Carbide Reduces Machin- ing Allowances Scale the average casting can ' milled almost easily the inner surfaces. Where allowance has been Tantalum Carbide Successfully Applied Milling Cutters Tungsten carbide not always satisfactory cutting steel due cratering action, caused the ity tungsten has for steel. Tantalum has not this and difficulty brazing the tool has been come.—Page 1673 er Detects Flaws Specimens with Varying Sections With X-ray tests, thicker secti with harter lenorl nal vith snorter wave iengtn, make poss ble obtain satisfactory radio 4 graphs of entire specimen 165? * 7 * Tests Welds and Castings with Gamma Rays Equipment completely porta the rays have great penetrating power, na the por < sly na ina tne test 1S easily ima quickKi made.—Page 1654 * Incentive for Effort Should Per Cent Over Daily Pay Machine tool plant’s wage tive plan based payment base hour rate plus premium based costs per 100 units produced. set time calls for output pieces per hr., the premium for pieces the man’s hour rate for min Page 1658. * * * Elaborate Production Control Operated Economically Two men and girl hand uction control work and much of the cost work System pro vides daily producti n and cost fig ures for each department, wage incentive system, and au r tion control sheet for the man ment.—Page 1657. MAY 1931 Operators’ Daily Production Record Posted Department Foreman and each man learns what each operator did the preceding day ind how much each e irned in pre ims Page Friction Between Departments Over Tool Accuracy Eliminated Jigs, fixtures, tools and gages nspected standards division, enting disputes between departments is to accuracy, and saving time yney and labor Page 1665 Metal Not Dumped Unless Oper- Weight Depresses Platform This releases safety pawl. the ime time a safety switch above oper rtor’s head must be thrown before motor operating ladle can function Page 16¢ Machinery Builder Sets Standard for Practically Every Operation Plain cylindrical grinding com in. basis, drilling r.p.m. and feed basis, milling indths cut per to tl per min. given e Page lé ¢ puted on a cu Penalty for Scrapped Work Reduces Spoilage Spoiled work is taken from oper tor s future premiums at same rate a for excess producti n Costs Are Lowered Production Control System 1s abDie to contre hey know what costs sho 11a and can find the cause if they are reased men know they are paid output Page 1661 Formula for Arriving Economical Production Quantities Machinery builder multiples the preparation cost the den per annum and divides value piece times percentage representing 1662 > | | Py Page 1659 | wice THE IRON AGE MAY 21, 1931 Page f NUMBER NEW BRITAIN AUTOMATIC CHUCKING MACHINE Compact and rigid the extreme, smooth and vibration- less under any possible cutting stress. The durability the most modern cutting tools alone limits production from this powerful single spindle Automatic Chucking Machine. Regularly equipped with hydraulic chuck and two massive tool slides, each capable both longitudinal and radial cuts. THE NEW BRITAIN-GRIDLEY MACHINE NEW BRITAIN, CONN. = = of e | | ~ RON AGE.. New York, May 21, ESTABLISHED 1855 VOL. 127, No. DR. ROBERT MEHL Superintendent, Division Physical Metallurgy Naval Research Laboratory Bellevue, ORK which has been done at the Naval upon the penetration ot light rays, the X ray and the Research Laboratory the use gamma gamma ray, through opaque objects. The efficiency rays radiography has been limited this penetration dependent directly upon the wave most entirely steel castings. There length the ray, the shorter ray show fundamental difference the application ing the more efficient penetration. Either ray may radiographic method welds—in both. physical dis- characterized, therefore, wave-length, better, continuities are sought, and effective wave-length. for this reason the results seen from Fig obtained steel castings that the effective wave may taken indicative length the ray from the beginning should destructive testing magnetic, units. wheres said immediately that gam- X-ray, and gamma ray—the last men- hat the gamma ray from tioned the one which has been de- X-ray radiography, both veloped and studied most recently. Some wave-length means, radio- methods using light rays its advantages, such its ease ap- graphically, that smaller which will penetrate opaque plication and its ability penetrate steel fraction the beam between the two methods welds. The article, published with the With effective wave- are two kind: (1) those permission the United States Navy, length 0.15 wave-length the gamma members the American Society for Beyond this the exposure ray; and (2) those differ- Steel Treating and the American Weld- times become extremely ences operation man- ipulation resulting from great. Thus for in. steel exposure time, cal- ing Society. differing physical features culated, about 500 hr. the necessary equipment. would required. With Both methods depend gamma rays, because 1651 pes } } | / / A A oO > Oo > Fig. wave-lengths the gamma ray and the X-ray. their much shorter wave-lengths, the time exposure does not increase very rapidly with increasing thick- ness. Quite satisfactory exposures have tained in. steel without using ridiculous quantities radium unconscionably long exposure times. will not possible say here much about the physics radium. should sufficient, however, merely state that radium salt contained small metal capsule, radium emanation, radioactive gas which radium gives off, held small glass and metal capsule, may used. the emanation, known chemi- ‘ally radon, used, correction the exposure time must made allow for the fairly rapid loss strength with time. For simplicity’s sake let disregard radium emanation and deal radium. Determining Time for Exposure Before attempting prepare any radiographs necessary know what the exposure times should be. These data have now been accurately determined. Fig. 2). The abscissa Fig. units 100 milligram hours when the radium the various in- dicated distances from the film. Thus for radio- graph through in. steel in. exposure time 10,000 milligram hours would required, hr. with one gram radium, hr. with half gram, and (a). Knowing these data practical problem may immediately attacked. Convenience and Simplicity Gamma Radiography Besides the possibility radiographing very thick sections, the outstanding feature this new method its simplicity and convenience operation. This may best shown some photographs actual ex- perimental arrangements. Fig. the radium placed small glass funnel and surrounded all sides objects. Fig. shows the complete portability the method; the piece radiographed arm forge press. effort had made transport the arm laboratory—it was radiographed “in place.” Fig. the radium mounted the top © O | | + + t 4} ~ 4 9 LAL 4 amet Exposure Times With 10@ Radium Fig. 2—Method calculating exposure time for various types radiographs. tripod the center cast steel gun slide, in. wall thickness. Some radiographs could have been taken with one exposure this piece. These examples show the complete portability and simplicity the appara- tus. The inspection questionable veld the top skyscraper would Radiographs Varying Sections Possible i] > But now let turn some radio- graphs and see what results may ob- tained. Fig. X-ray radiograph small steel casting, in. length varying from in. in. thickness, with sand inclusions. Note the great con- trast shown, but also note that the end sections, much thicker than the rest, are (a) These exposure times represent what program now under way, the object which yy Be ; is to discover films which will decrease these ex- posure times, Preliminary results indicate that Fig. 3—Radium placed small glass funnel surrounded objects examined. 1652—The Iron Age, May 21, 1931 films wiil prepared decreasing these exposure times per cent. hoped that this improvement in speed n reach as high as 50 per cent Saving in exposure time | } | r | 4 a Fig. 4—An example the portability the method—arm forge press radiographed. under-exposed. Fig. gamma ray radiograph the same piece. Here will noted that the con- trast less, the film “flatter,” but study these two radiographs shows that every defect shown the X-ray film also registered without fail upon the gamma ray film. Furthermore the end-sections are now also satisfactorily exposed. fact, this dimin- ished contrast, inevitable corollary shorter wave-length, makes possible obtain satisfactory radiographs greatly varying sections with one exposure. Sensitivity Marked Advantage The sensitivity the method for the detection small defects immediate interest the practical man. obtain information this special radio- graph was prepared. The object Fig. was pile steel plates in. total thickness into one which was cut series slots. Slot No. quite distinctly seen the original radiograph, was mm. wide and deep; its depth was only per cent the total thickness. obvious that the sensitivity satisfactory. Now radiography has two natural fields applica- tion, that steel castings and that welds. Most the radiographs have prepared were taken steel castings, but the general characteristics these radio- graphs may easily interpreted for welds. Defects Detected Steel Castings Our laboratory was called upon prepare some radiographs defective 9-ton casting located from very poor castings; the stern post casting was extre poor. It must not be concluded that all casting ire this nor indeed that all parts the ting shown here equally bad; even the stern post casting was entirely on many if not most of the radiographs take stern post one the new 10,000-ton cruisers. This casting had developed crack after installation, which was promptly welded. Some uncertainty the re- mainder the casting existed, however, and repre- sentatives our laboratory took some films when the ship was dry dock (b). The films were attached lightly the The thickness steel was only in. one case eight radiographs were taken These radiographs revealed extremely bad casting. with total exposure time about hr. was quite obvious that the steel was poor, for there were many blowholes revealed and the general appear ance was dirty. The square marking the center one radiograph showed depression, easily visible the surface, made chaplet. Around this square there was circular crack, with cracks radiating Fig. one these, there condition the casting, but toward the center. evidently chiefly long irregular crack, apparently hot crack. some in. long was found another radio graph. After some radiographs this sort were pre pared, indicating poor quality the side the cast- ing top during pouring, the cruiser put sea, and during trials, split the casting around, letting the sea. The ship then went into dry dock for long period time order install new casting, and immense expense was incurred putting the ship into commission again. The moral obvious: Had this casting been radio- graphed immediately after manufacture would cer- tainly not have been installed the ship and time and money would have been saved. somewhat similar problem for radiography was presented our laboratory shortly after the stern post casting. knuckle large casting with greatly varying section, running The object was casting known the keel casting, likewise for the cruiser. was in. thickness. Two radiographs were taken this casting. The section this ran from in. in. long jagged crack was revealed section 4 im Fig. 5—Radium mounted the top tripod inside cast steel gun slide 4-in. wall thickness. The Iron Age, May 21, 1931—1653 — — — 4 q A q % 4 < _ iil , 2 . Fig. and 7—Upper radiograph X-ray picture small steel casting. The other gamma ray radiograph the same piece in. thick. The metal was found very poor condition with host serious cracks, the thickness varving from in. down in. Although the interest radiography present this meeting chiefly welding, these radiographs casting have been shown because they illustrate the features the method, gen eral features which are applicable welds steel castings. ] work the stern post casting could not have been done any other method, for was necessary the work under the ship and dark dock. This represents, then, the advantages resulting from the complete portability Fig. steel plates, in. total thickness, one which series slots was cut. Slot No. only per cent total thickness, visible. 1654—The Age, May 21, 1931 Practically, the important point make that the The steel knuckle casting, the other hand, repre- sents trial the method for the detection defects ranges thickness beyond the X-ray limit, and again might said that other method would have been useful. But now let turn some welds. general more difficult prepare photographic copies from radiographs welds than castings; the defects sought are more lightly represented the film. The first, Fig. 10, old one, showing lap weld with lack fusion. The two plates welded were in. thickness. Fig. rather badly porous butt-weld in. plate. Such weld obviously would im- mediately rejected. Fig. 12, however, shows satis- factory butt-weld, again in. plate. Although Fig. 9—Blowy metal and long irregular crack gamma rays. 10—Gamma ray radio graph lap weld with lack fusion some slight porosity indicated the weld generally quite acceptable. general may said that gamma rays give equally good results welds castings. cases where portability requisite, the method will doubtless find its application. Naturally still too soon say exactly what place may attain among non-destructive testing methods. The obvious advantages great penetration and complete portability certainly seem justify the careful consideration industry. The Navy has nat- urally been the first the field and has made the most extensive study the method. Its success has been sufficient justify the Navy purchasing stock radium order inspect castings and welds the various Navy Yards and also continue study the method itself. application the method has yet been made the industrial field, though several instances this 4 4 > 7 | | | Fig. butt-weld one-inch plate shown with the gamma ray. awaiting only the development suitable arrange- ments for making radium available for the work. Naturally, since this method entirely new, some time must elapse before such arrangements may Fig. 12—A weld one-inch plate revealed the gamma ray consummated. With the advantages portability, simplicity, and great penetration, seems inevitable that industry will add this method its list ser- viceable non-destructive tests. Principles Locating Industrial Plants principles industrial plant location enumerated paper presented Herbert Ryding, president, Tennessee Coal, Iron Railroad Co., Birmingham, the American Mechanical Engineers its meeting Birming The value the study will lie particularly its setting down the many points which should considered problem the sort. other words supplies the abstract analysis which should avail- able making the decisions the concrete case. Mr. Ryding pointed out that under any circum stances the best location for industrial plant where the combined cost production and distribu- tion the product can maintained minimum. Time was, not long ago, added, when the location industry from the freight- rate standpoint was not paramount importance, cause the carriers could, very large extent, just their freight rates such fashion over come least very greatly mitigate geographica disadvantages. the present time, however, Interstate Commerce Commission enforces firmly so-called “long- and short-haul the Inter- state Commerce Act, which forbids rates for shorter distances being greater than for longer distances over the same route, and which has the effect mak- ing distance the prime factor fixing the relation ships rates between points origin and destina tion. Added this, the commission required establish rates which will yield the carriers fair return the investment, and authorized fix minimum well maximum rates, and pre vent discriminatory rates intrastate versus inter- state traffic. The laws also require that both water and rail transportation fostered and maintained equal vigor, and also that rates such permit the development the country whole. The effect the administration these laws the problem industrial-plant location give each commodity fixed place the rate structure and fix the rate from every point every other point with distance the main controlling factor. The hauling freight the highways truck new form transportation that bids fair disturb seriously the rail rate situation. This form trans portation has grown leaps and bounds, affording the railroads very serious competition. Not only this matter grave concern them, but shippers and the general public, because the known effect which bound have the rail service and the rate The establishment proper relationship between these forms transportation and their coordination, will require great deal thought and labor. Schedules essential factors determining the section the country which locate and then determining location city, suburban rural district atured the paper Reference also was made survey industrial development the United States and Canada made the National Electric Light Asso- ciation and the Metropolitan Life Insurance Co. Thi ntained statement follows: “It significant bonuses, free taxes, free land, free factory buildings, which inducements one time were fre quently offered, and still are from time time, did not ippear among the three reasons most frequently ad- for the selection the location plant.” The Iron Age. May 21, 1931—1655 & | CO : 1656 May » 1931 a { All nat | aynoct 4 r + J A - COST CONTROL AND WAGE INCENTIVES EFFECT SAVINGS large metal-working plants have installed cost control and wage incentive systems that have worked with varying degrees success. number dif ferent systems are vogue, the application which has been described articles published THE IRON AGE from time time. Among the outstanding companies which have adopted such systems are the Otis Elevator Co., the American Can Co. and the Cincinnati Milling Machine Co., mention only few varied lines metal working industry. The Monarch Machine Tool Co., Sidney, Ohio, has given thor- ough trial the Dyer system, which that employed also the Otis Elevator Co. and some other large organizations. COST control system, including wage incen- tive plan, under which per cent its em- ployees are paid according work produced being used the Monarch Machine Tool Co., Sidney, Ohio, which has found the system highly efficient effecting plant economies. The effort labor meas- ured scientific plan, direct and indirect payroll expenditures are controlled, and the work measured their ability control costs and fur- nish leadership. These measurements and controls provide bases for planning and scheduling production for regulating payroll expenditures and manufacturing costs. The system, known the Dyer system, was stalled Dyer Engineers, Inc., Cleveland. production control system has also stalled part the company’s scheme manage- ment. Efficiency also has been increased the elimi- nation old equipment. There not machine tool the plant more than three years old. Labor saved when possible having one man operate two ma- chines type that usually had individual operator. basis for control both direct and indirect payroll expenditures, nominator designated unit minute quality work, includ- ing fraction minute for relaxation. Standard data are obtained and standards are set up. These standards are com- piled from elementary weight- values derived from motion and time studies. weighted value the time cured stop watch studies and adjusted standard effectiveness, and this added percentage for laxation, according the type elementary operation performed. both repetitive and non-repetitive erations the total weighted values motions furnishes the standard. setting standards through system scien- tific analysis, work often regarded unmeasurable measured, permitting greater number ployees placed under wage incentive system, curacy claimed because standards are set with mechanical precision, and danger favoritism eliminated, standards are often set long before they are actually applied. Each Department Has Its Own Standard Costs standard costs set for each department. the preparation departmental standard, the first thing that the management desires know how much can produced the department and how much should cost Actual production cos are compared weekly with the standards that have been estab lished such detail that glancing cost control anal ysis how near the standard the department has approached and the reason for ive cost, should there any. Thi cost control inaiVsis Cv plete summary roductior and costs the entire plant There are these analy one for each department, start- The Age, May 21, 1931—1657 wr wr wr | | \ — 4 \ | } A ing with cleaning rough castings and ending with the shipping room. Under this system man’s time divided int minutes standard measured minutes, day work, waiting time and P.N.P. producers’ non-productive time. Measured minutes cover the time which one operator spends work, which set time has been allowed. the work productive, classed black units. For all unnecessary work, work that could have been avoided, the operator given credit for red non-productive units. The foreman given credit for only productive black units and held responsible for all non-productive work done his department. operators whenever the raw material not standard. machine and tooling that will produce the operation Red non-productive units are allowed Standards are always set for the particular the shortest time. the routing cannot followed for any reason, operators are allowed extra time non-productive units order that they may have the By keep- ing this classification, the management proper incentive perform day’s work. informed every phase shop activity, and, when costs are above standard, due unbalance equip- ment, material control, upset schedules because quick deliveries other causes, the information for economical production available. minutes When units produced are excess spent, the difference recorded premium units and men are paid accordingly. When the minutes spent are excess units produced, the difference becomes loss waste and known measured units equal 60, expressed Meas. 60. recognized that greater volume work can produced under standards. Therefore, when standard not set for the job, certain portion the time regarded waste, and called day work Employee Gets Premium for All Saves Increasing Output The wage incentive plan based the payment base hour rate plus premium based costs per 100 units produced, which approximately what employee receives his hourly rate for making the same number units that produces excess the set standard; or, other words, gets all saves time increasing his output. the set time for piece calls for output pieces per hr. and man produces pieces, his premium for the tive extra pieces approximately his hour rate for min. There benefit the company labor cost due increase the employee’s production over unit hr., there reduction the labor cost per unit, the only gain the employee being the gain that results from increased output without in- crease overhead. other words, the labor costs for piece are the same whether man maintains exceeds the unit hr. rate. Experience the company indicates that, provide the necessary incentive for increased effort, employee should offered premium per cent over his daily pay. While the set standard performance units per hr., representing normal effort, the standards indicate that efficient ployee should produce units per hr., and the plant This allows man per cent bonus above his daily rate. man spoils work, taken from his future premiums capacity rated that basis. THE MONARCH MACHINE TOOL COMPANY PAY ROLL SHEET WEEK ENDING DEPARTMENT _. 2—A daily record, designated payroll posting sheet, made 1658—The Iron Age, May 21, 1931 contains analysis every record, and posted ing day. This record shows whether man entitled 4 | DATE DATE DATE DATE DATE DATE DATE | | | THE DYER COST CONTROL ANALYSIS PLANT SUPERVISOR PER ENT Drvis PAY Re L CosT rar PRODUCTIVE WASTE PR T TOTAL PROD | EXCESS) waste Toran | TOTAL 25,000 72.50 _.00 al 8 are included the total. The figure top the column, 125,000, the TOTALS standard capacity for the month. + day work and producers’ non-pro ductive work | Mine~ ur the same rate allowed for ess per 100 units produces above the standard Bonus earnings are computed follows: Sup the employee produces 670 units 540 min., pose man’s hour rate 70c., which equivalent day, paid premium $1.28 for per 100 min. computing his premium, 130 units, which added his regular day deduction per cent set aside compensate wage $6.30. The standards ibject non-productive men. That reduces the basis inle there change methods his premium computed per 100 raw materials that would necessitate the adopt new standards. The are guaranteed PAY ROLL No. Weekly and Monthly Reports Sent Every Foreman The cost control analysis made out weekly, tne Weft y nyure t ule at the tt tne nonth. ided the for ind rlance the report shows the inder the same olur weeks and months. These are ompleted Tuesday noon, and copy once one month filled in. The first imn i ndicates the t i nur er oT il p! duced. Only productive black units are included total, rapped work and red unit having deducted, leaving the net salable production ecified pay period. The figure top ry Per cent capacit based higher base wages and points out the laggards ment being filled and ever The Iron Age, May 1931—1659 Dept.- G | | Unie | | i | — SHEET NO » OF SHEETS 4—A material control record sheet the key form the operation the production control system. every sub-assembly man working hr. every morning and for week and producing unit hr. rate. allow- ince made for unnecessary work and for out- of-balance condition machinery. Percentage the measured work the standard the percentage spent productive men The payroll divided into productive, waste and The payroll the non-productive labor. amount spent for true productive work. Waste pay- roll includes day work units give recognition the reduced efficiency day workers, measured units 60, lost time units due working these being non-productive sub-standard rate and waiting time, andard cost basis. The valued payroll includes all contributory labor such fore- and checker and also pro productive men Sweeper, trucker non-productive work done ] and non-productive labor valued the standard The total payroll the total the three items enumerated and includes the pay all labor used the department. Productive, waste and non-pro- ductive costs are distributed the basis actual facts and represent the cost productive effort, cost idleness its equivalent and the cost contributory effort respectively. Cost per 1000 units are into and into waste and non-productive costs that represent the cost excess the standard per contributory effort, and addition there column for excess productive cost, which the dif- erence between the standard cost shown head the column and the actual production cost. excess productive cost the result rates excess standard rates and extra payment due Waste and non-productive time tandard cost, and this extra shows excess other words, productive cost. aste non-productive time figure. Total dividing the total pay- units produced. money nent for w indicated the productive cost cost per 1000 units obtained roll the number thousands 1660—The Iron May 21, 1931 One these used for the cost per 1000 units goes down, the payroll cost must down, and, the cost the product goes up, the payroll cost shows increase. Effectiveness the control shown the two columns under the heading “Cost Control This factor the ratio between standard and actual expense and grand total cost per 1000 units. The total dividing standard costs actual costs, and the expense fac- tor obtained dividing standard expense total actual expense total. cost control factor obtained The operators’ unit hour denotes the speed which the operators are working. this figure the management knows that the operators are doing their part. true mathematical figure and obtained dividing the red and black units the minutes standard operations and multiply- ing the quotient 60. The departmental unit hour formula is: near 75, minutes standard+ measured time. can that measured and waiting time reduce the department unit hour. Both these full foremen and the depart- ment unit hour considered one the good mea- sures supervision. seen are under control The supervisor’s unit hour obtained divid- ing the units excess the departmental unit the pense cost control fac- hour ex- tor and adding 60. another figure de- tell glance the super- there waiting signed are time department, the departmental and operator hour the expense cost con trol factor Mex ORDER No SALES PART No PART NAME #0 Ds n Process Fo & Stock Process per week, less time for oiling the total minutes department. 1000 units for productive effort, due wasted time a Fi down 1.00, the supervisor’s hour will the same the departmental. Daily Records Posted Noon Every Department daily record, designated payroll post- ing sheet, made containing analysis every man’s record. This, shown Fig. posted noon each department and gives record the previous day. tells the foreman promptly what was accomplished, and from each man learns what and his fellow workers did and what they earned premiums. gives the name, clock num- ber, time spent contributory labor, producers’ non-productive labor, waiting time, day work time, black and red units produced and premium for the day. summary made the bottom. This record indicates the foreman whether men are producing much they should. Also, fur- nishes the management graphic record man’s unit hours, shows whether man entitled higher base wages, and points out the laggards, the latter information being value the selection men laid off dull times. The posting sheet summarized the bottom the sheet and fur- nishes the data for the cost control analysis. man’s daily time card shown Fig. This lists various operations, the aggregate time spent standard work, day work and producers’ non-pro- ductive work, all amounting 540 min. hr. The man produced 398 units 330 min. spent stand- ard work premium units, for which paid addition his day rate. The daily time card made out checker and goes the production department, where supplies data for the daily posting sheet. From 10,000 12,000 parts are required for the nine models and sizes lathes made, and these take 50,000 55,000 operations, each which has been time studied. Standard data, compiled from these studies, are used for setting the time all oper- ations except the assembly floor, where time studies instead standard data are used for all operations except scraping. The system has not in- volved much added expense, the work done two time-study men the production department and third the tool room, where most the work Time studies have been made various times that make operation, and these have been combined into standards for every machine and for parts all weights and shapes. The use various methods computation has made possible the set ting time for practically all classes work. Plain cylindrical grinding computed cu. basis, drilling r.p.m. and feed basis, milling based many thousandths cut per tooth, planing based feet per min. given feed per stroke and gear cutting based wholly time basis, cutting time being allowed Neither cutting time allowed for cutting off saws, flat time based standards being used. For clean ing, sand blasting and painting there are standards derived from area basis and reduced price Foremen, tool makers, sweepers, truckers, check ers, time-study work, typing and filing all come under the bonus system. Stenographers are allowed bonus based much per letter plus much per 1000 strokes which are computed with counters the typewriters. foreman’s premium based the cost per 1000 units his department shown the cost control analysis sheet, the rate differing with different foremen. Bonus for and truckers computed the same way foremen, but lower rate. expected that the system, after sufficient use give thorough test, will enable the man agement control costs, know what costs should and find the cause they are too high, and will velop higher efficiency throughout the plant, proved quality work and less spoilage men are penalized for scrapped work. also ables the foreman know more about the men under him and their work. For the men the wage incen- tive feature advantage because not only are they paid according their output, but pportu- nity for advancement afforded the best producer The first detail connection with the adopt MATERIA PART NAME A 5220 6—In case order entered through the purchas ing department, such for rough casting, this requisition form used. shows part number, name, material, and quantity ordered. Space provided for delivery dates used for ordering parts for each assembly This sheet gives part number and name, lot number, number ordered, number unit which the item forms part and the bin number 5220 + > 4 4 4 4 - — — The Age, May 21, 1931—1661 | 2 OATE ISSUE | DATE WANTED | | arith +} \ + of ll mack né 2 ld Wa ib-assemblies and attachments. An analvsis of this ind a Compa) ) Vitn a rresponding list To € previous vear ne ed the trend n the demand fry tren, and ot machines nd attachment the various machines and add the clerical cost preparing order. The value the piece includes material, labor and burden. The percentage used the cost carrying the stock, such interest, stor- mo | Order No. the cost carrying the inventory balanced with obsolescence, etc. the use this formula, the demand, and set-up cost and maximum return are assured from money invested. minimum set for each part based upon the number operations and Wo Weight Date Ordered Date Wanted I the time required produce the proper order quan- What might called the key form the opera- tion the production control system material control record sheet. (Fig. 4.) One these used for every sub-assembly. dozen these sheets might required controlling production all the units that make one lathe. The sales office, upon taking order, makes sales and factory order, which contains complete information the model, special attachments, etc. machine given serial number, which 8 BIN PART Check | Req PART NAME | No No From | Per | Amount Finished Storekeeper : | RETURN THIS TAG TO COST DEPARTMENT WHEN FINISHED | y 7—A unit assembly card used when parts for ub-assembiy are finished. This sent the mbly foreman, who withdraws the from the finished stock room ‘ON or the vea Inn king this fo 114, JO 8—All parts used each unit are listed assembly withdrawal card pre-determine the cost set-up 1662—The Iron Age, May 21, 1931 — Keep Tag With Wor | | Oper. No Operation } Premium Each [Set = | | 4 forecast that fairly accurate for the first three mont! Vn I over a productio: | | iryge number manul; tured parts and | ] ihe demand per annum hanged throughout the ondition Che duction use ile fore (Orde) Quantity | Value piece percentage (See below Standards are set for the set-up all jobs, — placed the order, and the inspector stamps this number the machine after completed. One copy this order goes the production depart- ment, one the superintendent and third tied + the lathe and shipped with The sales and factory order used the pro duction department making the material cor trol sheet. this control sheet listed the sub- assembly under its unit name and beneath are listed the various parts that make the Every sub-assembly has unit number which production department and entered the material production control sheet. The production control sheet reproduced indi- cates the method keeping the record. ex- ample, suppose order for machines requiring the manufacture type head stock has been } ar hy received and the production department schedules these head stocks for production. The quan- tity order entered the material control sheet that number units listed process the parts dog plate and these are Model Apron Control Builders Parts Name Bed Legs Bed Aligned Mownt Motor Mount Guards Testers Parts Pump and Piping Model No Omit Item No. Ordered By Delivered By final assembly card made out soon order received for lathe. This sent the superintendent who holds the card until parts are ready for the final assembly listed the left side the sheet. Beneath the same column are listed the blue print number, the part number and the number the bin which the part carried the stock room. The data listed the right side the produc- tion material control sheet comprise rough and finished material record and serve guide the production department ordering production. They also serve perpetual stock inventory. the top this record listed the order number and beneath it, the small squares, are shown the sub- assemblies stock and process, the parts stock and process and the material for each rough stock order. separate column used for each machine order, i.e., order received for duplicate machines, each would listed separately one the vertical columns. How the Factory Order Handled factory order made duplicate for the quantity each part made. copy this goes the engineering department obtain the blue print and then the standards department for the standards. The blue print and standards then the factory with the order. There the pink duplicate the order placed box the foreman’s desk and the other stays with the parts the floor. When the part moved from one depart- ment another both the order and pink duplicate are moved with it, and the pink copy goes the next foreman’s desk. When the order completed and delivered the stock room the factory order re- ordered order sheet (Fig. 5), bearing the part number and name, lot number, ordered, number unit which they are form part, and the bin number. this case mate rial requisition (Fig. was issued the purcha ing department for the rough casting This show the part number, name, material and quantity dered and space provided for entering deliverie pink duplicate the requisition filed the production department for following deliverie original requisition returned the produc tion department, and the castings received are entered this blank. When shipments are com pleted the factory order released When parts for sub-assembly are finished, order card (Fig. filled out and sent the assembly foreman, and withdraw the required stock from the finished stock room. All parts used each unit are listed assembly withdrawal card (Fig. 8), copies which are kept the production department, stock room and sembly foreman. The stock room uses this produc tion record for issuing parts against the unit assembly order card. After the assembly com pleted, the unit assembly order card goes back the production department and the proper entries units stock are made the material sheet. When order for lathe received, final as- sembly card (Fig. made out and sent the (Concluded page 1698) The Iron Age, May 21, 1931—1663 Card Add Items } HREAD gages are checked for angle lead and pitch diameter one setting this universal measuring microscope. Readings one-hundred thousandth inch are obtainable. personal element making fine measure- ments tools has been eliminated and the possibility disputes between departments over the acceptability work removed the re- cent action the Reo Motor Car Co., Lansing, Mich., establishing standards division which main- tains the standard accuracy for the entire plant. All commercial tools, that is, tools bought from outside sources, are sent this division from the receiving room passed upon before going the stockroom. Likewise all work turned out the company’s toolroom must inspected and accepted the division before used. This method abol- ore 1664—The Iron Age, May 21, 1931 SPECIAL TOOL INSPECTION DEPARTMENT REO PLANT ishes the practice department passing the merits its own performance, such the toolroom inspecting the tools which makes. Prior the creation the standards division the inspection jigs and fixtures was under the supervision the superintendent the toolroom and the inspection gages and tools under the fac- tory inspection department. This division re- sponsibility was terminated the substitution the standards division, the personnel which con- sists superintendent, jig and fixture inspector, gage inspector, gear specialist and tool inspector. The jig and fixture inspector and the tool inspector 4 | j ~ _ 1 4 i “ae q | a each have apprentice. The jig and fixture ap- prentice spends two and half months the de- partment before completing his course training and becoming tool maker. The gear specialist picks out the master gears and checks the gear hobs and gear cutters. The standards division well equipped with pre- cision instruments. all jobs where limits are less than 0.001 in., indicating micrometers are used not only the division itself, but also the fac- tory for checking work process. There are some Zeiss passameters distributed about the factory and constant use under the supervision the foremen the production departments. There are two optical dividing heads, one the standards di- vision and the other the toolroom. Among the measuring devices the standards division are improved optical universal bevel pro- tractor, optical division testing machine, optical gear tooth caliper, horizontal optimeter, inside indicator gage, universal measuring and the usual sets Johansson and Hoke gage blocks. Largely account the difference shape between the Johansson and Hoke instruments, has been dis- covered that both have their own applications, and under the circumstances the investment both justified. Whenever the standards division rejects tool, makes out rejection slip which accompanies the tool. the job has been done the company’s toolroom, the material goes the salvage depart- ment; otherwise, returned the vendor. The superintendent the division makes monthly re- port the factory manager, describing the work which has been done and future plans. This fre- quent enough maintain satisfactory supervision over the division’s activities. ENTRAL standards division the Reo Motor Car Co., (at left). Here all tools, gages, and jigs and fixtures are passed upon before use. checked this Zeiss length measuring ma- chine. master gage blocks are required for EASURING pitch diameter tap three-wire method with Zeiss indi cating micrometer. The dial gage reads plus minus 0.000) The standards division saving the company money, time and labor compared with the former system. has done even more, has increased efficiency and removed the cause for irritation be- tween manufacturing departments relieving them inspection duties. 4 = a = . / ~ j The Age, May 21, 1931—1665 hot metal from 35-ton ladle into con- verter prior blowing. Ladle controlled from distant station, lights serving indicate when the ladle properly spotted HREE 25-ton converters, two metal mixers and three 250-ton tilting open- hearth furnaces comprise the main units the new steel plant the National Tube Co. McKeesport. These have taken the place three old 9-ton converters and one 200-ton mixer, now scrapped, thereby greatly augmenting the capacity the plant and just greatly increasing the flexi- bility operation. The new steel-making equip- ment was built the Pennsylvania Engineering Works, New Castle, Pa. was designed for use either straight open- hearth plant for duplex operation, which the partly blown metal from the converters finished the open-hearth furnaces. The plant makes also considerable tonnage Bessemer steel fill or- ders calling for that material. can readily make straight open-hearth steel the scrap and metal process, desired. The first heat steel was made Dec. last. grade The new steel-making unit has length about 1800 ft. along the Monongahela River bank. This carries from the mold yard and blower house the west end the skull cracker and stockhouse the east end. Stretching along this area, order east the blower house, are the scrap yard, open-air converter bay, mixer house, open-hearth building house. The mold yard and stripper building are 1666—The Iron Age, May 21, 1931 south the converter bay, with ladle repair house between. The converter bottom house just north the mixer building. Space for gas producers has been reserved north the open-hearth building, but the producers have not yet been built, coke oven gas and tar are now used for fuel. Storage tanks the northeast corner the open-hearth building provide considerable capacity for storing tar fuel oil; while the skull cracker and cinder yard, just north the open- hearth stockhouse, complete the list major units the layout. system signal lights connecting mixers, con- verter control pulpit and open-hearth floor serves tell just what heat being made, being passed along for further refining. Mixers Completely Safeguarded unusually complete interconnection safety devices has been adopted the mixer house. Each mixer tilted from independent pulpit. square platform about ft. each way, the point where the operator stands handling his operating levers, connected mechanism below with ratchet and pawl the bottom the mixer. The pawl held the force gravity tightly the ratchet, except when the operator’s small platform depressed his weight standing upon it. This releases the pawl and permits the mixer turned down. — “ NATIONAL TUBE CO. WORKS LEXIBILITY operation, both what made and how much can made daily, features the new steel-making plant the National Tube Co. McKeesport. Such portions the old works could employed were retained, with considerable changes, but most the equipment, includ- ing all that used making the steel, new. This plant feeds mills making pipe all the present approved methods—lap-weld, butt-weld, seam- less and electrically-welded. the same time safety sw