The Iron Age 1931-07-02: Vol 128 Iss 1

ESTABLISHED 1855 comment, inspired the article VOL. 128, No. — GETTING BACK ARITHMETIC following symposium reader thought and . which appeared THE IRON AGE June 11, presents some unusual and noteworthy viewpoints. previous time our history have many able minds been concentrating upon the intricate relationships economic causes and effects. Were there other reasons for our en- couragement, this alone would guarantee future progress. contribution sound thinking represented the opinions the capable and experienced industrialists and financiers which follow. The careful consideration them will broaden our horizons and aid the solution our common problems. A J Common Sense and First Principles Ras banks in the larger financial centers are pessimistic they seem believe that all busi- ventures undertaken now are headed for failure. Consequently, they would never believe that the purchase of new machinery could result profits within any reason able time. pessimism that distinctly retarding recovery. the smaller cities think the banks are willing just what AGE New York, July 1931 you are proposing; willing far they can helping out this situation. They cannot take too much paper that not re-discount- able the Federal Reserve, and un- der the present laws loans for pur- chase equipment are not re-dis- countable. The privilege could easily abused. There used such things axioms dent truths—these seem to have gone the board recent years But even there are self-evi- dent truths, there are underlying principles which mathematicians truths their every-day equations Economics much more complex affair than mathematics, but doubt if economists can get away from first principles any more than can the mathematicians first principles are almost axiomatic, like the axioms, fact the mathematicians, and this practical world are proving just much so. Extravagance, waste, pro method forced selling, improvident buying duction by unnecessary expenditures whether personal or pu IC, are the resuit ol ° careless thinking, and not of any known first principles in economics Reduction the cost produc tion—a large factor which will the methods you outline the very first essential thing, and accordance with known first principles. Reduction our travagant ideas level more accordance with the present situa tion probably important, per- haps the most important, first step Common sense will then see what is to be done, step by step, instead being forced into the background illogical remedies foolish panaceas resulting from our strenu ous wishing things were otherwise than they actually are now. Extravagance, whether personal maintain our standards living. feared that material low ering these standards may necessary unless the common sense ! mankind can soon separate the 2—The Iron Age, July 1931 economists (however sincere they may these distressing times), who have lost sight fundamental principles, from those who can continue think straight adverse circum- stances. FRANCIS FARQUHAR, President, Farquhar Co., Ltd. Must Build Farmer Buying Power 4 formula you refer does not hold true our case the years since the war have pent money for new equipment far beyond anything that ever lid the past, and today, for the most part least, our shops are equipped to the minute with the best machinery available. the present time have many millions dollars tied idle machinery the very latest make simply be- use our customers, the farmers, are not able buy the labor-saving equipment they need wondering why all these studies you people make the present situation you leave the farmer entirely out your calcula- tions, that where the potential buying need exists today. Our cities are overbuilt, but the farms the country need improvements volume keep most the industries the country ac- tive for many years come they could obtain what they need and what they would buy they had the wherewithal. Your schedule would ible some cases, but not the complete answer. ALEXANDER LEGGE, President, International Harvester Co. Non-Elastic Markets Restrict Price Reductions long manutac- turers pass the public all the savings secured improve- 1 | cirency, they cannot expect such purposes Bankers must look repay loans. doubtful whether reductions in costs of many com- modities are any benefit any one that result lower prices the consumer without any addi- tional profit the creased production commodities that not possess elastic mar- ket may well cause more damage the manufacturers and distributers than any benefit the consuming public. illustration, many people believe that the nation whole would have been better off the unabsorbable surplus of. 000,000 bushels wheat had not 1 been produced this year even 3 bushels had cost just much produce. are makers mechanics’ hand tools. One our leading items carpenter’s claw hammer. The sell- ing price this hammer the con- sumer today $1. If, some way, were able make two hammers the time now takes make one, and those who supplied with material and supplies were able the same that could produce this hammer sell the consumer half the cost, 50c., the consumer would have buy two hammers place one enable and those from whom bought pay the same amount wages. The market for nail hammers possesses very little elasticity. consumers would buy very few additional hammers, that found ourselves able make two hammers the time now re- quires make one, should compelled lay off nearly one- half our force. This is, course, looking the industry whole and ignoring any competitive ad- vantage might possess. If, the other hand, recog nized the inelasticity our market and kept liberal share the sav- ing for our own business, would able increase the purchasing power paying good wages the employees retained and better dividends our stockholders, who would then able buy radios that would furnish employment the employees could longer keep busy. This the that missed your article Reduc tions in cost that bring increased volume of production of commodi market may prove more curse than blessing. Reductions cost that increase purchasing power FAYETTE PLUMB, President, Maladjustments Primary Elements Need Correction i+ seems to me that economic depressions are maladjustments the relationship the primary elements the ma- chinery commerce. this partic- ular instance should noted that the country was beginning emerge from the 1920 depression about provement had then set in, 1t w ould be sate to assume that the major e dustry in motion after 1 j “a that during the period between collapse 1920 and the coll apse 1929 the development labor-sav ing machinery reached its peak + that the actual production cost o all commodities wa < st i 4 1 half during that period. nanges in matter record that chang commodity price 5 were quent inflation the corporate shares. fairly obvious that the result such the period phase re iched ts peak in ments of the commercial! machine were fair state adjustment What has taken place since 1923 constantly increasing ment which has eventuated the stoppage the entire machine. historical fact that took three years start the wheels in- Stated other during that time words, that part the sel all commodities produced during that period which was paid the primary producers commodities was reduced per cent and that part which went into the earnings corporations was increased Dy a sim ilar amount. fairly obvious that the result such economic trend would the inflation corporate earnings and the conse- value It should also be procedure would the continuous diminution the purchasing power ot the wage earners ot the nation interesting sidelight the ire situation, however, is the in- crease instalment buying during review This and the served the purpose creating false purchasing power the pro duction the nation replace the purchasing power eliminated the reduction the share the production distributed fruits oft the wage earners And for a time the presence of the mon key wrench the machinery was hidden and the machine went taster and faster to tts eventual mash up Instalment buying may properly De considered as the corporate cap talization the individual and the application his earning capacity the purposes interest and amor ition on the debt created by his nstalment purchases there ore perfectly obvious that such program instalment buying initiated this country during the past decade must necessarily come to a sudden and violent stop when the aggregate earnings of the im dividuals engaged the program become insufhcient provide interest and amortization cn the debt thus created was taking piace the investor in corporate n ime inoculated with i ) timism which oon abandoned the yardstick earning the -asurement of the market vaiue oO corporate hares it therefore De came common practice ror tors purchase shares borrowed money at prices which were out ot all relationship to earnings and un essen- ler conditions which maa ae tial for them derive substantial market profits in order to continue carry their margin holdings. The Age, July 1931—3 | collapse asmuch such situation must necessity predicated continu- ously accelerating increases stock values it was from the outset fore- doomed collapse. Simultaneous- with the exhaustion the instal ment purchasing power ot the masses came the collapse the stock market October, 1929, and the wave of inflation which had been founded upon speculative winnings in the stock market on the one hand and instalment buying the masses on the other hand, crashed against the rocks to the complete confusion all concerned. The result this debacle was a Situation in which the demand for all types manufac- tured goods suddenly disappeared, which the swollen earnings corporations suddenly ceased and which the market for productive labor was suddenly eliminated. would seem that such situa tion would be entirely hopeless and that the entire economic structure the country must completely col lapse. There are the other hand forces which are apparently infrequently visible those whom they most affect. single stance, 1929 the price cotton held steady approximately lb. the present writing below 10c. course obvious that the purchasing power the country has been tremendously re duced, but highly possible conceive that cotton which was immovable, indigestible surplus 20c. will circulating commodity 9c.a lb. should further ob- served that, inasmuch the entire cotton-raising country was paralyzed the loss its 1930 crop, which was most cases raised the same scale the 1929 crop, will October, 1931, market large crop cotton which has been raised cost very much less than half the cost the crops 1929 and 1930 will further observed that the cost the 1931 cotton crop has not been reduced through any intelli- gent effort the part the raisers but the stern necessity raising crop with the funds and materials available. The average cotton farmer’s cred- 4—The Iron Age, July 1931 it has been exhausted since the dis- aster 1930. not been able obtain credit the country store, nor has he been able to obtain funds the country bank. has had raise his own food and feed and he has had to go without the luxuries which he had for some years begun consider neces- sities. The net result the year’s operations will be a crop of cotton valued something like $700,000,- 000 which has probably cost dol- lars and cents less than $100,000,000 to raise. The difference between these two figures will represent the net return the operations the Southern cotton farmers for the 1931 crop. When this released the sale the 1931 crop, belief that large part the financial obliga- tions the individual farmers will liquidated. These obligations are mostly due to the country banks and country stores. When these ob- ligations are liquidated the country banks and country stores will position liquidate their obliga- banks and obtain further credit. well known that burnt child dreads the fire and certainty that operations for the season 1932 will only slight- larger scale than 1931. should clear, however, that the turning point the present de- pression will the return the major crops 1930-31 and that the simple liquidation the obligations now outstanding against the farmers the country will the beginning the return what may hoped for more stable and intelligent prosperity than that which trag- ically exploded October, 1929. very interesting consider the result such momentous eco- nomic fluctuations the ebb and flow wealth between the primary producer and the corporate share- holder. The greater part all the fruits production during the last ten years finally found its way into the hands the owners the larger corporations. Shrinkage the value these securities, deple- tion surpluses through operating losses and numerous other influences which have tended chasten the hearts corporate directors have destroyed the major portion the wealth which was concentrated the treasuries the banks and large corporations. the other end the cycle there about pro- duced the hands the farmers and other primary producers new surplus wealth which will again restore normal circulation within the economic system. obvious that the same number hours labor will not necessary under the conditions the next era pro- duce the commodity requirements the same world. further ob- vious, however, that shorter shifts and shorter hours will prevail, that more leisure will available the individual and that result this change greater proportion the fruits and results world pro- duction will distributed among the masses who participate that production. general, feel that the United States today point along the economic highway which may prop- erly compared with 1923. be- lieve the next era violent pros- perity will begin approximately three years from October, 1931, during which time the fundamentals for such prosperity will estab- lished. believe between 1934 and 1938 boom similar the 1926- 1929 era wiil effect. believe, however, that the sanity the busi- ness leaders America will prevent where possible drastic maldis- tribution wealth took place the corresponding period the last decade, and that the ultimate col- lapse the impending era will delayed few years longer for that reason. further believe that each recur- rence the ebb and flow cycle will result less drastic readjustment than the previous one and that 7 & o ~ | | | pags the end will learn that the secret prosperity not winner-take-all but constant, even and equitable distribution the fruits men’s labor among all those who partici- HERE question but what have modernize American industry and American railroads. The thing need very careful about not over- build our industry, but discard the obsolete as we create the new. firmly the opinion that pate the production thereof. all { rac economy and preparation tor the DONALD McDONALD, JR., Vice-President, As stated above, personally I have seen many these depressions that they give fright tear whatever, otherwise than the suffer in it GEORGE HOUSTON, larger portion of pose that means that the unemployment. The only difference between this one and others that is more extensive and invoives a the world than ive other depressions, and I sup lay last somewnat longer So many attempts are being made > > > > 1 ol the obsolete equity ment it in various ways to stabilize Dusines this country was discarded now, and bring back prosperity, and would not have the impression some them are rather pitiful being over-built production lowering prices the time for the sake get President, rarely buy falling market. Baldwin Locomotive Works whether produce something else, and the lowering ot prices now Two and Two Still Make Four unfortunately, have been through all the depressions since 1873 and have had opportunity study the conditions existing during these depressions and watch the passing away them. way they are all alike and yet they are all different, one from physical disease and the patient prescribed for very much hu- man patient prescribed for va- rious doctors. may that the consultation that held over patient does any rate, physical good, more less. nature eventually brings the patient out the disease and restored health. This economic disease, through which are now passing, natural causes, very much phy- sical disease brought on, and will cured the same manner. any rate, know they are always cured, simply a questi yn of going along with patience and doing a | our individual selves, that is, each industry doing all can hasten the end careful management, imply brought about fear and | lea that business can be improv ed. hurts the business future and, without doubt, help tu lengthen the period sion Your article is a very interesting one and subject, but, as you very pertinently you cannot ithematics; two and two will make four spite all the juggling that we do ECHOLS, President, Or Greenfield Tap Die Corpn Commercial Banks’ Rela your journal, together with one else, much overestimates the ability commercial banks par- ticipate business. quite true that if, with capital which avail- able, producer finds possible less cost, ought get definite advantage out that situation tion New Equipment However, as I see it, it 1S quite mm possible for the commercial properly take any very substan tial part enabling the prod provide equipment. agree with certain extent, although there probably point at which our opinions would pro- (Conclude d on page 73) The Age, July bank to improved think that you may — —— = WHAT TECHNICAL MEN CAN HORNING President, Waukesha Motor Waukesha, Wis. title this talk Technical Men Leave rather irritates me. seems deadly this time, for out all this economic episode there comes realization that the world little knows the crushing despair and distress that come the heart every executive who must reduce hours turn men out into world that does not need them. Men mad sometimes when their fortunes are swept away, but have learned from many that this experience nothing the pain and anguish which comes laying off old and trusted employees. There certain type unemployment shops and among technical men which comes from the in- creased mass sales and production. This 6—The Iron Age, July 1931 unemployment comes during period readjust- ment and seldom permanent. The period read- justment finally solved new products within the industry, other products outside the industry, which may engage the training the technical men. these transitional periods, which may considered minor larger sense when only one industry, that the most serious problems unemployment occur and when difficult for industries stabilize. time like this, when major world-wide eco- nomic readjustment going on, industry more less helpless except where has built huge cash re- serves and has not over-capitalized the earning power its better years. hear great deal theoretical talk about stabilizing employ- ment. From observation among many in- dustries, appears certain that the leaders industry are willing make almost any sacrifice keep the organization intact and have devised every possible means sus- taining employment, even the serious de- universally, every expedient has been exhausted before resorting reduction salaries, rates pay reduction organization. reserves. Valuable Men Are Retained This brings the matter down what technical men can assure their own employment during periods readjustment. Nothing can take the place value services organization assuring con- tinuity service through thick and thin. While there are always extenuating circum- stances which apply some cases, without ex- ception the most valuabie men Periods great activity must depend floating population less efficient men fill the demands industrial activity, and some considered certain that this dilu- tion efficiency contributing cause the following depressions. During periods de- pression dire necessity drives those companies that would survive clean house. Next excellence service, length service is, with management, invariably the determining factor whether man kept not. Then comes regularity service. 4 4 ASSURE THEIR OWN EMPLOYMENT men fail because they are unwilling make the sacri- fice time and effort necessary qualify them for larger responsi- bilities, declared Horning, president, Waukesha Motor Waukesha, Wis., addressing the summer meeting the Society Automotive Engineers White Sulphur Springs, Va. One reason for their failure develop their latent powers, his opinion, subconscious pessimism which insidiously saps their courage and brings their aspirations down the dead level holding their jobs. Another obstacle their success their pronounced individualism—a lack intimate touch with the world outside the office wails, inability understand human nature. Mr. Horning’s address, presented abstract, holds message both for engineers and for management. Technical men, says, represent one the best types our civilization has created. Their untapped capabilities constitute major challenge managerial skill. The tragedy every business the frequent discovery some man who, having met every de- mand the growing company, has finally come the end his capacity for further growth. The management given the problem what with him, how give him another start salvage him without losing that priceless gift which the very fountain all achievement: combination pride, hope, initiative, inspiration and enthusiasm. broken spirit the saddest all human tragedies. The finest work management preserve the spirit while trying save the man, the investment him and his further possibilities. Want Increased Pay but Not More Responsibility This coming men stall keeping with the business the most frequent experience industry, and comes much more often than the case man becoming deeply discouraged and volun- tarily trying leave. Our experience that men technical positions have very little tendency break away. Only few are constantly making the whole effort for advancement, but, the case most men, the hope seems just hold their although this never expressed and may jobs, The vast never reach the level consciousness. majority men hope for improvement salary, but few are willing accept the wider responsibility that goes with the higher salaries. have been led suspect that there layer subconscious dis- couragement most men’s hearts, insidiously cor- which brings their attitude down this holding the job. business likely become less con roding, dead level just grows, Management scious the individual and his importance the company’s difficult achievements. The cost turnover among technical men compared with the possibilities that lie nothing The major cause turn dormant most them. over lies the choice men and failure man agement surround the men with conditions that permit them produce their best results. The sec ondary cause lies the unwillingness the men pay the price success—the sacrifice time and effort and the constant drive toward perfecting themselves. Turnover Measure Management Efficiency this connection should said that manage ment receives its greatest encouragement help men when sees and feels the willingness the men help themselves. The most discour- aging trying and living beyond his position. re- markable how frequently management becomes dis- couraged with young man who shows poor judg- ment and taste managing his personal affairs. Turnover largely the measure the efficiency management choosing the right person for each position and creating conditions that bring out the much all best men. Turnover may not mean The Iron Age, July onl — ra 4 4 that lost the training the man who leaves, and all the other inferred losses; more than any- thing else may mean low efficiency under which all the remaining men may working. may translate turnover into terms good will. The measure inside good will organization the ratio between what men are willing give and what they can give. Good will means lower turn- over. Being Kept Too Close the Office Detrimental Technical men should creative. They are often brought right down the level clerks routine work and the domination standards and rules. They have most difficult task visualizing what the public wants. There ever-changing picture these wants the one hand, and must met embodying ever-changing development More discouragement comes man agement from the results these changes than rom other source, and they are the cause discouragement engineers. The picture that tech- nical men get the public demands very inac curate one and comes through too many hands. The engineer often kept too close the office and not developed enough see things with the eyes the user and feel his mental twist. many cases these facts are effect hidden from the engineer, and even when gets them they are the form opinions and opinions very careless observers. Engineers are often criticized for honest work they which predicated the false infor- mation they have received. This results dissatis- caste the old organization. This fault man- agement for which technical men suffer, and one cause technical men leaving their positions. Another cause misunderstanding the engi- neers’ difficulty producing conditions the labor- atory that correspond with field service conditions. This difficulty that cannot corrected except vith real road tests. Engineers often fail intro- duce the factors sheer neglect, which road service means, realize that the ignorant user expects his apparatus work almost without care. These factors put blemish the finished work the engineer and sometimes are the cause dissatis- faction his work. The engineer often finds that sales and adminis- SUGGESTS ARE HEADING sMOST years ago, THE IRON AGE May ‘omy? Ollipaily paper Charles Hildreth, that time general secretary the National Machine Tool Build- ers’ Association. The diagram showed steady sequence busi ness cycles alternating ten vear schedule, peak to peak. In the 10-year ¢ the de ill lasted abi Vel © 60 AC) © repeated that order, have char- acterized move- ments pig tron -4 tury. oO t 0) al Age, July 1931 vears and the subsequent advance the new peak three years. the 9-year cycles there was 5-year decline and 4-year rise. The 8-year cycles showed six years decline and two years advance. Mr. Hildreth has been keeping this chart date and finds that has depicted conditions, during the past two decades, about the same manner before. The reproduction the chart indicates that, these conclusions hold true and history does UILDING ACTIVITY © a t | & 23, 1912, appeared diagram OYEADC I) VEADC — Awranc trative ends cannot keep the customer using the itself put into effect much delayed turnover product within the limits service for which and weed out those who have been allowed decay; was designed. Matters policy force engineers, they seldom have replaced. How much turn- under these conditions, perform miracles meet- over necessary keep organization first ing new situation. This common problem that class condition and how much excessive matter most serious the engineer and very trying results, and cannot stated. the organization and presents most serious predica- ment for the production man. Much discourage- Causes Dissatisfaction ment comes engineers who fail their perform- Dissatisfaction with compensation less fre ance miracles. quently the cause turnover among technical men Some turnover necessary. The common ten- than any other branch the service. There dency all human activities slow down. wide range compensation among technical men. characteristic human nature that, where life system has ever been devised that properly meas easy, men stagnate and character decays. There ured the value technical men. Their compensa always need stir men action. Dire tion largely determined what they can get, and always the incentive achievement. The aver- not always based their value. age man living about one-fourth his pos- Another cause dissatisfaction among technical sibilities, and, aside from the ordinary spurs that men, particularly those inventive turn, that management may use, few men losing their posi- comes under the head compensation feelin tions leaving the organization may have salu- that the raw conception idea should receiv tary effect upon both management and organization. substantial portion the gross returns. Here ther positive evil. the sign decay. Usually the and responsibilities development This type first thing necessary save falling company from page 51) » & FOR NEW PEAK 1935 peat itself indicated, have made new low thi Philadelphia No. anthracite foundry pig iron wer year and may look for high about 1935. used. Before that the prices were for Scotch pig iron, Following out the analogy, another major cycle reported the United States Treasury Depart years length may come after 1935, culminating ment connection with imports that 1945 and with its low about 1942. The World War apparently threw the cycle out Points this chart for several decades have been so, for the 10-year interval would have worked out from quotations No. foundry pig minated 1918, whereas the two peak hown (in iron Philadelphia, reported weekly THE IRON 1917 and 1920) took the place 1918, the interval AGE. From 1844 1874 average prices having been bridged over largely controlled pri REA CONTROL will noted that the subdivisions the full cycles are repeated over ~ 4 q 4 , , The Age, July 1931—9 first glance rate setting may seem “just another system.” However, the lack lies the heart many foundry- man’s troubles. should used cover molding and core making means reducing and controlling direct labor cost, basis for standard cost finding, and basis for exact esti- mating. large percentage gray iron foundries, more especially the smaller jobbing foundries, have the day-work method payment Some the larger jobbing gray iron foundries and good many steel foundries use piece work, but unfortunately piece rates most cases are set merely accordance with the judgment the superintendent, foreman rate setter. Two Kinds Time Studies Piece work insures lower labor costs than work, even when the rates are set merely ment. Nevertheless, piece prices ordinarily may considerably reduced the use scientific rate setting, which involves stop-watch studies. There are two distinct kinds time studies—one with reference the individual pattern core box, the other with reference individual elements the vork. all jobbing foundries, and many foun- dries making standard product, time studying individual patterns would tremendous and more less continuous task; consequently, shall deal with the second method—time studies covering ele- mentary operations rather than specific patterns. Here molding and core making are not merely operations, but each represents combination large number elementary operations connection with each which there unit that will properly measure the distinction labor difficulty between one pattern core box and another. Molding, for instance, calls for certain flask handling, sand han- 10—The Iron July 1931 SCIENTIFIC RATE SETTING HARRISON Partner, Stevenson, Harrison Management Engineers, New York dling, core and supply handling, finishing and other elements. Thus, only necessary establish basic rates, expressed proper units measure, order make possible build synthetically over-all time allowance cover the making mold from any pattern any flask. the table are listed numerous elements floor molding, grouped accordance with the units which they are measured. Under this system there are two distinct steps. The first make time studies and build charts tables covering all elementary time allowances. This task rapidly completed once and for all. The second step has with establishing time allowances for individual patterns and core boxes from the basic data. some cases the elements groups elements connection with time studies elementary time allowances are measured single unit time which multiplied the factor representing volume, pieces. other cases the unit changes with the size, volume piece and the basic data may best presented the form charts tables. The “flask elements are good illustration this point, the allowance per 100 sq. in. flask area varies with the size the flask and therefore may best presented chart form. There are three charts which reflect the varving amount labor difficulty making the joint. Time Studies Should Made Locally While there much similarity between the time allowances established different foundries the same type, necessary make time studies locally order sure that the standard times reflect local conditions, equipment and methods. The time required make these studies varies with the range the work, but well spent because the permanent, basic and vital nature the informa- tion developed. | REDUCES FOUNDRY COSTS work luxury few foundries can afford. good wage incentive system should reduce the labor cost the average day-work foundry per cent, states the author this article, which abstract paper presented the cost session the recent annual meeting the American Foundrymen’s Association. points out why scientific rate setting molding and core-making operations important means reducing and controlling direct labor costs, basis for standard cost finding, and basis for exact estimating. jobbing foundries rate setting continuous task, and any foundry task that must done whenever pattern goes into the sand for the first time. calculate time allowances specific patterns requires that the patterns measured and certain computations made. This takes varying amount effort according the type work. The compilation for molding machine pattern may made min. the ordinary run side floor jobs the time per pattern may min., and center floor jobs longer time the pattern large and intricate. miscellaneous work, therefore, rate setter may readily cover patterns day. Since time allowances these patterns need computed only once, rate setting time job. Wage Incentives Are Effective For those who are still using day work, should said that wage incentives are especially effective such largely manual operations molding and The pace day workers these slow compared with the Piece core making. operations ordinarily pace under any effective wage incentive plan. work bonus frequently will double the output per man-hour with large reduction direct labor costs. bonus system does not apply short runs inherent jobbing work. Once the elementary times have been established, the rate-setting problem becomes easy that jobbing foundries longer have ex- cuse for operating day-work basis. The aver- age foundry executive does not understand ap- preciate the difference between piece work and cannot picture piece work his plant bonus. likely draw the erroneous conclusion that wage incentive system possible. fact that bonus much more elastic than piece work that may made work effec tively under almost any condition. Short runs and other difficulties encountered jobbing foundries may covered properly designed bonus system, even where piece work might not readily plicable. Where rates are set judgment, there assurance that two rate setters will get the same results, even that given rate setter will get the same results different times. Scientific basic data, the contrary, lead rates that are not only equitable, but also are ordinarily lower uniformly “rule-of-thumb” methods the average than under Day work luxury few foundries can afford. good wage incentive system should reduce the labor cost the average day-work foundry r Moreover, scientific rate setting will save Ce iit money compared with rate setting judgment. Unintelligent Competition Feared not What foundrymen have fear competition much unintelligent competition the member who does not know his costs therefore, which aids the determination Elementary time allowances system, costs important. provide means predetermining direct labor costs and total costs by indi- words, they make possible standard cost system. Under standard cost t operating for the is accounted the actual cos month for under two heads: standard product, and varia- tions from standard. (Concluded on page 52) 4 ADVANTAGES TWIN-MOTOR DRIVE FOR ROLLING Westinghouse Electric Mfg. EVELOPMENT the twin-motor drive for main rolls logical step the modern trend toward greater plicity rolling mill machinery. The term “twin motor” refers form rolling mill drive which each pair rolls driven indepen- drive the motors may not exactly same speed all times. Nor depend en- tirely the coupling effect the metal being rolled maintain correct load division and sreed relation drive for been ndent used for wheel and tire mills, piercing mills, and tube expanders and reelers these installations the motors have rotated one direction only tically constant speed, and the metal between the provided effective coupling and rather definitely fixed the speed versing beam mills with independently driven edging rolls are also successful operation. demonstrated Experience with beam mills has relations two reversing motors that tne speed working the same piece steel could adjusted take care varying drafts, with indications unusual roll slippage. This experience therefore formed important step the development the twin-motor drive. When the electrical equipment for ing mill first came under consideration was felt that the continuous capacity and maximum the reversing motor should greater than any- thing previously used, provide power roll heav- ier sections higher tonnage rates. both 10,000-hp. and 12,000-hp. equipments with max- imum torques 3,940,000 and 4,725,000 respectively, were considered. previous licate mill had been equipped with 8000-hp., r.p.m. drive with rated maximum lb.-ft. torque ot For the higher motor torques was thought that the drive for the new mill could improved mechan- ically eliminating the mill pinions. This mechan- ical improvement has been realized. But other ad- vantages the twin-motor drive, such greater flexibility, greater ease handling, lower motor 12—The Iron Age, July 1931 East Pittsburgh inertia, higher average rolling speed and greater tonnage output far outweigh the expected ad- vantages that the latter now This, course, the history many developments. Reaching Limitations Shipping Size Design reversing equipment for continuous capacities 10,000 hp. and 12,000 hp. r.p.m., and good for maximum torques approaching 4,000,- 000 and 5,000,000 respectively, presents some interesting problems. motor with armature would have advantages account its implicity and comparatively high efficiency. The maximum capacity which has far been built with single-unit armature 8000 hp. r.p.m. One such motor has armature diameter 180 in. about the maximum diameter which can shipped in one piece. design proportions, about 10,000 hp. continuous capacity r.p.m., with 3,300,000 lb.-ft. maximum torque, the largest motor which could built with single-unit armature. The inertia such motor would 230 per cent that the 10,000-hp. twin-motor drive finally adopted. So, while theoretically may possible build single-unit motors for much greater capacities than are now required, practical considerations such shipping space and inertia rather definitely fix the limits capacity which can built into one arma- ture. double-armature motor offers the best possi- bilities for single machine 10,000 12,000 hp. capacity With double-armature motor this rating necessary decide whether use three generators four generators and which one four five possible schemes main connec- tions should Even with double-arma- ture motor the inertia nearly twice that twin- motor drive. the construction electrical equipment for high-capacity reversing drive somewhat more complex than for small and medium ratings. Pinion stands suitable for transmitting torques 4,000,000 5,000,000 become very large and heavy, and their design and manufacture involve SING two motors drive the two rolls reversing blooming mill confers certain advantages control addition, gets away from the exces- sive sizes—sometimes involving difficulty shipping encountered with single motors the great powers now required. Some the factors involved are outlined paper before the Association and Steel Electrical Engineers Cleve- land, June 16, and here abstracted. serious mechanical problems. The twin-motor drive therefore offers both mechanical and electrical ad- vantages. The twin-motor drive finally selected for the 54- in. blooming mill consists two 5000-hp. r.p.m. double-armature motors with combined rating 3,940,000 Each maximum torque armature wound for 350 volts and the two arma- tures one motor are connected series. The two drive fer mill, motors operate parallel and receive power from upper left, with the lower motor almost hidden under the spindle from the upper unit. fore- three 3000-kw., 700-volt generators, connected ground the flywheel-type motor-generator set parallel. The motor-generator set has 90-ton, 15- ft. diameter steel plate flywheel, and driven 6500-hp., 368 r.p.m. induction motor. Mechanical arrangement the motors, spindles, motor drive are quite different from those con- and rolls shown. The mill rolls are normally ventional reversing equipment driving through pin- in. diameter over the collars and the motors are ions. Probably the first thing which impresses mounted centers. The relative eleva observer the quietness the mill. The steel tions the motors and rolls are such that the lower ters the rolls without shock and the usual vibration deg. and the and noises the mill spindles are absent. There spindle operates ang upper spindle has angle deg. below practically tendency when the rolls are together, and deg. above hori- the steel entered the rolls. zontal when the rolls are set for maximum separa- this account the roller does not have exert tion. The mill spindles are ft. long, which can ente for the mill chatter when the usual care entering the steel. The maximum angle the upper spindle for the fore saves time the early breakdown passes pinion drive, corresponding the same roll separa- With twin-motor drive the phase positions the ion, 8.5 deg. rolls can shift independently, that they can quick the steel, thus removing the One diagram shows the comparative space re- quirements and spindle angles cause roll chatter. the other hand, with r.p.m. drive with pinions and 10,000-hp., r.p.m pinion drive the independent movement the rolls twin-motor drive. will noted that, with the limited the back-lash the pinions and spin- pinion drive, the spindles operate under the most dles. The real flexibility favorable conditions when the rolls are close to- movement these the gether. ing worse rather than improve it. Next, the observer will note the unusually high Quietness Characterizes Twin-Motor Operation deceleration the mill But the heaviest loads usually come when the in- acceleration and got large and the upper spindle considerably in- This due the comparatively low the clined. With twin-motor drive the spindle angle motors, which allows the control designed for minimum when the rolls are considerably separated, fast field response without causing high which more nearly the condition for maximum currents and high reverse power cur- rents. The electrical equipment therefore used rolling loads. ents. unusué ] cele The Iron Age, July 1931—13 2 iq 5 ; — --- Main Horizontal Rolls better advantage and the capacity for useful work increased. Advantage Celerity Changing Direction Quick response the motors increases the tering speed and average rolling speed. This creases the rolling time and increases the percentage time the metal the rolls. This effect re- flected the increased power input necessary keep the flywheel motor-generator set speed. 8000-hp., 54-in. mill drive the Pittsburgh dis- trict has flywheel set with 5000-hp. driving motor. Satisfactory operation obtained with slip regu- lator setting 5000 kw. When rolling the same weight ingots with the same number passes, and with practically the same load currents, the mill with twin-motor drive, slip regulator setting 7500 8000 kw. required keep the flywheel set speed. And this when rolling rate which easil\ maintained, showing that the rolling done faster rate. Arrangement main spindles for 44-in. slabbing mill tor drive. | {C1 Lowor Mofor Principal advantages the twin-motor drive for reversing service can summarized follows: The motor capacity which may applied single pair rolls greatly increased. Pinion losses, repairs and maintenance are elimi- nated. The motors may designed have greatly re- duced inertia; resulting less strain the equipment, more torque available for useful work, reduced motor and generator heating and faster acceleration. Roll chatter and spindle vibration are practically eliminated. Higher rolling speeds can maintained and mill tonnage can increased. Relative first costs twin-motor reversing drive and pinion drive will vary with the size and torque requirements the mill. The two motors twin- motor drive, with necessary shafting and bearings, are more expensive build than single motor equivalent capacity. This increase cost may (Concluded page 20) Mechanical arrangement twin-motor blooming mill drive, compared with 8000 hp. pinion drive, both designed for 54-in. mill. 14—The Iron Age, July 1931 | | 3 45 C.L.of Mo tor = | | } w — 4 ‘ one tL >. ~ + = ~ “ na > : + > ) + + ~ ~ =tec ay Ewing Gallow é | 4 “ f 4 ENAMELING MECHANIZED the latest installations for applying and burning vitreous enamel steel has furnace with two overhead traveling con- which extend through and loop back the outside. equipping the furnace with temperature controls the unit becomes automatic and continues operation. Dipping, spraying, drying and brushing units are placed along the exposed portions the conveyors, that all phases the process are concentrated and conveyorized. Such installation the plant the Peer- less Enamel Products Co., Belleville, which con- ducts business for stove and other manu- facturers. This plant operates mass-production basis and some very unique setups have been de- vised speed the processing and handling the work. The enameling setup was designed and built the Surface Combustion Corpn., Toledo, Ohio, the furnace being known the Beemack type. This furnace the counterflow type, heated with gas, constructed brick incased steel and designed for more than 1000 sq. ft. ware ft. length outside, ft. wide and ft. high, the walls consisting roughly in. firebrick and in. insulation. divided into two separate heating chambers, longitudinally, each with overhead conveyor carrying its load through direction opposite the travel the hour. > side one end the furnace, showing parts coming out after the enamel burned and passing the next operation. 16—The Iron Age, July 1931 | | COUNTER-FLOW layout volving duplicate runs through the furnace, with heat interchange between cold incoming parts and hot outgoing parts, used with great satisfaction Illi- nois plant. Not only much heat saved the arrange- ment furnace dryers, dip tanks and spray booths, but greatly facilitated thereby. PRINCIPLE OWEN Chicago District Manager, Surface Combustion Corpn INTERCHANGER | RYER CONVE YOR AYOUT furnace unit, showing the way heat interchanged from the outgoing parts those entering the unit. The arrows show direction motion the conveyor carrying parts through the system other, and returning outside and parallel the furnace. These conveyors, the overhead monorail type. are supported steel framework just above the They long tools, which extend down furnace. the roof, into the furnace through two narrow slit and the work suspended from these tools. The conveyor chains operate large sprockets, driven through speed-reduction units that the heating reriods can regulated controlling the pass along over the motor- conveyor speed. The chains top the furnace special patented airtight structure, from the brickwork. This pre- vents both the overheating the chains and loss heat through the tool slits. Each loop conveyor ft. long and ft. wide from chain chain and extends 16% ft. beyond each end the furnace. Opposite the center the fur- nace, each side, dryer, utilizing the waste heat from the hot zone, through which the conveyor The dip, spray and brush units are placed along the conveyors and the work passes through the dryers, after the coats have been applied, that can brushed edged before entering the fur- nace vitrified. Heat Interchange Saves Fuel Each longitudinal chamber the furnace di- 4 vided into five sections, known respectively heat interchange, preheat, high heat, heat interchange The high-heat zones occupy the and cooling zones length furnace, are ft. center section the muffle each hot contain alloy muffles. The extends through the preheat zone and termi- flue which extends the dryer; waste nates gases from the dryer are exhausted through The hot zone low-pressure water-cooled gas burners, set The Surface each side heated with six the ill and firing into the muffles. outer gas-air proportioning, Combustion principle furnace atmosphere can had automati- employed. duct carrying the that any cally and continuously, air under pressure extends along the center top the furnace. structure, hoods surrounding the conveyor chains, right pressure keep the heat the furnace the from rising through the tool slots. This air fed into the airtight and ft. Each dryer ft. long, ft. wide high. They are constructed brick and are open the top, but are hooded that the products combustion pass through, from the bottom the top, and out the stack. The conveyor, tools and work irectly through. The openings each end closed with doors, the opera- ous. But the heat the air prevented from entering, Hot air sucked from the furnace fan into duct which ends long, narrow just under each opening and the outside. furnace (Concluded page 51) The Age, July 1931—17 TACK GS HEAT HOT PREHEAT HEAT = c GER INTERCHANGER , ZONE | INTERCHAN é | | | OOL ING PREHEAT HC | HEAT LING | ks | | ERMANENT type mooring mast—being that the Naval Air Station Lakehurst, Photograph