The Iron Age 1934-12-06: Vol 134 Iss 23

THE IRON AGE od- Managing Editor Consulting News Machinery Editor Pittsburgh Detroit Boston ave FP. L. PRENTISsS R. A. Fisks A, I, FInpLey L. W. Morrerr R. G. McIntTos# Cleveland Editor Emeritus Washington Contents the CODE The Appointed ARTS Modern Polishing Production Basis oke, Welding Reinforced Chair Construction rive Business Men’s Prosperity Survey ngs Today’s Foremen Are Bigger Men ad- ans- . . New Things Materials and Processes Alloy Steels Railroad Equipment er- When and How Train Welders are this Washington tne lum- Construction and Equipment Buying Jer- have THE IRON AGE PUBLISHING COMPANY FRANK, President GRIFFITHS, Secretary BAUR, General Advertising Manager vater PUBLICATION OFFICE: Corner Chestnut and 56th Sts., Philadelphia, Pa. EXECUTIVE OFFICES: 239 West 39th New York, that, mar- ADVERTISING STAFF reign Member, Audit Bureau Circulations Emerson Findley, 311 Union Bldg., Cleveland Member, Associated Business Papers Herman, 675 Delaware Ave., Buffalo, Hottenstein, 802 Otis Chicago Published every Thursday. Subscription Price: Peirce Lewis, 7310 Woodward Ave., Detroit United States and Possessions, Mexico, Cuba, Charles Lundberg, Chilton Bldg., Chestnut $6.00; Canada, $8.50, including duty; Foreign 56th Sts., Philadelphia, Pa. mina- $12.00 year. Single Copy Cents. Ober, 239 39th St., New York What W. B. Robinson, 428 Park Bldg., Pittsburgh Cable Address, ‘‘Ironage, Sweetser, 239 West 39th New York prod- Warren, Box 81, Hartford, Conn. EIGHTIETH YEAR SERVICE THE METAL WORKING INDUSTRY Recent develop- ments wheel suspension have brought variety new parts. All these parts carry great responsibility. And, they are more less intricate forg- ings, the highest importance that bars and billets sound and free from sur- face defects that might cause hidden points weakness. Whatever the steel you decide use any part, having Bethlehem make long step toward obtaining the maximum com- bination desirable characteristics which the analysis capable. Bethlehem Alloy Steels have not only the internal soundness and per- fection surface that mean reliability and long life, but the machinability and uniform heat-treating that make for low production costs. BETHLEHEM STEEL COMPANY GENERAL OFFICES: BETHLEHEM, PA. BETHLEHEM ALLOY STEELS THE IRON AGE.....DECEMBER 1934 Page = 4 ta yi he 7 | THE IRON ESTABLISHED 1855 DECEMBER 1934 Vol. 134, No. The Appointed Time our firm opinion that this the appointed time for business and industry gird their loins and step forth battle for better and bigger business. There are several good sound reasons back this opinion. One these is, perhaps, negative reason, but important never- theless. that the theorists and experimenters have been given their chance and have failed make good. The professorial sword longer hangs over the heads those who have deal with cold facts and meet actual payrolls. The second sound reason, also more less negative one, equally important. that organized labor has had and has spent its political fling. Hereafter must earn whatever advancement may achieve, not political chicanery, but the demonstration enlightened leadership which puts public interest ahead union funds and power. The third reason more less political one. the undoubted realization the Administration that whatever may have caused victory the last election, the next one will depend upon substantial business recovery. Thus, for the next two years, the inter- ests the Administration and the interests sound and progressive business will coincide. business and industry not capitalize this splendid oppor- tunity for demonstrating their public worth, they will deserve what- ever fate may lie store for them, whether State Socialism, Communism Fascism. however, there are plenty indi- cations that they will live their large responsibilities. Our business leaders are already hard work, shaping program action which gives promise the attainment recovery plus the achievement reforms which well intentioned man can take exception. are not going back wholesale acceptance pre- depression ideas and ideals; are going reject those that were bad, cleave those that were good and inaugurate some that are better. the meantime, business “on the spot” the sense that the public, political and private, looks for leadership and action. cannot all provide the leadership, but all can help provide action. can this forgetting the depression, taking fresh hold courage and enthusiasm and striving with all our might make our own businesses bigger and better. 5 = om- eels per- and orm for FIG. old “heads” washing. 4 FIG. up” the wheels 16—The Iron Age, December 1934 HIS article illustrates and de- scribes some the methods followed the plant the White Sewing Machine Co., Cleveland. This company has been making sewing machines for years and thus its methods are the result long practice, together with the adoption innovations from time time. Sewing machines must present attractive appearance the prospective purchaser; thus all polishing operations conducted with care. produc- tion costs must carefully considered the production any unit sold competi- tive basis, the polishing costs, course, must kept normal. The company’s output approxi- mately 60,000 machines annually, each machine having polished parts. Thus total about 2,500,- separate parts are polished annually. Eighteen polishing and buffing lathes are operation, and keep the operators supplied with suitable wheels stock approximately 500 carried all times, set ready for use. often was looked upon nec- essary evil carried out cheaply possible rule thumb methods. Thus every individual pol- isher had his own theories which put into practice often the detri- ment efficient production. sive production during the past fifteen years have invaded the polishing room that today progressive plants the old art polishing receiving con- siderable attention. recent Considered the abstract, polish- ing simple operation consisting removing scratches and bringing out suitable luster putting the parts over successive wheels coated Mat pol- tri- the ish- ing ing the ted Polishing Production Basis with various grits abrasives. From practical point view, however, each individual operation must considered separately and this one reason why polishing room practice varies greatly, even shops the same locality. Economy any polishing opera- tion depends large measure the care exercised setting the wheels with glue and emery. the wheel head has been damaged that broken places the wheel must washed remove the old head. This operation performed shown Fig. This so-called roller type washer designed the White company’s engineers. consists two cast iron rollers driven single overhead belt speed Fig. shows, the rollers are partly immersed water while rails are provided keep the wheel place the roller faces. the rollers rotate water conveyed the wheel face. This softens the old head that can removed read- ily. The moisture does not penetrate the wheel the centrifugal force throws off constantly. If, however, the wheel head has not been injured all that necessary clean with any grease solvent, such gaso- line, after which ready for set- ting up. The only difference between heading and setting wheel that the first operation consists applying successive coats glue and abrasive, while setting calls for one perhaps two coats only. The glue used the plant ques- tion first run hide product sup- plied especially for setting wheels. Due the fact that old glue loses its holding power rapidly, only enough last few hours made time. The glue heated special heater provided for this purpose with pro- vision for keeping the temperature point not exceed 150 deg. Fahr. setting fine grit wheels somewhat lighter mixture em- ployed than used for coarse grits. general, however, the mixture what FRED JACOBS FIG. Balancing device for polishing wheels. FIG. 4—Part the FIG. 5—Hand hole cover plates. The Iron Age, December 1934—17 ist ly, all Iron Age, December 1934 FIG. Polishing fixtures for plates. FIG. 7—Die cast hand wheels and racks. FIG. 8—Polishing the hand wheels. FIG. 9—Electric light shades. called two one, that two parts water (by weight) one part glue. For fine grits, the mixture diluted. Setting the wheels done one man only. shown Fig. the wheel coated with glue and then rolled the abrasive, different grits being kept covered wood troughs exclude dust. This important, for few particles foreign matter might leave deep scratches which would necessitate repolishing re- move them. Each polisher balances his own wheels just before mounts them for use. This done level bal- ancing ways shown Fig. this test the wheel shows out balance, lead nailed the light side the wheel compensate for the heavy side. This cut and try operation, but experienced man can approximate the amount lead necessary within close limits. Part the wheel stock shown Fig. The wheels vary from in. diameter and from in. face. Some are wood, leather faced, others are felt, and others built muslin buff sections glued together under pressure. Many these wheels have formed faces fit the work. The wheel shown the lower foreground in. diam- eter, in. face, wood with leather face. These wheels are made the White plant from clear grain pine in. sections with the grain each alternate section running right angles. The leather facing comes to- gether with butt joint, while the leather held securely place the wheel gluing and pegging. The parts shown Fig. are hand hole cover plates. During the vari- ous polishing processes the parts are stored the type box container shown which holds 108 pieces. The use such container keeps the plates from getting scratched. Re- ferring the part resting its edge, the three spots are the result elec- tric welding. The object polish- ing the parts remove these marks and finish the entire surface ready for plating. The polishing operation that the operator holds the piece wood fixture which hinged and provided with two handles. When the handles are brought together with slight pressure the piece gripped firmly. The wheels used for polish- ing are wood, leather faced, and all wheels are operated surface speed 7500 ft. per min. First the pieces are put over wheel set with No. 140 manufactured alumina. Then come two greasing operations one after another over wheels set with q q face sew. are are also | diffi No. 180 emery. The second wheel one that has been worn comparatively smooth the first operation. Last the parts are put over greased wheel set with emery. After the parts are nickel plated they are buffed with white buffing compound. Then they are chrome plated. The parts shown Fig. are hand- wheels. Formerly these were made cast iron, but die castings have been substituted. The object the pile rack which the parts are placed prevent scratching the highly finished surfaces. This rack will conveniently hold wheels. cast iron base with four uprights made ordinary iron pipe screwed place. The polishing operation shown Fig. The operator holds the wheel over arbor and bringing angle against the wheel, the face which grooved slightly, the action the polishing wheel causes the hand wheel turn. Thus polished readily and evenly. The pol- ishing’ wheel hard felt. The first ‘operation consists cutting down with No. 140 manufactured abrasive. This done greased wheel. Then similar operation greased wheel set with No. 180 emery fol- lows. Next the parts are buffed with white compound, after which they are ready for nickel and chrome plating. The parts shown the box Fig. are electric light shades used sewing machines. This receptacle made hold parts. These shades are made sheet brass. After they are blanked out punch press they are cut down with tripoli and then buffed with rouge loose muslin wheel. The object this operation make very smooth surfaces that the metal will “flow” readily when placed between the forming dies. After the parts are formed they are polished the outside with muslin wheel set with No. 180 emery. Then they are again buffed with rouge bring out the luster. The inside also buffed. This somewhat difficult operation performed soft wheel small diameter that con- forms the inside contour. this the axis the wheel Square with the work instead par- allel. other words, the work pressed against the side the The parts then are nickel and chrome plated. The work rack shown Fig. made hold sewing machine only board with bored holes, deep enough hold the shuttles that they not project above the sur- face. Thus several boards can FIG. 10—Work rack for shuttles. FIG. Polishing curved shuttle face. FIG. Polishing shuttle point. stacked one above another. Over separate polishing operations are in- volved polishing the shuttles, many them being performed formed wheels. The operator Fig. polishing the curve shuttle face formed wheel, the shuttle being located holder. Several wheels are used, set with No. and 120 manufac- tured alumina and No. 140 emery. The latter wheel greased. Then the shuttles are put over similar wheel that has been worn smooth the first operation with No. 140 grit. Fig. shows how the under surface the shuttle point ished, the wheel face being undercut accommodate the work. Many small parts are polished tumbling with steel balls with water and soap compound. this opera- tion carried out properly the result- ing parts present even surfaces for plating. The value this method readily apparent, for these small parts were hand polished the cost would prohibitive. After tumbling until satisfactory polish results, the are thoroughly cleaned and dried tumbling them sawdust. The Iron Age, December 1934—19 i. 6 m- 7 ri- sh- ‘ks ion ith sh- all ces ith ith procedure, will worth while how these chairs are constructed. They are made partly and partly wood, the dif- ferent parts being combined reinforce each other. That is, the posts, backs and seats are wood. The stretchers, rails and seat bracing are gage steel. The stretchers are in. steel channels, and the steel boxing under the seats in. angle iron. The vertical steel supports are in. angle iron. The steel mem- bers are assembled separately shown Fig. and then combined later with the wooden parts shown Fig. These illustrations show detail how these chairs are con- structed. The history how these chairs came made and the essential part played welding very inter- esting and illustrates forcibly how the progress and prosperity man- ufacturer depends his keeping date all branches his man- agement technique. For instance the plant the Allen Chair Co. discussing the welding Fig. rails and seat bracing are ga. steel. These are optional and used for Allen Chair Co. West Concord, Mass., makes, among other things, steel reinforced chairs for use schools and other places where the service severe. The steel parts are joined together spot welds. Tests have shown them possess great strength. Furthermore, the cost these chairs much less with welding than would with other meth- ods construction, not men- tion the superior appearance and greater strength. actually wood-working shop and there secure material for article welding seemed most de- cidedly anomalous. The fact the matter that this company has been trying expand its market. With setup chairs the limits competition were Pennsylvania, New York and New England because freight rates. Consequently knockdown chair was developed and patented 1930. restaurant use, are not shown blueprint 20—The Iron Age, December 1934 Reinforced Chair good deal development was still and was not until Oc- tober, 1931, that the present type chair was placed production, after more than year experimenting and testing. The steel frame standard, but the wooden parts can greatly va- ried meet different specifications for design and decorative schemes. The result that custom-made chair produced. They can also shipped parts and assembled des- tination, with corresponding reduc- tion freight charges and wider area distribution. Spot welding has made this type chair with the desired characteristics possible. The steel parts were first held together the experimental mod- els means bolts. Then rivets were tried. With both these the appearance was not what should be, the cost was high and the steel stock too heavy and expensive. employing the spot welding method fabrication lighter steel could used and the process reduced cost. addition this, and equal not Fig. 2—Assembled chair, show- ing wood parts attached. 7 7 the wl me chi the not ple the arc pli: has wel the con 1S flar the eac are a Construction greater importance, the fact that the welded construction maintains its rigidity much better than possible with bolts rivets. From this will seen that the merchandising policy and the intro- duction new product reality this case dependent making use the latest type welding ma- chinery. Returning now the discussion the welding procedure, will from Fig. that the four top pieces the steel frame are exactly the same size. This bit stand- ardization which has helped sim- plify operations and keep costs down. The ends each of. these four pieces has five welds. That there are welds per corner and welds for the top frame. The stretchers, already stated, consist in. channels. Each end bent with two flanges. Each flange has two spot welds, that there are four welds the ends each stretcher. other words there are eight spot welds per stretcher, for four stretchers. there are two extra stretchers for hat rack there will more welds. The two ore = FRANCIS WESTBROOK front vertical pieces are also similar each other, are the two back vertical pieces but the latter are curved shown Fig. that they are not interchangeable with the front pieces. The spot welding machines used are those made the Federal Machine Welder Co., Warren, Ohio. The Fig. 3—Jig for weld- ing steel parts, with work inserted. parts assembled are first placed The jig itself, without the parts it, shown Fig. The welding oper- ation progress shown Fig. Experienced welders are able aver- age frames per hour including placing the parts the jig and doing the welding except the front stretcher = Fig. 4—The welding jig simple form. which put later. The time about equally divided between placing the parts the jig and doing the spot welding. This rate production without the use helper for the welder. The front stretcher has put later because would the way the earlier operations. There are welds the first oper- ation and eight placing the front stretcher. requires about sec. for each weld. The machine has special set jaws for this work which makes possible reach all the points necessary weld. The speed set for the fastest operation. The steel used hot rolled, pickled and oil cooled. The pieces are placed the spe- cial jig shown the illustrations the following order: side pieces, cor- ners and then the other parts. They are all locked place two wedge The Iron Age, December 1934—21 ter va- es. uc- rea irst od- the sed g rods that serve key and hold all the parts firmly together while the welding being done. After welding the frames are gone over hand see that there are rough places burrs left the steel. The outside the welds filed give smooth surface and then the whole frame dipped opaque lac- quer enamel. The material used particularly tough air drying lacquer enamel. Only one coat put the frames first. After assembly the entire chair given one two coats transparent wood lacquer. The new chairs have met with gratifying success even the midst the. depression. For instance 500 have been purchased for reforma- tory for boys Rhode Island, they have been installed number public and private schools and they are use some restaurants Boston. One the illustrations, Fig. shows them service one the Alpha restaurants that city. This type construction lends it- self particularly well restaurant use and other places where the scheme decorations changed every once while. Not only can seats with different colored upholstery leather changed very easily but backs front legs entirely dif- ferent design can installed the job. this way restaurant may secure the effect new furnishings making the chairs harmonize with any new scheme decoration very reasonable cost. The method attaching the wooden 22—The Iron Age, December 1934 parts the steel frame very sim- ple. They are held screws with special threads increase their hold- ing power and addition there slight countersunk cavity just under- neath the frame where the screws through. This means that when the screws are tightened the metal frame put under tension which keeps the screws from loosening. change the back only necessary remove four screws and replace them the new back. LEFT Fig. 5—Welding the steel parts jig. BELOW Fig. 6—The finished product has pleas- ing appearance. From the foregoing will seen how welding has made possible for wooden chair manufacturer ex- tend his market, meet competition and stimulate his sales time the business depression which the country has experienced many dec- ades. While this specific appli- cation welding very significant and suggestive what can done and what may expected the future almost any line manu- facture. 7 4 =, 2 ' t 7 Business Mens PROSPERITY SURVEY the chance give voice your own ideas which national policies you believe most likely speed recovery your line business. BALLOTS like this are being published this month many business papers affiliated with The Associated Business Papers, Inc.—reaching virtually all key men every line industry, trade and profession throughout the nation. USINESS men, nationally, may appreciate opportunity express their convictions strictly non-partisan and impartial body—with the assurance that doing, business views will presented effectively the political, banking, industrial, business and labor leaders the country. een for UESTIONS the economic ballot below are prefaced with your line the sensus business opinion all fields industry—so let our industry well represented the responses. pli- the Check your convictions, sign, clip and mail this ballot. nu- regards the possibility Congress adopting universal thirty-hour work week, you favor such continuation existing hourly rates pay. your line business are you satisfied with enfotcement maximum hours and minimum wage your line business there obtainable ample working capital—from banks? Yes from from government agencies? Yes your line business you favor limitation industrial output—by government control? Yes your line business you favor plan for control prices—by code provision establishing your line business you think that government measures now effect are helping small and medium sized enterprises? Yes hurting such enterprises? Please return this ballot 330 West 42nd St., The Iron Age, December 1934—23 7 q 4 — i SSS SS SSS SSSA SSS SSS SSS SSS SSS SSS SSS ° Weg William Knudsen, executive vice-president General Motors, whose views foreman responsibility and training are outlined this article. Knudsen, which quoted this page, excellent summary what General Motors thinks the fore- man’s place today. previous years the foreman has been regarded the key man industry, now more than ever the key man. the management’s representative closest the rank and file workers, his responsibilities have increased rather than diminished since American in- dustry started operate under NRA. Management not only conscious the new relationship with labor which has been developing recent years, but also accepting volun- tarily means promoting the best interests all parties concerned. The recent statement General Mo- tors regarding its relations with fac- tory employees shining example management’s new point view. Said this statement, “This relation- ship requires harmonious working together the end that the quality and cost the product may such that the business will prove con- tinuingly successful and will survive. The management General Motors conscious the fact that cannot get along without labor any more than labor can get along without management. Both are the same business and the success that busi- ness vital all concerned.” brief, pointed comment Mr. 24—The Iron Age, December 1934 Because the top management convinced the rightness policy doesn’t necessarily insure its accept- ance executives all down the line, And just vital that the minor executives directly command workers the shop have the proper point view that the management itself, considerably removed from in- timate contact with the men indi- vidual plants, aware it. function efficiently organization must set that every execu- tive, from the bottom the top, thinking the same terms every other executive. accomplish this desirable aim, General Motors giv- ing special training more than 5000 foremen its manufacturing plants. This training chiefly the science industrial relations, espe- cially pertains closer coopera- tion the foremen with their men. From the courses, which originated General Motors Institute Flint, foremen get deeper appreciation the guiding impulses human be- havior one hand and the broad phases industrial economics the other. The instruction intended define the position the foreman un- der collective bargaining rights that employees now have with manage- ment well make foremen BURNHAM FINNEY Detroit Editor, THE IRON AGE more responsive relaying ideas down through the plant organiza- tion. Specifically, the aims and operation employee representation are ana- lyzed from the viewpoints the worker. Differences individual de- sires and incentives Ways and means reaching better understanding are discussed in- sure improved supervision policies. Cooperative methods, the judging men, group morale and transmission orders receive special attention. Corporation organization, planning, control materials and waste, equip- ment handling and the science per- sonnel work are studied that the foremen will appreciate some man- agement’s problems. Clearing House for Ideas “In reality, this training clear- ing house ideas, policies and ex- perience,” said Major Albert Sobey, director the institute. “Here ion crystallized order arrive coordinated thinking the latest phases industrial relations.” Foremen who are conveniently Flint attend conferences the insti- tute. remote centers, faculty mem- bers visit the plants and lead the conferences there. some cases the meetings are directed members the plant organization who have ceiv tute men ized this sion tion ence tute than than ther Outl spon Mr. shou man man. there Today’ > 7 4 Foremen Are Bigger Men ceived special training the insti- tute. All sessions are limited men that personal questions and problems can analyzed. Standard- ized text sheets written especially for this study are used. General discus- sion helps clarify perplexing situa- tions presented during every confer- ence. The courses were first con- ceived seven years ago the insti- tute, but the current training far more extensive and widely attended than any previously offered. Mr. Knudsen convinced that the job more difficult today than ever because more technical. Manufacturing processes are more complicated and there more trouble handling help. Outlining his views regarding the re- sponsibilities and duties foremen, Mr. Knudsen says: “My first principle that there should ‘working foremen.’ man either foreman work- man. Group leaders should abol- ished. The second principle that there should some reasonable ratio PEAKING before group in- dustrial executives, mostly fore- men, Flint, early this year, William Knudsen, execu- tive vice-president General Mo- tors Corpn., made the following statement: “Somebody that you are foreman now- adays, management one side, labor the other side, and the foreman the middle. Now should like tell you just earnestly know how that the foreman not the middle. the middle, that going just too bad. The foreman out front and must out front good deal more than ever was.” between the number workers and foremen. believe the ratio should “The foreman has two major du- ties. The first his duty the article being made, and the second his duty his men. The second the more important the two. “At times have had choose between man high ability, tech- nically, and man with somewhat less technical ability but more able handle help, which itself art. the latter case must have sufficient knowledge fully con- versant with the quality and what reasonable quantity expected. Above all, must man. Foremen Must Know Their Men “We must have foremen who fully understand their position when men are fired they have good reasons and the men must stay fired. The foremen must know their men; there can question about this. believe the old saying, ‘An army good its non-commissioned officers.’ believe there should one man give the foreman orders. This does not mean that cannot give him information, instruction sugges- problems call for bigger and better foremen and this, turn, demands systematic training and education policies well methods. The Iron Age, December 1934—25 _ de- in- ies. the tions, but there should definite person give him orders. This re- lates not only his materials, but his tools, quality, costs and safety. Definite lines authority should established, the foreman will know what expected and can properly represent his men. “The class work has much with the way train foremen. The foreman should know exactly what the requirements for quality are and should furnished with the proper GENERAL MOTORS EXECUTIVE TRAINING PROGRAM OUTLINE PRINTED MATERIAL MANAGEMENT AND THE EXECUTIVE JOB. INDUSTRY 2-PRINCIPLES EFFICIENT ORGANIZATION THE EXECUTIVE JOB. PLANNING. 2-PLANNING THE DEPARTMENT. 3-THE DEVELOPMENT PLANNING ABILITY. QUALITY CONTROL AND WASTE ELIMINATION. I-THE CONTROL OF QUALITY 2-THE CONTROL OF SCRAP. 3-THE CONTROL OF WASTE 4-WHAT INSPECTION ? 5-THE INSPECTION AND SALVAGE DEPARTMENTS. SECTION-D- EQUIPMENT. THE FUNDAMENTALS EQUIPMENT CONTROL 2-TOOL 3-THE TOOL AND MAINTENANCE DEPARTMENTS. BUILDING AND MAINTAINING THE ORGANIZATION. THE DEPARTMENT ORGANIZATION. 2-THE PERSONNEL CONTROL LABOR TURNOVER 4-PROPER SUPERVISION. HANDLING MEN RELATIONS INDUSTRY- HISTORICAL EVOLUTION. 2-DEALING WITH DIFFERENCES. S-DEALING WITH MEN-HUMAN MOTIVES AND DESIRES. 4-DEALING WITH THE GROUP WITH HUMAN BEHAVIOR WITH MEN-INTELLIGENCE AND TRAINING. WITH SUBORDINATES. MEN- GIVING AND RECEIVING ORDERS. AND MORALE CONTROL. CO-OPERATION. AND RATING NEN. SECTION-G- EMPLOYEE RELATIONS. THE BACKGROUND OF EMPLOYEE REPRESENTATION 2-TYPES AND OBJECTIVES OF EMPLOYEE REPRESENTATION. SRESULTS OBTAINED WITH EMPLOYEE REPRESENTATION PLANS. 4-PLANS OF EMPLOYEE REPRESENTATION IN GENERAL MOTORS. RELATIONSHIP EMPLOYEE REPRESENTATION PLANS. drawings check his memory when- ever desires. also respon- sible for quantity, and should told what expected him. There value boosting the quantity dis- counting the requirements fore- “The personnel department has the responsibility filling requisitions made the foreman for men. the human material out the gate not what the foreman wants, favor giving all possible leeway SECTION-H-INCENTIVES. WAGES RELATION THE EXECUTIVE WAGE QUESTIONS. SECTION-I-POLICIES. EXECUTIVE AND COMPANY POLICIES. SAFETY. SAFETY PROGRAM 2-THE PROBLEM WORKMENS COMPENSATION. JOB STUDY. I-THE METHODS WORK DEPARTMENT 2-PRINCIPLES JOB STUDY. AND MOTION STUDY. AND THE DEPARTMENT. 3-METHODS APPLYING HOUSEKEEPING. ECONOMICS DEVELOPMENT ORGANIZATION. 2-MODERN ECONOMIC ORGANIZATION SECTION-O-FINANCIAL ORGANIZATION AND CONTROL BUSINESS. CAPITAL. 2-BORROWED CAPITAL. ANALYSIS. BUSINESS CONDITIONS 2-FORECASTING. BUDGETS. COST CONTROL METHODS. I-DEPARTMENTAL COST REPORTS. 2-DIRECT MATERIALS COST. LABOR COST. DEPARTMENTAL EXPENSES. OVERHEAD. ANALYSIS. THE REQUIREMENTS MODERN INDUSTRIAL LEADERSHIP. Above the outline printed material used connection with the executive training pro- gram General Motors Corpn. The program not intended hard and fast outline which foremen groups should adhere without variation. Instead considered more guide the subjects which foremen should study order secure better understanding their jobs, their relationship management and labor, and the mechanics employee rep- resentation. 26—The Iron Age, December 1934 get him the type men needs. those plants where have had the best foreman control, there has been the least labor trouble. And, first all, the personnel department should have good, up-to-date file the inefficient and shiftless, that even times shortage not get these men back the plants. feel that are not getting new deal industry but that are going back the old deal industry which existed previous the ex- tremely rapid development indus- try subsequent the war. refer the shop management which dealt with men great masses right after the war rather than with the depart- ment. the practice which gradually left the foreman with gang men with only the privilege being called down for something, but with most his duties criss- crossed organization lines other kinds. couldn’t hire his men, sometimes couldn’t fire them, Most the time had little with the planning the job had charge, and often the tools were never inspected him until the job was set up. “The industrial science look for- ward will the relationship that establish the basis coopera- tion between the men and the fore- men. Here our problem and should our problem for years come. The biggest thing before in- dustry get better management out all departments, and through cooperative methods give more and better work that the public’s in- terest our product can retained and our future assured.” The 1935 convention the Ameri- Ceramic Society will held Buffalo, Feb. 23. Headquarters Hotel Statler, where all sessions will held. connection with the meet- ing, plans have been made for holding exhibit “Made New York State” ceramic products and also the showing series educational process exhibits, both which will well the ceramists. railroad line constructed welded rails now being tested the German State Railway. There are almost joints over the entire divi- sion where the test being made. express train, without passengers, will driven over this division until mileage about 63,000 obtained. The speed the train will vary from miles per hour. the welded rails stand under high speeds they will introduced all express lines Germany. Demonstration 7 7 7 7 all the tra def sar gin dev anc q has cap exh ers for J sch wel stri sup $1Ze 1 cow nee a mer Ps 7 7 Te a When and How Train Welders “When should train welders?” Well the answer the same all other training programs, and like the others, the proper procedure sel- dom followed deciding when train question often asked, Much time and expense caused defective work and delayed marketing the product could saved the same foresight were used fore- telling our personal needs the development the product. The en- gineer may carry his research develpoment work for several years and when satisfactory conclusion has been reached and major change suddenly discover have men capable doing welding work. After exhausting every effort hire weld- ers through the regular employment department decide train men for this work our own welding school. The school should located well-ventilated building and the in- struction should given under the supervision expert welder. The size the school will depend, course, upon the number welders needed, but any case one instructor should not have more than men. Demonstration Bench MOORE Supervisor Trades Training Westinghouse Electric Mfg. Co. There are number things that should studied carefully the manufacturer before establishing welding school. First, make sure that good welders are not available from other sources. Second, the work general nature highly special- Third, how many different clas- sifications welding will there be? the first place, there may welding school already established the vicinity that could supply the need for welders. Such independent gated, however, assure that equipped give practical training, well valuable information from engineering point view. the second place, the work very highly specialized, most the train- ing will carried the shop the job itself and only the preliminary training will given the school. This will have bearing the pro- gram established and the size the school. the third place, the num- ber classifications determine the extent the training schedule. there are very few divisions the work perhaps general schedule will sufficient, but the classifications are many then the schedule must arranged that not only provides general training, but will also cover ~ Storeroom any specialized job that the men may expected do. any case the schedule will have devised that part the training will given the shop after the man has com- pleted the school course. Procedure Followed Westinghouse The next question “How train.” East Pittsburgh the stu- dents are given lecture safety before receiving instruction any kind. this they are warned espe- cially against the danger exposing the eyes skin the rays. They are then instructed the operation and care the different types welding equipment and tools which they will required use during their instruction period the school and also when they into the shop regular welders. Each student given hand shield and placed booth with one the advanced stu- dents that may observe and get (Continued Page 76) Fig. 2—Front view welding booth. shows the resistance, and the reacting coil. Fig. welding school. Read.ng equipment are: testing machine; and expanded-metal cages; instructor desk and chair; multiple-operator arc velding outfit; demonstration bench; gas tanks; and welding booths made sheet metal and measuring ft. high. Ten the booths are con- the multiple-operator machine the others having single-operator sets which may mounted overhead the wall back the booth. Benches and chairs (H) are located the end the line booths, shown The Iron Age, December 1934—27 = ret ‘ich ege her | for- that era- ugh and in- ‘ters the will ding the ional divi- from all Workplace Layouts That Save FOR LEFT HAND NORMAL FOR LEFT HAND MAXIMUM FOR RIGHT HAND NORMAL FOR RIGHT HAND Fig. and maximum working areas for the hands the horizontal plane. the workplace the industrial worker too often overlooked means for effecting operating economies. The layout the work- place partly determines the method the operator must follow doing given task, and almost wholly de- termines the motions must employ. Since certain motions are more fatiguing and consume more time than others, quite possible effect worthwhile cost reductions merely rearranging layouts. Before the re- arrangements can made, however, will necessary consider what motions the human body can make and which motions are the most ef- ficient. When this thoroughly un- derstood, will relatively simple matter make good set-ups any kind work. The efficiencies which have been ef- fected the use the so-called cir- cular workplace are fairly widely known. The feeling seems exist, however, that the principles the circular workplace can applied only layouts for repetitive hand operations. matter fact, the underlying principles can applied improvement the layout Iron Age, December 1934 nearly all classes work good advantage. Classification Motions Two general workplace layouts. The first has with the classes motions that human being can make. There are five general classes follows: Finger motions. Finger and wrist motions. Finger, wrist and forearm motions. Finger, wrist, forearm and upper arm motions. Finger, wrist, forearm, upper arm and body motions. usually stated that motions the lower classes can made more quickly and with lesser expenditure effort than motions the higher classes. This, however, true only when the motions are made under not greater than normal loau over paths might possible exerting prodigious effort lift heavy ob- ject inch with finger move- ment, but the same object could lifted the same distance less time, and with far less fatigue finger, wrist and forearm movement. Similar- ly, may seen that short fourth class motion can made more quick- than long third class motion. applying the concept motion classes actual layouts, the attempt should made reduce all motions the lowest possible class. This, course, must interpreted with com- mon sense. actual practice, bear- ing mind what has been said the preceding paragraph, there difficulty recognizing the lowest practical class motion which can employed accomplish any given task. The lowest class motions the finger motion. job can accom- plished using only finger motions further improvement can made. The use pure finger motions only, however, seldom practicable. most layouts, the aim will elimi- nate all body movements, reduce many fourth class motions the third class, and reduce the length all motion paths. Normal and Maximum Working Areas The second concept underlying workplace layouts that normal and maximum working areas. The area which the worker performs his operation should kept minimum, this automatically keeps the class motions which must used the lower classifications. Fig. sketch which shows how the normal and maximum working areas for the hands the horizontal plane are usually determined. drawing the sketch assumed that the worker comfortably seated standing his bench table proper height. His arms hang rally from the shoulders. Placing his right hand the near edge the table approximately opposite his left side, can sweep his right hand through the AMB without any 7 ra the for - tar wit tio the tin the art wh cal : len len rec tak rig pol pos the 4 Time, Effort noticeable energy. The area included between this are and the edge the table generally said represent the normal most com- fortable working area for the right hand. The tacit assumption made that point within this area easy reach another provided the dis- tance moved the hand the same. This not the case. The points which lie along the arc AMB can reached with motion the third class. reach all other points within the area bounded the fourth class mo- tion must employed. requires the average about per cent more time make fourth class motion than does make third class mo- tion the same length. Hence the AMB should receive preference when making layouts. Now even when third class motions can employed, motions equal length can not made the same length time all points along the arc AMB. Motions are made most quickly near point and most slowly point When motions must made much beyond point the di- rection point fatigue increases materially. The closer the hand ap- proaches the more unnatural the position which the arm must assume. fact, the elbow rests the table, the point can not reached all. The are which bounds the maxi- mum working area traced the fingers when the arm, fully extended, pivoted about the shoulder. For the right hand, this are CKD Fig. The limitations discussed above not apply the maximum area. All can reached fourth class motions, and motions can made quickly one section another. positioning material within this area, the chief concern should keep the length the movements and Money MAYNARD President, Methods Engineering Council, Inc. minimum. possible, the section near should not used. Besides in- volving maximum travel, requires rather awkward and fatiguing wrist motion reach material located bins anywhere except point other words, when the arm not fully extended. The above discussion applies equal- the areas used the left hand and arm. Improving the Usual Circular Workplace Layout order confine all motions the third class, material should placed only along the paths which the hands normal., follow along the FLE and AMB Fig. The only point which the hands can work together without involving the use shoulder motions change the position the arms the point reality this not point but small area, which determined the Fig. 2—Typical circular workplace set-up. The Iron Age, December 1934—29 mpt ons om- the vest the ade. nly, imi- hird all reas The eeps how king yntal that his the left hand any wrist and finger motions that can used without moving the arms. The usual circular workplace set-up made shown Fig. Inspec- tion will show that the arc the cir- cular workplace coincides with the normal area the two hands only two points. This shown schematical- the arcs described the left and the right hands respectively when mak- ing third class motions and when the arc the circular workplace set-up the hands can reach only points and the are when pure third class motions are used. better arrangement would shown Fig. The arcs and represent the space which should occupied materials, and the point where the work should done. Fig. the vertical plane, the arc described the fingers when third class -movement made the arc AB, while the arc the maximum arc made fourth class movement. These arcs determine the efficient placing materials the vertical plane. This set-up useful for small as- semblies where only few different parts are used. not profitable place material beyond points and for the length the movement re- quired reach beyond these points becomes relatively great, and fatigue increases was explained above. short fourth class movement could made less time and with less fatigue which suggests putting another row rial must positioned. Efficient Work Areas the Vertical Plane the vertical plane, the arc de- scribed the fingers when third class movement made the arc Fig. while the arc the maximum made employing fourth class movement. These arcs 30—The Iron Age, December 1934 Fig. 3—The arc the circular workplace illustrated coincides with the normal area the two hands only two points. Fig. 4—Improved arrangement shown ‘schematically. The arcs and represent the space which should occupied materials, and the point where the work should done. determine the efficient placement materials the vertical plane. When ordinary open containers are banked they are commonly arranged shown Fig. This just the opposite the way they should arranged order permit the use pure Fig. 6—Common but faulty arrangement open containers. third class motions. parts can chutes, the containers can arranged ficient arrangement but seldom possible use it. should ap- proached closely possible wher- ever vertical motions must em- ployed. When positioning tools which are suspended above the work area, care should taken locate them within the sphere which would generated rotated above the body the operator material interferes, the tools should located the sphere which would generated similarly rotating the arc AB, but any case, they should located that they can reached without the necessity employing body movements. The principles efficient work areas should applied all lines work, for they are universal. tion with bench operations, but they and should applied the ar- rangement tools and materials around machines work such molding, forging, and the like and the arrangement levers, hand- wheels, and on, when designing ma- chine tool equipment. imaginary boundary lines which limit the normal and maximum working 7—A good arrangement when parts can placed hoppers. areas all planes are clearly visual- ized, quite easy detect inef- ficient arrangements work places and know exactly what steps must taken bring about improvement. making layout, the first step that they can obtained and used with the shortest, lowest class, and least fatiguing motions. When this has been done, the layout studied further balance all motions nearly possible with respect (Continued Page 92) : — tage was The — 60 « star requ side: but cyel tinu full abro nace furn tage freq prob lines they rials and- the limit king parts inef- must ment. step tools and this otions ect New Things Materials and Processes EDWIN CONE More About High Frequency Melting these comments page THE AGE for Sept. 13, 1934, was stated that induction melting furnaces using current two frequencies were use Europe and certain advan- tages were claimed. Further investi- gation discloses the following facts the authority the Ajax Electro- thermic Corpn., Trenton, J.: The use high and low frequency was simply experimental and has not resulted commercial installation. The work was carried with in- adequate amount 60-cycle power. cycles when melting from cold start. the charge proper condition, can melted but the time required several times that required frequencies the order 1000 cycles are used. coreless induction furnace the same capacity and same power, power will stir the bath con- siderably more than 1000-cycle power, but the effective heating with cycles considerably less. experi- ments carried out abroad was found refining high carbon steel bath that the temperature the bath con- tinually fell when “oreing” down with full 60-cycle power the furnace. Results experiments carried out abroad independent investigators both high and low-frequency fur- naces not indicate greater speed refining the low-frequency furnace. The stirring steel bath during refining unquestionably advan- tage but the violent stirring low- frequency furnace leaves one with the Problem separating the finely divided slag particles from the steel the resultant ingot reason- ably clean solid non-metallic in- clusions. questionable ordinary fre- quency (60 cycles) will give lower kilowatt-hour consumption per ton metal treated than higher frequencies and the first cost installation will great not greater, due the extreme cost 60-cycle power factor correction. there sufficient high-frequency power available for superheating the bath even for holding its tempera- ture constant there good reason for going the extra expense in- stalling 60-cycle power. Copper coils suitable for carrying 60-cycle power are not best adapted for high-fre- quency current. Trends Steel-Making Costs recent meeting one the local sections New York large technical society, some interest- ing remarks were made the cost steel production. prominent scient- ist said that the expansion the American steel industry has been the direct result the cheapen