The Iron Age 1938-02-03: Vol 141 Iss 5

Thomas Cold Rolled Strip profitable solution product and production problems. bright finish uncoated and Electro Coated zinc, copper, nickel, and brass. addition Thomas Steel offers personalized service only made possible having manage- ment, sales, and engineering departments located the mill. Let Thomas representatives show you how Thomas Strip improves products and reduces production costs. Write The Thomas Steel Company now. THE THOMAS STEEL CO. WARREN = ‘ ANSWERING: This battery Hoskins Electric Furnaces, type FR. helps Buick find the answers their metallurgical problems. Their labora- tory model its equipment, because the results must repre- sent the facts. For your laboratory, for use your plant, Hoskins Electric Furnaces will likewise give you the results you seek. You can set them wherever you can run pair wires; they throw off very little heat, and gasses; they make noise; unskilled operator can run them; they are pensive operate and maintain; the Chromel elements are long- lived. For full information, ask for Hoskins Mig. Co., De- troit, Mich. Type FR, Lead Pot 2—THE AGE, February 1938 AGE, published every Thursday the CHILTON CO. (INC.). Publication Office, Chestnut 56th Sts., Philadelphia, Pa. Editorial and Executive Offices, 239 39th St., New York, Entered second class metter November 1932, the Post Office Philadelphia under Act March 1879. $6.00 year S., Canada $8.50, Foreign $12.00. Vol. 141, No. FRITZ FRANK President VAN DEVENTER Editor ROWAN News Editor FINDLEY Editor Emeritus E.WRIGHT Managing Editor Machinery Editor Art Bditor Metallurgical Editor Associate Editors JURASCHEK Consulting Editor Washington Editor Resident District Editors Pittsburgh Chicago Cleveland Detroit Editorial Correspondents London, England Cincinnati FRAZAR Boston Hamburg, Germany MEYER Milwaukee SANDERSON CHARLES POST San Francisco ASA ROUNTREE, JR. Toronto, Ontario Birmingham Leroy ALLISON Roy EDMONDS Newark, N. J. St. Lowis TURNER Buffalo Owned and Published CHILTON COMPANY (Incorporated) Publication Office Editorial and Chestnut and 56th Sts., Executive Offices Philadelphia, Pa. 239 West 39th New York, OFFICERS AND DIRECTORS MUSSELMAN, President FRITZ FRANK, Executive Vice-President FREDERIC STEVENS, Vice-President JOSEPH HILDRETH, GEORGE GRIFFITHS, EVERIT TERHUNE, WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JOHN VAN DEVENTER JULIAN CHASE THOMAS KANE CHARLES BAUR CARROLL BUZBY BAUR, General Advertising Manager DIX, Manager Reader Service Member, Audit Bureau Circulations Member, Associated Business Papers Indexed the Industrial Arts Index. Published every Thursday. tion Price: United States and Pos- sessions, Mexico, Cuba, $6.00; Can- ada, $8.50; Foreign, $12.00 year. Single copy, cents. Cable Address, ‘‘Ironage, ADVERTISING STAFF Emerson Findley, 621 Union Bldg., Cleveland B. L. Herman, Chilton Bidg., Chestnut & 56th Sts., Philadelphia, Pa. H. K. Hottenstein, 802 Otis Bidg., Chicago H. E. Leonard, 239 W. 39th St., New York Peirce Lewis, 7310 Ave., Detroit Ober, 239 39th St., New York W. B. Robinson, 428 Park Bidg., Pittsburgh D. C. Warren, P. 0. Box 81, Hartford, Conn. under AGE Contents FEBRUARY Let's Some Real Devil Using Arithmetic Collective Bargaining ............. The Economics Industrial Truck Precision Raised Nth Degree Diesel Plant ......... Machining Housings Reduce Axle Gear Noise ...... Better Control Heat Treating and Other Processes Automotive Industry ...... Statistics Metal-Working Activity ................. Rate Activity Capital Goods Plant Expansion and Equipment Copyright 1938 Chilton Company +? : 112 4 Sy 118 a RYERSON CERTIFIED STEELS Include: Alloy Steels—Tool Steels Heat Treated Alloy Steel Bars Allegheny Stainless Steel Finished Shafting Screw Stock Extra Wide Cold Finished Flats Beams and Heavy Structurals Channels, Angles, Tees Zees Hot Rolled Bars—Hoops and Bands Plates—Sheets Rails, Splices, Spikes, Bolts, etc. Strip Steel, Flat Wire, etc. Boiler Tubes and Fittings Welding Rod—Mechanical Tubing Rivets, Bolts, Nuts, Washers, etc. Reinforcing Bars Babbitt Metal Solder RVERSON 28—THE IRON AGE, February 1938 had never been done, and many said could not done. But Ryerson, realizing the growing need for better, more uniform steel, began working the problem. After many years planning and preparation, tightening specifications and making inspections more rigid, Ryerson last able give industry “Certified are position definitely certify the uniformity and known high quality all steel stock. The outstanding feature Ryerson Certified Steels the special plan the alloys. Whole heats alloys which the chemical elements, grain size, cleanliness rating, etc., fall within specified narrow range, are selected for Ryer- son stocks. These are tested for heat treatment response and the results charted. Complete information sent with each bar. Thus you know exactly what you are getting and how each bar will respond heat treatment. Large and complete stocks Certified Steel are available for immediate shipment. Write for new illustrated book- let which tells the complete story. JOSEPH RYERSON SON, Inc. Plants at: Chicago, Milwaukee, St. Louis, Detroit, Cincinnati, Cleveland, Buffalo, Boston, Philadel- phia, Jersey City. . 7 7 7 | 1 ... THE BON FEBRUARY 1938 ESTABLISHED 1855 Vol. 141, No. Some Real Devil Baiting EVIL baiting old occupation. Witch doctors all ages have used gain prestige and power from superstitious public. Untold generations Africans have paid tribute grotesquely painted witch doctors whose was supposed drive out the devils disease. Un- doubtedly the contortions these mountebanks were effective, however, the extent that they took the victim's mind off his troubles. Nearer home, indeed home, the Indian medicine man profitably employed the same tactics. For fee, would undertake drive out the devil drought and make rain come appease the thirst parched country. happened rain, the medicine man was that much ahead; and planned that way; did not—well, was good show anyway. The modern politician slouch devil baiting. has found effective the past proclaim himself the friend and champion the and enemy the has not found advisable, however, name define strictly the devil that was setting out bait. much better leave something the nation. unknown devil much more terrifying than one that you can recognize Tom Jones Bill Smith. Besides, you pin your devil down, might have convinc- ing comeback and able prove that had neither horns nor tail. can't blame the politicians for using technique that has been time honored and effective. But can blame people, this supposedly enlightened day and age, for falling for it. People ought insist calling their shots and not permit them bang away all the balls the table. the Now the time disregard the imaginary devils and fight real one—the devil depression who hurts everybody. Labor, most all, should want fight him for sticks his fork further into the workers than into any other group. But first labor should determine who summoned this devil depression. has been told that the employer. Why not find out? Why not summon the employer and have him state his case. Have him give you his reasons why business bad. Employers, believe, would glad this opportunity. Few them would without invitation from labor because they might accused, politicians, prop- aganda. But there law prevent labor, union non-union, from calling upon the employer tell why his business bad what thinks could done make better. | é : lag Fi i J | | facts economics and management are deeply shrouded fog great many employees. That why they listen the voices demagogues telling they ought have larger share their employer’s revenue. not that they are avaricious con- sciously revolutionary. They not know the answers the agi- tator’s claims. They are the dark the employer’s side it. And must admitted that employers seldom have done much enlighten them. Let take hypothetical case candid, liberal employer and show how presents some these basic facts his workers conference. will call him Mr. Brown, head the Brown Co., small manufacturing con- cern. His 100 factory employees have shop committee with which the company has dealt num- ber minor matters but far the question wages has not reached the stage. However, has been informed that outside union pressure has brought that stage almost head, and now has assembled the plant workers general conference “talk turkey.” the conference the employee view- point will voiced two mem- bers the shop committee, First Spokesman and Second Spokesman. Mr. Brown: given un- derstand that you men feel should make general advance wages. Frankly, I’d like see all you making more, just like better myself. hope that between can work out way it. But first want take you into confidence and give you some facts about the busi- ness which have just assem- bled. I’m going lay all the 30—THE IRON AGE, February 1938 cards our hand down before you, faces up. have here careful estimate the sales department the amount our product which can reasonably expect sell dur- ing the next year. And this other report are figures Mr. Robinson (production manager) what will take produce that amount goods. Using present equipment present effi- ciency finds that will require 208,000 man-hours labor. man-hour our measure work —one hour’s labor for one man. the light our past experience and all that can predict the market situation this means that will have $145,600 spend for wages the plant. “By dividing this amount among the 100 men now our employ can continue provide you with hr. work week for weeks average hourly wage rate 70c. course there are other ways dividing it. can done without disrupting our manu- facturing schedules might in- crease the work week hr., raise the weekly wage from $28 $30.80, and provide each you with 48% weeks’ work during the year. That way the annual wage would remain the same—$1456. “Another way would give you hr. work week for weeks, which would increase your annual earnings $1617. But what would become the other 10? The same job could done 110 men working hours week for weeks. That would give jobs unemployed men, but would reduce your average annual earnings $2.80 week, $145.60 year.” First Spokesman: Can’t you get the working hours down with- out reducing earnings, Mr. Brown?” Mr. Brown: “Yes, one way. Your working hours can short- ened without reducing annual wages you men individually can produce more goods per hour and per day. other words, through our combined efforts can reduce the number man- hours required produce our quota for the year, that spells fewer working hours for each you.” First Spokesman: “But each those divisions that you named doesn’t the hourly wage remain the same—70c? Isn’t there some way get up?” Mr. Brown: “Yes, remains the same each instance. can you larger smaller annual wage, longer shorter work week, but the only way can change the basic hourly rate for you produce more. the number man-hours necessary produce our quota goods re- duced, that figure divided into the money available for wages would give hourly proportion- ally higher than 70c. you see that better productien per man would enable you fewer hours and earn the same wages, the same hours and earn more. either case raises your hourly rate.” Second Spokesman: “Isn’t there still another way, Mr. Brown, which you could get our hourly rate and our annual earnings both up, without our turning out more work per hour? Couldn’t you ° ° ° FRED DeARMOND ° that raising your prices the product make?” Mr. Brown: “You are quite right. could charge more and sell the same volume then could pay you more, because would increase the amount avail- able for wages. But that big general, the higher put our prices the less goods sell, that cannot ordinarily expect raise our revenue raising our prices.” Mr. Robinson: “If may inter- rupt, Mr. Brown, would like point out that every concérn followed the plan raising its prices order raise wages no- body would any better off it. You would get little more your pay envelope but you would pay all out higher prices everything you buy.” Mr. Brown: “You see, this thing like cutting pie. Whether you make four five six slices it’s still the same pie; more slices not make more pie. Likewise an- nual wages often are not increased higher wage rates. They may only serve make less work, therefore add nothing total earnings. The only sure way increase earnings produce more the job. Check that and find holds good every- where. The unions can get you higher rate but they can’t get you more money—when isn’t there had.” Second Spokesman: “Excuse me, Mr. Brown, but see you still haven’t proved isn’t there had. How about the company’s profits?” Mr. Brown: “That was the first place turned when con- sidered the laudable desire you men make more for your ef- forts. Last year did approxi- mately $300,000 business and after all expenses were paid had something like $10,500 profit per cent. date this year running about per cent. (CONTINUED PAGE 116) THE IRON AGE, February q ima 7 The Economics the Economics Materials Handling Methods and Equip- ment. handling progress prepared Mr. George Stringfellow, vice- president Thomas Edison, Inc., appears these significant words: cording reliable estimates, the ap- plication the battery industrial truck the materials handling prob- lems industry results saving more than $150,000,000 year.” there added this figure the similar savings resulting from the use gasoline and gasoline-electric pow- ered industrial trucks, the whole amount must approach nearly quar- ter billion dollars. This bit amazing first glance, and certainly warrants attempt answer the question, “How are such savings ef- trial enterprise that the attention management never intently cen- during period rising business activity—such was witnessed the first nine months 1937. such time rising labor and materials costs adversely affect the costs produc- tion general. With this comes, course, sharpening competition, which always tends depress prices. Caught between the nether and upper millstones rising costs and lower- ing prices, the manufacturer struggles prevent his profits from disintegrat- ing. With little control over the prices can get for his goods, looks within his own organization for ways and means reduce his costs operation—and discovers the ad- vantages equipment modernization. With inventive genius constantly work devising better, quicker, and less expensive methods making goods, recent paper materials 32—THE IRON AGE, February 1938 Industrial battery-powered 4-motor crane truck capacity 8-ft. outreach. Sepa- rate motors for hoist, boom, slew and truck drives. his search does not proceed very far until finds machine here that will double production the same time equal labor cost, another machine there that will give equal production large decrease both labor and material costs, method procedure that will produce equal better re- sults less time with lower material cost, scheme operation that utilizes heretofore wasted energy along efficient and time-saving lines. invests this new equipment and installs the new methods operation, feeling that well the road producing dividends out decreased production costs; and -then realizes that, secure the full benefits from his new equipment and methods, there accomplished. Almost invariably the moderniza- tion materials handling methods lags behind the modernization pro- duction processes. men realize the outset that the in- stallation new types highspeed, automatic production stantly renders obsolete the old mate- rials handling methods; that the new production equipment absolutely de- pendent for its efficient operation increased rapidity bringing rials worked upon, and tak- ing them away again when they have been processed. From the mass production plant primarily, this elementary sential idea obtained: The use ef- ficiency any production machine product its load factor multiplied its utilization factor. the full load capacity hp. and the average load but hp. the load factor use per cent. the working day hr. long, but the machine actually used but hr. per day, the utilization factor likewise per ~ 7 q 7 Pas pa- in- eed, in- new tak- lave es- ef- lied full use day the per ruck Operation ERCURY center control and rear control tilting, telescoping fork trucks handling heavy pallet loads sacked grain, thus doubling warehouse storage space. cent. The efficiency use the machine then 0.80 0.80 per cent, since this represents the value the actual use the machine compared with its theoretical complete use. Now, quite evident that both factors entering into this figure are subject the efficiency with which the materials handling system serving the machine question with material worked upon, and takes that material away the next process sequence. Consequently the first law the economics materials handling systems evidently this: The First Law system materials han- dling most efficient (other things being equal) which gets the largest needed, dependably. Three factors are evident payload, destination, and time. These factors may elaborated upon follows: The payload should large possible compared with the weight the mechanical equip- ment required move it, since the ex- penditure energy required move double-size load, plus the equipment, not twice the amount required move single-size load, plus the equip- ment. Hence, the larger the payload, within limits, the less the unit cost moving. moving payload from almost direct proportion the dis- tance covered; hence the shorter the distance which must covered, the more economical the handling. And, the time consumed handling affects the economics the situation from two points view: (1) getting the goods where they are needed when they are needed and, (2) getting the utmost possible use out the mate- rials handling equipment. From these ° ° FRANCIS JURASCHEK Consulting Editor, The Iron Age ° ° ° points follows that the quicker the equipment operates, the more loads can carry given period, and the more effectively can serve produc- tion machines; hence the more eco- nomical its operation. The gist the first law eco- nomics can expressed therefore these words: The greatest economy the use any materials handling sys- tem may had when that system designed handle large payloads over short distances, quickly. This law true all mechanical handling sys- tems. With respect industrial trucks its truth evident the fact that equipment has steadily grown larger and more powerful, that payloads might increased and handling time decreased. the same time, the range application has multiplied, both regards the character work done and the availability the truck for continuous service hr. day, over any area travel. con- sideration these facts introduces second law, peculiarly inclusive the special characteristics the indus- trial truck: 2—That system materials han- dling most efficient (other things being equal) which most completely self-contained handling func- tions; that is, which eliminates the greatest amount rehandling. The Second Law quick glance the history the development the industrial truck re- veals the truth the second law economics. The prototype was tractor, designed pull string trailers. Each trailer had loaded and unloaded separately. Then came the straight load-carrying truck, com- bining the functions load-carrying and transfer the one piece equip- ment. Following this came the low- lift drop-platform truck which picked skid-loads material; then the high-lift truck pile skid-loads tiers heights less then feet. THE IRON AGE, February 1938—33 q ¥ = ! ha q 7 5 4 From this point development has been rapid, with the introduction the tilting fork mechanism pick pallet-loads, the ram mechanism pick coils, the curved pan and finger grips pick and up-end rolls, and the telescoping lift, ex- tend tiering operations many tiers high. all these developments the essential point bear mind was the fact that, little little the truck was turned from mere load-carrying mechanism into complete handling mechanism, self-loading charging, within extraordinarily wide limits. And, the more nearly ap- proaches the complete self-contained unit, the more re-handling elimi- nated. Since re-handling, rather than transfer itself, which adds the great- est expense any process moving materials goods, the more com- pletely materials handling system eliminates the labor loading, un- loading, and in-between re-handling, the more economical will the opera- tion be. Finally, just production ma- chine, materials handling sys- product the multiplication the load factor and the utilization factor. Here, both these factors are much function the planning the sys- tem the equipment used. This the third law the economics materials 3—That system materials han- dling most efficient (other things yate battery-powered tilting fork truck handling self-nesting blocks zinc spelter which require skids pallets. being equal) which continually util- izes the full capacity the equipment involved. The Third Law Manifestly, equipment, matter how efficient its inherent qualities may be, can truly economical unless these qualities are used the fullest possible extent. accomplish cer- tain task now taking min., new piece equipment may which cuts the time down min. itself that makes saving time Transportation, with Ready Power gas-electric unit, traveling up-ender, with center control and front wheel drive. Picks coils strip metal 16,000 weight and up-ends them. 34—THE IRON AGE, February 1938 which permits five-fold multiplica- tion output. But, unless the min. per job which saved the new equipment can effectively util- ized other equipment the plant, additional equipment, the ap- parent saving costs may not real saving all. And herein lies the essence the argument mentioned the fourth paragraph this discus- sion. Coordination the key the effective use any modern industrial equipment. Unless that new equip- ment is, careful planning, fitted exactly the production scheme, its economy will question- able. There somewhat be-whiskered story Irish power plant en- gineer who was told that the installa- tion certain type stoker would enable him use much cheaper grade coal, and save half his an- nual costs. With twinkle his eye replied, “Begorra, put two those stokers, then, and save That sillier than thor- oughly modernize one operation chain processes, and expect the net costs. industrial materials han- dling system not entity; al- ways part and parcel scheme operations which every phase must strictly coordinated with every other phase secure any beneficial results. Here, then, can see the the question evoked Mr. String- fellow’s statement regarding the sav- ings brought about the use mod- ern industrial truck handling methods. plant, ies the ned liscus- the ustrial equip- ted uction skered stalla- would an- eye two ave thor- ina net uction han- al- larger every inated any sav- mod- battery-powered 12,000 capacity non-tilting center control ram truck with articulating frame; designed for heavy coiled strip handling. These savings are the result the application the three laws econ- omy stated above, expressed the use industrial trucks thoroughly modern design construction. First, there has been accomplished definite coordination production and materials handling, with the result that the use efficiencies both types equipment have been made extraor- dinarily high, through careful plan- ning and sound integration; second, rehandling has been eliminated marked degree the use materials handling equipment which not only carries its loads, but picks them and sets down unaided external means; third, the loads are taken where they are needed, when they are needed, rapidly and dependably. contrasted with former methods handling, involving wastes time, energy, labor and machine utili- zation, the newer methods handling have integrated process with proc- ess that these wastes have been largely eliminated and stepped practically ideal peaks. place the value these economies affected industrial trucks alone between 150 and 250 millions dollars, is, therefore, make very conservative statement indeed. Truck Economics For the purpose comparing rela- tive costs the use one system materials handling with another, advisable consider two classes expense, direct and indirect. tery operated trucks these two may analyzed somewhat follows: A—Direct Costs. The first direct cost that investment, the ex- pense involved purchasing and in- stalling the equipment. Accountants have agreed that the best way com- pare two investments put down, side side, the fixed charges involved annually. The first item fixed charge any investment interest, the cost using the actual money involved; the second item deprecia- tion, the amount which should set aside each year amortize the investment the time the equipment used up; the third item insurance, the premium paid provide pro- tection against loss the use the due accident, fire, other mishap beyond the control the owner; the fourth item taxes, the annual contribution civilized society return for the opportunity make and market goods under the protection the property rights con- ferred government; and the fifth storage charges, the rental for the space used house the equipment when installed. While all these charges will vary with many factors peculiar each particular problem, and one set figures will apply any two situa- tions, example may worked out illustrate the application fixed charges general. Assume battery powered truck with initial cost $3,000, requiring batteries costing $500 each and charging equipment costing days week. will advisable have three batteries, each hr. capacity, but changed every hr. The actual investment will $4,800, and the fixed charges will probably run follows: (a) Interest figured the pre- vailing rate for the use money capital investments; say per cent. since depreciation reserve being built ~ear year amortize that interest that re- serve accumulates should credited against the interest charged for the invested money. complicated actuarial formula required deter- mine this precisely, but for all prac- drop-platform battery-powered truck used with Truscon all-steel skids for handling large loads light merchandise warehousing service. THE IRON AGE, February iplica- the util- Transportation super-duty crane truck 15,000 capacity, equipped with special sheet-metal grab. large Ready-Power gas-electric unit furnishes power for all drives. tical purposes amounts one-half the first interest charge. Therefore, usual take the interest fixed charge the investment, one-half the prevailing rate, say per cent. (b) Depreciation figured the total cost the equipment divided the life expectancy the equipment years. Trucks may estimated, hr. service years maximum; batteries from months three years more; charging equipment years. (c) Insurance, taxes and storage are variables which, for ordinary esti- mating purposes are usually taken to- gether flat per cent the total investment. Operating Charges (d) Power. This includes the kilo- watt-hours energy required keep the batteries fully charged, and any costs involved attendance the charging panel. may assumed hete that the average energy cost will run about 2c. per kwhr., and that for the batteries involved this example the total current use amounts about 100 kwhr. per 24-hr. day. also assumed that changing the batteries and putting the used battery line three times each day will take total about one-half hour per day the combined time the truck op- erator and skilled electrical charg- ing panel attendant. IRON AGE, February 1938 (e) Maintenance. Costs mainte- nance the truck, batteries and charging equipment will include oil, grease, distilled water, small parts, tire replacements, periodic inspections and minor repairs. Major replacements ° ° ° UTOMATIC Transportation battery powered center control tele- scoping fork truck for heavy duty hand- ling and stacking exceptional Capacities 10,000 Ibs. rebuilding should regarded charge against the depreciation re- serve, they will increase the life the truck. Labor. This the cost the truck operator, and may vary from the wages unskilled laborer who manifests aptitude for truck han- dling semi-skilled operator. Putting the above example into tabu- lar form. get these figures for the cost one year’s operation: Fixed Charges: (a) Interest, per cent (b) Depreciation truck, Depreciation Depreciation charg- er, year life ...... (c) Insurance, taxes and storage, per cent 192.00 Operating Charges: (d) Power, 100 kwhr. 300 days 0.02...... 600.00 (e) Maintenance pairs, average ....... Labor attendance charging panel, 150 hr., (e) Operator, semi-skilled, 7200 hrs., 0.65 ....... 4,680.00 Total cost use equip- ment for one year .... $6,881.00 4 i q j re- ife the the who han- tabu- the 144,00 300.00 500.00 15.00 600.00 300.00 Since this figured the basis 7200-hr. work-year, the cost per hour use figures per hr.; which 65c. goes for operator’s wages and 30c. for the “wages” mechani- cal equipment. Assume that the average load han- this truck amounts 4000 that load-carrying hauls consume per cent the time (the balance be- ing used loading, discharging, and no-load return trips), and that the average speed from loading dis- charge point payload hauls four miles per hr.; then the total payload use figures out 17,280 ton-miles, cost about 34c. per ton-mile hauled. Costs. These are diffi- cult determine most cases. The principal sources are the costs pro- viding adequate aisles, passage ways and ramps for truck operation these not already exist; the costs maintaining the surfaces such aisles, passageways and ramps under the pounding truck-travel; and the possible re-location machines and storage and shipping facilities ac- commodate the needs coordinated ° ° ° LTERNATING CURRENT arc welding was used fuse all the steel framework building the new office structure the Westinghouse former works Sharon, Pa. helmeted welder shown work one the building columns. system handling. Such items should, possible, and debited equally with di- rect costs calculating the total ex- pense installing mobile industrial truck system handling. All plant maintenance charges due truck op- eration, and the costs entailed lost production during the changeover systems handling should charged in, while interest should likewise charged whatever plant changes are made necessary the new system. Estimating Savings Against the total direct and in- direct costs truck system should credited the savings costs effected the use that system. First, course, should the comparison the direct costs the present system handling with the estimated costs the new truck system. This, how- ever, does not tell the whole story. There will indirect savings contrasted with the indirect costs. Al- though very difficult evaluate, careful study will generally show that these items will have decided influ- ence final production costs: Decrease interest charges and insurance manufacturing and storage facilities. Decrease interest and insur- ance charges inventories. Decrease labor burden and managerial overhead. Decrease idle hours ma- chines and workers. Decrease charges for spoilage goods. Decrease.in hazards workmen. Decrease expenditures due labor turnover. Adaptability the system growth plant capacity. the case gasoline powered trucks has sometimes been claimed that fixed charges are less than the case comparable piece battery powered equipment, but that operating costs are more. While this may true certain cases, there reason doubt its universal application, espe- cially for gasoline-electric units. later article this series will continue this discussion economics, with figures from number actual case-studies. THE IRON AGE, February THE new factory recently com- pleted for the Detroit Diesel Engine Division General Motors. The new plant, which meas- ures approximately 480 240 ft., situated 75-acre plot near the western border the city. has begun program for the manufacture complete line new lightweight, two-cycle diesel engines. General Motors has been making ‘large size two-cycle diesels for streamline trains and marine service during the past four years. These engines have ranged from 600 1200 hp. New products now extend this line varying sizes down one-cylinder 22-hp. model. The complete line engines will built one existing factory and two new factories, one which, the Detroit Diesel Engine Division General Mo- tors Corp., Detroit, operation, and the other which, the new engine factory the Electro-Motive diesel locomotive plant LaGrange, will operation within few months. The existing factory that the Cleveland Diesel Engine Divi- sion General Motors Corp., (formerly the Winton Engine Mfg. Corp.) Cleveland. The new Detroit plant located 75-acre tract the Pere Mar- quette Railroad and Outer Drive. The first unit laid out for production engines per 8-hr. day. The devel- opment also includes the completion and opening the new General Mo- tors diesel laboratory distinctive- modern building adjacent the MOTORS CORP. 38—THE IRON AGE, February 1938 Precision Raised Nth Detroit manufacturing plant. This the largest and most completely equipped laboratory for exclusive diesel study the world. Product Program The product program includes three series models, based three different cylinder sizes, having 71,223 and 503 cu. in. displacement per cylin- der, respectively. The model series will include one, three, four and six cylinder models rated from 160 hp. maximum 1800 The series will include four, six and eight cyylinder models rated for industrial and marine purposes 200 400 hp. The larger series comprises eight, twelve and sixteen cylinder en- gines ranging from 600 1200 hp. The model series will manu- factured the Detroit plant; the 223 series the Cleveland plant and the large engines, which heretofore have been built the Cleveland plant, will made the LaGrange plant, be- cause the principal application the large engines has been the locomo- tives built the LaGrange plant. The Cleveland plant also will continue custom build engines for the marine field. The Cleveland plant will also make complete “power packages” for The Detroit plant now producing four engines built around basic cylinder size and design—a der engine—a three-cylinder engine, four, and six. Thus possible produce quantity, the same machines, all the parts cylinder such the dry liner, piston, connect- ing rod, bearings, etc., and then assem- ble these standard interchangeable elements into multi-cylinder engines. From the very start the design these products, production men have had the privilege criticizing the original design and making sug- gestions that would expedite manu- facturing operations well achieve economies and high quality. Factory Building The factory proper consists monitor-type structure, 240 ft. width and 480 ft. length. has maxi- mum window glass area. Worker comfort further enhanced the use high ceilings, spacious work places and aisles, and excellent paint treatment that serves reflect and make the most the daylight. The largest area devoted the machine lines for producing the major parts the engine. Next the ex- perimental machine shop which are built experimental engines for future development. Finally the far end the building the injector depart- ment which manufactures all fuel injectors used all diesel engines wherever they are pro- duced. Adjacent the machine shop the engine assembly line, running right angles machine lines, and ad- ! i q ~ : same inder nect- sem- eable have the sug- ality. vidth the work paint and the are uture end part- tests pro- ad- THE new diesel test laboratory measures 223 ft. length and 105 ft. width and constructed that the noise and vibration powerful engines under- going test inside are practically eliminated. egree Diesel Plant joining this the final dynamometer test department. The electrical equip- the power the engines test the main power plant for plant use. Precision operations are keynoted the machine shop. Here will found the most modern the precision bor- ing machines, diamond-boring ma- chines, centerless grinders, honing machines, and similar equipment asso- ciated with precisionmanufacture. One the most important the precision operations that producing piston and connecting rod assemblies. Con- trary general automotive practice, selective assembly not stead, each the parts made inter- changeable size and weight. This achieved the use in- genious machines which automatically weigh the piston the rod and ma- chine precisely the weight re- quired. Outer diameters pistons and cylinder liners are finished center- less grinders close limits both size and surface quality. Connect- ing rods are precision-bored and are subsequently honed. Interchangeable Engine Parts Interchangeability finds its best ex- pression the machine lines for the large units such cylinder blocks and heads. Here excellent ex- ample the coordination engineer- ing design and production planning. Cylinder blocks and cylinder heads are geometrically similar for all sizes and end-for-end. The drilling the top and bottom the same except for the fact that larger block will have more holes. This basic design makes possible use but one line spe- cial machines for the entire range engines, regardless the number cylinders. possible use many fixtures interchangeably multiple-spindle drilling and tapping heads without change. For boring the dry cylinder liners, for example, the liners are assembled, three time, into huge fixture which has the same form and size three-cylinder, cylinder block. Then the fixture goes into the same machine used for boring the cylinder barrels. The only change required replace the boring cutters with cut- ters smaller diameter. The blower department charac- terized the simplicity equipment and process for intricate and pre- cise operations. For example, the blower housing has two bores that must finished accurate limits. This done rough boring the hous- ing single-end precision boring machine with massive boring spindle. one bore finished, the table in- dexes the work forward, complete the second bore. Subse- quently, each housing processed the same machine for finishing boring operation. The blower rotor three-lobed affair, each lobe having spiral form along its axis. There one specially designed set-up machine this piece automatically. takes three separate settings the rotor complete the job, using special formed cutter that encompasses third the profile each time. -As the cutter traverses the face the rotor, the rotor casting auto- matically indexed produce the spiral form. After machining, each rotor goes balancing machine, where checked and drilled necessary produce balance. Crankshafts are checked 100 per cent for static and dynamic balance using the standard GMR balancing machine. The same machine also used for balancing flywheels. The plant also has modern and well-equipped heat treating depart- ment together with laboratory. Extreme Precision Attained The precision manufacturing de- partment—in niche all its own—pro- duces the fuel injectors for all diesel engines built General Motors. its present form represents the hitherto unattainable objective translating the skill the instrument maker into unbelievably precise man- ufacturing limits interchangeable and reproducible parts. The maximum clearance between the barrel bore THE IRON AGE, February ° ° ° | | = | 7 =} the injector and the plunger, for example, must not exceed mil- lionths inch. the tip end the injector, the maximum clearance between the needle valve and its bore must less than 0.0001 in. All parts are measured Electro- limit gages accurate the millionth part inch. One-ten-thousandth time such precision has been un- heard mass production. This organization had design much its own production equipment and build accordance with the ex- perience gained many years research and experimental production. Another big problem was the matter drilling the spray nozzle holes. These holes are various diameters, depending upon the size the engine. The general range lies between 0.006 and 0.014 in. diameter. Drilling done means tiny drilling ma- chines designed here, which the rotated extremely high speeds means air turbines. The drill spindle floats and pressed into the work the operator’s finger. All the internal parts and bushings are lapped hand battery special lapping machines both for internal and external parts. another section this depart- ment the assembly line for the small engine injectors, well benches for assembly large units. Before leaving this department, each injector tested first machine which tests its seal under pressure 5,000 Ib. per sq. in.; then another ma- chine that “pops” the nozzle assure clear passages. The final step the 40—THE IRON AGE, February 1938 test department which each injector tested individually and calibrated according specifications exact laboratory procedure. Finally, worth noting that all precision grinding operations in- jector elements are performed LEFT SIX-CYLINDER version the Model 71, two-cycle diesel engines. Unit construction enables engines one six cylinders man- ufactured unit plan. ° ° BELOW IGH windows, modern lighting fixtures and ample spacing drawing boards make the en- gineering depart- ment model work place. centralized grinding department, lo- cated the precision machining de- partment but completely isolated from it. This done for two reasons: keeps the precision grinding de- partment free dust, and protects the precise drilling and lapping opera- tions the other department from the fine dust and grit that may orig- inate from the grinding wheels. New Diesel Laboratory Rounding out the diesel engine man- ufacturing facilities General Mo- General Motors tors, the modernistically-styled laboratory building erected adjacent the Detroit Diesel Engine Division plant. Following the pattern plan- ning other departments the new diesel organization, the laboratory has been designed central testing set-up, serving all diesel engine divi- sions the corporation. Consequent- ly, its equipment includes facilities for testing all sizes engines from the very smallest the largest. excess 4000 hp. will continuous op- eration the building. The building proper about 105 ft. wide and 223 ft. deep its widest section. vibrated concrete construction with rounded modern- istically-styled front office entrance. The latter two stories height. unique the fact that combines the functions self-contained power plant serving both the laboratory and factory with heat and power, together with unparalleled testing facilities. One the problems testing lab- ; oratories for high speed engines the insurance that recordings the delicate measuring instruments are not affected engine noise vibra- tion. Profiting the experience other large-scale laboratories and tak- ing advantage the latest scientific discoveries the field acoustics, the designers have created here set- which noise and vibration are subdued that may said they are completely under control. Not only have the designers eliminated the 7 Ag 4 overall view the manufacturing area devoted the production one, three, four and six-cylinder engines the new daylight diesel engine factory General Motors. Not shown this view are the high ceilings and the amount space devoted windows, with light-reflecting treatment accorded the roof and structural steel framework. chance the measuring instruments being affected, but they have made possible for the engineers who are observing particular engine entirely free the distraction pos- sibility error that lies hearing feeling the operation another nearby engine the combined effects The ground marshy and the en- tire building rests concrete-steel piles driven ft. below the surface, thus providing resilient dampening cushion. addition, each engine foundation rests individual con- crete platform with its own set piles extending into the ground. Con- sequently, every piece equipment which there motion effectively isolated from the building and other units. Normal engine noises are held almost unheard level the use soundproofed and sound ab- ° ° ° YPICAL the best modern factory construction the light and clean locker and wash room. Showers are adjacent. sorbing wall and ceiling surfaces. prevent noise from escaping the outside, the ordinary type window has been supplanted with fixed sections ornamental, translucent glass brick. Finally, insure that the exhaust noises are eliminated exhaust lines are led huge concrete muffler stacks for each dynamometer room. Since the dynamometer section modern ventilating system which dis- tributes clean air each work-space and capable changing the air completely several times minute. Heat supplied ceiling-mounted unit heaters. The feature the laboratory its group eight test rooms, each one fitted with the modern dynamometer equipment and complete instrumenta- tion for precise recording scientific measurements engine character- istics. noted earlier, this labora- tory coordinates the fundamental test work for all diesel activities, and for this reason, rating and size dynamometers each department differs according its function. There also experimental as- sembly department. All new and ex- perimental engines are designed the central engineering department, while component parts are built the ex- perimental machine shop. Then the various engine components are trans- ported the laboratory where the experimental engines are assembled, adjusted and tuned the assembly department. The entire laboratory section served service tunnel the floor, carrying the fuel, oil, water, air and waste lines. Each room has smaller service tunnel which feeds from the main line. Connecting the labora- tory building with the main factory building large service tunnel subway which conducts the various supply lines the main plant. THE IRON AGE, ther lab- Welding arches ° ° SPRARAGEN Technical Secretary, American Welding Society ° that welding available tool for fabrication, there definite possibility that in- clined stiffeners can detailed and placed economically vertical ones girder construction. test one university, under the auspices the Welding Research Committee, proved that putting the stiffeners work inclining them the direction the compressive stresses the web the girder increases materially the strength the girder. Aluminum Alloys Over 100,000 welded aluminum bar- rels for shipping beer now are ser- *Concluding section article reviewing weld- ing developments last year. First and second parts appeared issues Jan. and 20. 4 — ° vice. One these barrels may actual- Welded construction has found new applications the chemical, dairy, and rayon industries. Technique and field methods for fabricating large aluminum vessels have been developed ft. high, are being produced. Methods have also been devised for welding vessels thick. These limits have been achieved under production conditions and now apparent that even larger and heavier equipment can produced carry greater loads pressures, Aluminum foil in. thick be- ing seam welded production. EACTION chamber made carbon-molybdenum steel and destined for high-temperature service the oil industry. Dimensions are: ft. I.D. 113/16 in. ft. straight shell length. The vessel was constructed API-ASME code, stress relieved and X-rayed. (Photo courtesy Babcock Wilcox Co.) 42—THE IRON AGE, February 1938 another case, machine make spot welds one operation the machine and timer has been developed. welding aluminum copper. This combination metals used for fusing heavy-duty electrical circuits and the construction high-speed rotary electrical equipment where use aluminum parts reduced centrifugal stresses. connection must made the copper current distribution system such equipment and butt welded joint has been found satisfactory Housing During the past year, the much dis- cussed steel frame dwelling house be- came important development. Some these homes are prefabricated. Sec- tions and even whole houses are pre- fabricated the factory, many the systems using welded construction. others, steel framing arrives the building lot along with bricks, stone, wood flooring and other acceptable building materials. Welding and cut- ting are generally the accepted meth- ods fabrication these steel fram- ings. The steel brings protection against fire and does not shrink, warp sag. Railroads Welding continues save the rail- roads literally millions dollars each year. address made last sum- | a | 2 - the the This for ircuits -speed use ifugal made bution butt dis- be- Some Sec- pre- the on. the stone, ptable cut- meth- fram- ection not rail- each sum- mer, Wallace, director equipment research, Association American Railroads, cited the work one railroad which alone saved $58,- 500 renewing worn parts truck side frames, and $117,000 truck bolsters. Cars Last year witnessed remarkable development welded railroad cars— hopper, box, tank, With the rapid advance welding standard and light weight car con- struction, welding designs niques have been improved. Waviness buckles are longer tolerated. interesting large tonnage appli- cation high-tensile low-alloy steels this field was the construction 500 automobile-type box cars the Chicago, Milwaukee, St. Paul Pa- cific Railroad Co. these the side sheets vary from the usual construc- tion that instead being sheets fastened the car vertical posi- tion longways, the sides are made 21-in. wide strips laid horizontal position and running continuous from door posts corner posts. The lower edge six the strips has corru- gation rolled and lapped over and spot welded the next lower sheet. The bottom sheet has simple offset rolled the lower edge lap over the vertical flange the bottom chord. The steel analyses approximately 0.09 per cent carbon, 0.70 manganese, 1.40 copper, 0.90 nickel, and 0.10 per cent molybdenum. Average p