The Iron Age 1938-06-16: Vol 141 Iss 24

FRITZ FRANK President Editor Managing Editor News Editor Editor Emeritus JURASCHEK Resident District Editors Editorial Correspondents Boston Hamburg, Germany : Milwaukee Sen Francisco SANDERSON Asa Jk. Toronto, Ontario Birmingham Ovened and Published CHILTON COMPANY Publication Office Editorial and Chestnut and 56th Executive Offices Philadelphia, Pa. 239 West 39th JUNE 16, 1938 OFFICERS AND DIRECTORS hat Machines Are Doing Automobile Workers JOHN VAN DEVENTER Welding Facilitates Fabrication Flood Gates ........ Foundry Doubles Output with New Equipment .......... Member, Audit Bureau Circulations Weekly Steel Ingot Operating Rate ...... ndex n e Industria rts Index. Plant Expansion and Equipment Buying .... tion Price: United States and Pos- it, sessions, Mexico, Cuba, $6.00; Can- ada, $8.50; Foreign, $12.00 year. Single copy, cents. Cable Address. ay. Emerson Findley, 621 Union Blidg., Cleveland ° ottenstein, 8 cago 2 Peirce Lewis, 7310 Woodward Ave., Detroit nal C. H. Ober, 239 W. 39th St., New York eee W. B. Robinson, 428 Park Bidg., Pittsburgh Warren, Box Hartford, Conn Copyright 1938 Chilton Company 4 ANY operators equipment handling highly abrasive materials report Bethlehem Abrasive- Resisting Plates have from two ten times the service life medium carbon steel. Some report increased life over alloy steel plates selling from four eight times much. All agree that Bethlehem Abrasive- Resisting Plates keep replacements minimum and materially reduce maintenance costs all along the line. Bethlehem pioneered manufacturing this moder- ately priced abrasive-resisting steel. made two grades: No. 235 and No. 300. each case the Brinell hardness corresponds approximately the grade number, with ductility decreasing somewhat hard- ness increases. Data forming and fabricating and reasonable expectation service life are freely available upon request. 4 ty BETH THE IRON AGE JUNE 16, 1938 ESTABLISHED 1855 Vol. 141, No. Who Will Tear Down the Fences? UMAN nature does not change great deal one grows older. When was boy, there was tall wooden fence which separated one lot from another down near the railroad tracks. The boys who lived the other side the tracks and the boys who lived side them used converse every afternoon after school from opposite sides the fence. Each group, enroute the established rendezvous, would collect the maximum port- able supply rocks, antiquated vegetables, overripe eggs and, when the Lord provided, dead cat two. Armed with this ordnance, battle royal would ensue between the two geographical sections. Over the fence would barrage animal, mineral and vegetable matter delivered with energy and dispatch both directions. the conclusion festivities, there would usually many casualties one side the fence the other, and equal amount debris. After the daily battle, each side would its separate way and never, under any cir- cumstances, would member one gang mingle with the other. Why? one knew, except the old gentleman whose land the fence stood. Said he: fence blame. keeps the boys from mingling and getting know each had pulled down. With the fence gone, there was not much fun ex- changing dead cats other tokens enmity. And before long the erstwhile antagon- ists were mingling more peaceful pastime. think that there timely lesson this for older What need most today the tearing down the fences which separate group from group and class from class America. With the fences gone, there will not any more fun exchanging dead cat barrages. Who pull down these fences? This week, the Advertising Federation America meeting Detroit. Can you think bigger better task for the men who mold the public opinion and the public mind America than that pulling down these fences? cannot. Get these fences down, boys, and then you can take your vegetables and other prod- ucts market, instead seeing them destroyed the useless and unprofitable class warfare. fe: i hat HAT about the impact technology upon the individual the whose skill has become outmoded What about the fate the hand stripers, the wood body builders and the topdeck trimmers the 1920's? such men out when the new ma- chine new process comes in, are they re-absorbed some other operation such conclusive data are avail- able answer these questions has been presented you for aggregate employment the industry. Nor the record employee turnover, kept the individual plants the industry, satisfactory indicator for the reason that the largest percentage the total turnover occurs the first week employment and results from the newcomer not liking his job, getting another one, not being fitted the work for which was hired. Another factor that makes dif- ficult calculate individual displace- ment that employee one plant transfers his services an- other plant, the same industry even under the same corporation, his continuity employment ceases from the statistical standpoint. count- leaves and “in” the plant which goes, that far the industry records two men and not one. And yet actually there has been displacement, technological tinues the industry. spite these difficulties, how- ever, the Automobile Manufacturers Association has been recently engaged considerable study this subject their member plants which comprise This the second part article based address the author June before the Economic Club Detroit. The first part ap- peared the issue June 26—THE IRON AGE, June 16, 1938 Machines Are JOHN VAN DEVENTER Editor, The Age ° the greater part the automobile in- dustry. This survey, while necessarily not complete statistical measure the entire employment and dis- placement picture, sufficienly broad present reliable cross-sectional finding that indicative the en- tire industry. have been able obtain some these findings for the purpose reinforcing this presenta- tion with the latest available facts. The average record continuous employment, their present place work, for the men now employed the plants the A.M.A. members 5.9 years. This does not take account the years that many these men must have spent previously the automobile industry but other plants. One-fifth the men now em- ployed have had ten years more one plant. January this year, per cent the hourly paid men plant pay- rolls were years age over. The proportion the men years older employed the industry was increased per cent from 1920 1930 according Census figures, whereas with the performance other industries criterion, de- crease 7.1 per cent the propor- Doing tion these older men would have been expectable. labor turnover age groups years shows that the older employees have very low turnover rate and that the employment flux the indus- try almost entirely those less than years age. These data show that despite con- stant technological change the in- dustry, the great body regular workers have enjoyed conditions employment. The policy the industry may wear out machines fast possible keep- ing them busy, but the age experience proves conclusively that this policy not applied One reason for this above the aver- age record that the members the industry make special effort fit workers into new jobs nology outmodes their Classes are established for instructing such workers new operations for which there demand. ments are devoted light bench oper- ations which can handled older men who not wish are unable learn new trade. These supple- ment the customary occupations tra- ditionally reserved for older workers. DIVISION TECHNOLOGICAL BENEFITS MILLIONS DOLLARS 800 —— Automobile Economic Appraisal the Motor Car Industry result this policy, shifts occupation are normal process the industry. Such shifts are aided the fact, disclosed the Em- ployment Service, that per cent the occupations our automobile plants require previous experience and that per cent the jobs re- quire less than one year’s experience. examination the records 1927 employees with service records five years more, chosen random from the files three the oldest plants the industry, shows average number different jobs per employee during the total period employment. During the past ten years techno- logical changes have caused the dis- continuance four departments the Nash plant. the 490 men whose old jobs disappeared, 391 were Thirty-nine quit voluntarily take seek other work. Only the 490 could not placed. Thus only per cent the number involved were unable unwilling adapt themselves new routine. And now come that part this study which the most the part that tells why the automobile industry has made such astonishing progress diligently following the basic prosperity formula. refresh your minds, let re- peat this formula. More power, bet- ter machinery; better output per man hour, higher wages; more customer value price quality. Let take this formula apart bit bit and see what the automobile makers have done with it. First there the factor power. Power applied through machinery frees man from his modest limits strength and endurance and makes him superman free from physical limitation. 1900, the sunset the horse and buggy days, there was utilized all vehicle production the United States, total not more than 475,- 000 hp., measured available ca- pacity. Today, the manufacturers road transportation equipment have nearly million hp. available for use. interesting, while not strictly pertinent this chain thought, reflect that the big power plants the automobile industry are engaged turning out little power plants for AUTOMOBILE INDUSTRY 1929-1937 CUSTOMERS—Saving customers over period due reduction prices from 1928 parity with other manufactured goods. Bureau Labor Statistics data. FACTORY LABOR—Difference between actual factory payrolls and what payrolls would have been had the industry paid more than national average wages. Census Manufactures data. INVESTORS—Corporate Earnings excess six per cent Net Worth. Pub- lished corporate statements. GOVERNMENT—Special excise tax paid Federal Government motor vehicle manufacturers autos and auto parts under the theory that they are luxuries. Bureau Internal Revenue report. SALARIED EMPLOYEES—Difference between actual salary payroll and what salaries would have been had the industry paid more than the national average. Census Manufactures. customer transportation. And note how too, the capacity these little plants has grown and what tremen- dous aggregate new power they put work each year transportation. 1927, the aggregate maximum hp. the automobiles manufactured that year was 130 million hp. 1937, the aggregate power the cars pro- duced was 393 million. Now for the second factor—that better machinery. know, instinc- tively, that the motor car builders con- stitute the largest single factor the demand for machine tools, small tools, forging and stamping equipment, con- veyors and host other mechanical appliances. But not believe that many you realize the vast nature this demand. the decade be- tween 1925 and 1934 the industry, for new machine tool equipment alone, expended the vast sum $411,000,- 000. The third factor our prosperity formula “Better output per man hour.” The combination the in- creased application power and the tremendous investment better ma- chinery and equipment could not fail effect material increase the efficiency parts More accurate piston pins, for example, can ground today than could pro- duced years ago and man hour saving roughly per cent. Other operations show different savings, some greater, many less. But strangely enough, the face such efficiency gains there has been reduction the number man-weeks necessary produce car. One the lesser reasons for this may the slight shortening the working week since 1932. But that minor cause indeed. The explanation the apparent discrepancy between more efficient operations and yet equal even greater total labor time cost lies elsewhere. lies the fact that THE IRON AGE, June 16, 1938—27 | and lus- : lose in- out nce | j er- the ch- ing : for er- ble rs. PRODUCTIVE SAVINGS PLOWED BACK INTO CONSTANTLY IMPROVED UNCHANGED LABOR REQUIREMENTS PER EACH FIGURE REPRESENTS ONE 1925 1938 TURRET LATHES vs. AUTOMATIC SCREW MACHINE ENGINE LATHE vs. LATHE GRINDER PLANER MILLING MACHINE PRESS TOGGLE PRESS MILLING MACHINE vs. BROACH, HOBBING MACHINE TAUCKING SUPPLIES vs. CONTINUOUS SCREW MACHINE UPSET WRENCHES COUNTERWEIGHTED POWER TOOLS HAND TRIMMING ROTARY SHEARS TORCH WELDING FLASH WELOING TOOL STEEL vs. TUNGSTEN CARGIDE HAND BRUSH, SLOW DRYING ENAMEL SPRAYED RIVETING BUTT WELDING FLOOR MOLDING CASTING PROCESS PRODUCED PRODUCES COMPOSITE BODY SQUEAKY WEAK CLOTH ROOF ALL STEEL SILENCED SAFETY SLOW ENGINE VS. WITH POWER ECONOMY MECHANICAL BRAKES HYORAULIC PLAIN GLASS SAFETY PLATE SMALL PRESSURE TIRES BALLOONS LEAKY DOORS FORCED DRAFT AIR CONDITIONING FLAT FLOPPING FENDERS DEEP DRAWN, STREAMLINED, ONE PIECE STEERING WHEEL STEEL SPOKES NICKEL PLATING CHROMIUM AVERAGE SPECIFICATIONS SPECIFICATIONS $1007 DELIVERED PRICE DELIVERED PRICE WHEELBASE vs. WHEELBASE 2356 SHIPPING WEIGHT vs. 2896 SHIPPING WEIGHT 32.0 DEVELOPED 83.9 maximum DEVELOPED HORSE HORSE 28—THE IRON AGE, June 16, 1938 are dealing this case with rubber measuring stick. The measuring stick production the automobile industry the unit car, not the number kinds parts which into it. remember the time when the unit car averaged not more than two cylin- ders, two pistons, rods. Today the average car has six eight cylinders with correspond- ing multiplication parts. Fifteen years ago the typical low priced car had approximately 8000 parts. Today there are 15,000 parts the original assembly, many which are welded together into multi-func- tion units such the body. Take the average car produced 1925 and contrast with the average car today. The average car 1925 sold for $1,006 delivered. The average car today sells for $779—a per cent price reduction. The average car today has per cent more wheelbase and per cent more weight. The average car 1925 developed age car develops 82.4 hp. One hun- dred and fifty-eight per cent more hp. The average car 1925 had slow 4-cylinder engine, two wheel mechani- cal brakes, plain glass, small high pressure tires, and flat floppy The average car today has six eight cylinder fast engine, four-wheel hydraulic brakes, safety plate glass, balloon tires and deep drawn one-piece fenders. Efficiency gains and time savings the automobile industry have very considerable part gone stretch the unit value for the customer’s bene- fit. That there have been tremendous cost savings effected spite sta- tionary over-all cost reflected the vastly superior car today which sells for much less money. The fourth factor our efficiency formula “higher wages.” Hourly wage rates the automo- bile industry since the middle 1937 have averaged between and 92c. per hour compared with 75c. 1928. Weekly earnings the industry averaged $31.58 compared with average $25.11 for all man- ufacturing industry. Wage benefits workers the automobile industry, measured the difference between its actual payrolls and what these would have been had the industry paid more than national average manufacturing wages have amounted $664 millions since 1929. 7 } 1905 ANUFACTURE automo- bile fenders 1905 was characteristic most the processes that pre-mechan- ized age. course, did that way today, could em- ploy more people, provided that could find enough peo- ple who would pay high prices And now come the last factor our prosperity formula. “more customer value price and quality.” have already touched upon the subject increased quality which outstanding recipient the bene- fits progressive efficiency gains. However, there more tangible though less important component customer benefit reflected performance. Since 1929, the automobile industry has handed its customers $738 mil- lions their “price” share the in- dustry’s efficiency gains secured following the prosperity formula. This the amount which represents the industry’s reduction prices over that 10-year period from the 1928 mo- tor car price parity with all other manufactured products. Mind you, this price benefit only and takes account the even more impor- tant benefit improved quality. hold brief for the automobile industry. has its faults shortcomings and there plenty room for improvement. But industry whose record, have set before you, serious students economics can afford overlook. the most intensively mechanized industry the world, its performance has demonstrated conclusively, think, the compatability men and ma- chines when cooperating according the terms the prosperity formula. But has done more than this. Whether chance, whether the blind force driving competition whether superior executive calibre its management immaterial, but this industry apparently has hit upon perpetuating principle which others 1938 ODAY, far better fenders are produced mere frac- tion the time 1905, be- cause modernized mechaniza- tion has taught the way. And because this, automobile buyers are numbered millions instead thousands. THE IRON AGE, June 16, 1938—29 SPECIFICATIONS FOR CHEAPEST STANDARD TWO-DOOR SEDAN Make 1928 Oldsmobile 1938 Chevrolet .... 1928 DeSoto ...... 1938 Plymouth .... 1928 Nash-Special 1938 Lafayette .... 1928 Studebaker ... 1938 Studebaker ... 1928 1938 Packard ..... 1928 Hudson ...... 1938 Wheel- Dry Max. Brake Delivered base Weight H.P. Price 114 2795 $1050 112 2800 668 109 2580 960 112 2774 685 113 3250 1380 117 3200 805 113 3302 1355 116 3140 995 126 4000 2250 127 3600 120 1225 3575 1420 122 3015 101 948 Aside from improvements quality and addition parts, the price comparisons similar types 1928 and 1938 are interesting. Source: Automobile Association New Machinery Processes Hypoid Gear Gen- erators Gear Shavers Hones Mating Machines Dynamic Static balancers also piston, pin, rod scales Diamond drills Electric Gauges for Engine posts High Frequency Bearing and Cam Hardener Rotary Casting Brake Drums Bonderizing Mammoth Body Presses spring grinders Conveyor heat treat New Machine Counter balanced tools Shot blast BETTER PRODUCT Device Method Displaced Rotary Gear Cut- ter Run-in Burnisher treatment all Static Balancer previous testing matching Hone, ream, scrape Gauges Case Hardening treatment None treatment Smaller Presses; some welding jigs previous finish- ing process Hand-fed Ovens Purpose Installation Lower Car, room, floor tunnel. Quiet operation second and low gears with longer transmission life. Quiet, vibration free oper- ation, lower bearing loads and longer life. Longer life, oil gas econ- omy from better finish. Reduce oil and gas con- sumption and increase en- gine life. Longer repair-free car life with reduced oil consump- tion. Squeak-free long lived, non-warping Eliminate flaking lac- quer rusting under- Solid top, all steel body, Much longer life with lighter weight and greater and more uniform resili- ency. Uniform characteristics; fewer rejects and failures service. BETTER JOBS Displaced Tools lifted hand each job Sand blast Effect Labor Requirements Labor Savings Increased labor re- quirements high- costs. Higher labor costs. Perhaps some small labor saving. saving. Small labor saving. Eliminate Cyanide Hazard. Additional labor required. Considerable addi- tional cost. Some saving di- rect labor offset need for more rial. Considerable addi- tional labor cost. Some saving labor, much saving sweat. Benefits Achieved Less back strain and fatigue. possibility hernia. Eliminates dust hazard and gives smoother surfaces considerable expense for shot. control presses, monitor bars Incandescent lamps along with mercury arcs Water screen spray booths Bench height power- driven conveyor Air conditioning Skids with stacking trucks single release with safety stop Mercury arcs used alone Dry back booths Trucking and piling gravity conveyor The weather and few steam pipes Hand loading and piling Eliminates risk accidents. Reduces stroboscopic hazard and provides emergency light after temporary failure current. Cur- rent consumption higher. Dust nuisance and fire hazard re- duced. Considerable recovery lacquer solids for re-use. lifting work, little chance for dropping work. Clear aisles reduce accident hazards. Better working condition. Less variation product dimensions and finish. Lifting strains eliminated. Saving labor well. Progress improvement mechanization not necessarily for cost reduction. Frequently for the purpose improving quality relieving workers physical strain. The improvements cited above fall into these categories. 30—THE IRON AGE, June 16, 1938 will well study. has learned that pays divide its efficiency gains among its customers, its work- ers and its investors. Here industry which, even during the troublesome times since 1929 has benefited its customers $738 million, its workers $644 mil- lion and its investors $400 million, each dollar the increased wealth this has given the largest share its customers, the next largest ATHEW SMITH (right), charge engine production the Chrysler factory, 12200 East Jeffer- son Avenue, Detroit, one the real veterans the automotive industry. has been with Walter Chrysler ever since Mr. Chrysler identified himself with the automobile. workers and has retained the smallest portion for dividends and surplus. The ratios this division may not ideal but the principle involved the basic fertilizer consumption. When that principle becomes adopted and properly applied all industries America, will see the end the imaginary conflict between employers and employed. For then, having mu- tually solved the problem division can unite, with the machine for solving the problem multiplication production and consuming power that alone can lead sound and progressing prosperity. LAME cutting accurate shapes from flat steel plates slabs well known and widely practiced. But adaptation shape cutting ma- chines operate three dimensions produce accurate cuts circular workpieces, the production the large barrel cylinder cam here illustrated, unique. These cams are used the No. 315 automatic beaders built the Brook- lyn, Y., plant the Bliss Co. They are heavy-duty type and require accurate working faces. Airco-DB No. Oxygraph (Fig. 1), with auxiliary equipment de- veloped Durbin, assistant superintendent the Brooklyn plant, employed for the cutting. The ma- chine itself standard design, in- stalled some time ago for various flat- plate shape cutting jobs. But addi- tion the auxiliary equipment, its adaptation the cam cutting involved unique feature, namely, use the magnetic tracing device not only for its designed purpose but also the sole motive power for turning the special auxiliary cam-cutting set-up, arge Circular Cams Flame-Cut ° ° BROWER Air Reduction Sales Co., New York which weighs 700 lb. shown Fig. this set-up consists cylin- drical framework mounted bearing “balancing ways” which serve the mounting for master cam templet and the cam blank cut. Fig. shows the finished job two pieces. The cam made from low-carbon machine steel flat plate, which first cut the required rec- tangular shape, then bent cold semi-circle and finally machined side out outside lathe. When finish turned, the semi-circular pieces measure 11/32 in. outside diame- ter, 309/32 in. inside diameter, and in. width. The master cam templet was made from 3/32-in. flat cold-rolled sheet, bent cold the same radius Airco-DB No. Oxygraph with auxiliary equipment shown close-up the other figures employed for cutting large barrel cams for Bliss No. 315 automatic beaders. THE IRON AGE, June 16, re j AB = the cam made. The opening for the magnetic roller provided with stiffeners shaped not inter- fere with the roller. The master cam graduated increments 1/32 in. show how many thirty-seconds inch off center the cutting torch should set assure that the sides the cut will parallel throughout the curves. The set-up works con- junction with another fixture located beyond the magnetic tracing device, the work-table the Oxygraph. This fixture contacts with the torch bar through rollers, front and back, provide lateral adjustments the torch bar, that carries the magnetic tracing device and the cutting torch. the cross-slide screw the com- pensating device has threads the inch, half turn the crank sets the cutting torch 1/32 in. off center. The torch mounted adjustable adapter that torch and magnetic roller can set the start opera- tions the same center-line. operation, the master cam and workpiece are first mounted the re- volving fixture mandrel. Next, the entire assembly balanced means eccentric, adjustable machine-steel bars and, finally, placed accurate alinement with the torch bar the cutting machine. Fig. shows the set-up ready for the start the cut. Master cam and workpiece revolve to- gether one piece while the cut progresses. The torch permitted only lateral movement the master cam and, before stated, rotary pro- pulsion accomplished the traction the magnetic roller bearing against the edges the master cam. Cutting the cam further pic- tured Figs. and Although four operators appear these views, only two are actually necessary for the cutting operation, one control the off-center position the cutting torch and the other take care the round steel bar balancing weights, clearly visible Fig. These weights have adjusted their eccen- tric centers compensate for the kerf metal cut from the workpiece. This kerf metal amounts about Ib. for the entire operation. Set-up and operation data are follows: Oxygraph set-up and cut- ting time, hr.; finishing time (ma- chine file smoothing the flame- cut surfaces), cutting tip, Airco- style 144, No. oxygen pressure, ting speed per min.; and lineal inches cut, 130. estimated that done bor- 32—THE IRON AGE, June 16, 1938 ABOVE IG. 2—Close-up cam cutting set-up. The cut cam shown the left, and the master cam, magnetic tracing device and attachment for paralleling the cuts are the right. BELOW IG. 4—Start the barrel cam flame-cutting operation. Although four men are shown, only two are nec- essary for the actual cutting. 3—Finished barrel cam Bliss side and inside diameters spectively, and the thicknes§ is! ers Bliss automatic beader. The out- in. and 301/32 in., re- 1/32 in. The width in. ABOVE IG, 5—Finishing the first cut the cylinder cam. The round steel bar balancing weights are clearly visible this view. BELOW IG. 6—Beginning the last quarter, the home-stretch cut the bar- rel cam. ing mill this cam job would have taken hr., plus hr. additional fitting time. With the Oxygraph cut- ting was only necessary make three sets finished cams pay for the cost the special gas cutting set-up, including making the mas- ter cam. One the first applications the No. Oxygraph made the Davis- Bournonville Co., the predecessor the Air Reduction Sales Co., was cutting plate cams for Brown Sharpe automatic screw machine. Cut- ting these cams, however, was sim- ply matter following layout flat steel plate. Metal Gage Measured Magnetism Commercial Engineering Laboratories, Detroit, market- ing instrument designated “magnetic thickness gage,” which used for measuring the thickness iron and steel direct contact with one side only. The instrument was originally developed for quickly gag- ing the walls automobile engine cyl- inder blocks after being rough ma- chined. Cast iron pipe also can inspected for variations wall thick- ness, and steel plates and tubes sub- ject corrosion one side can measured contact with the other side. Three types instruments have been developed and are now available. The form used for testing automobile cylinders small hand model, con- shell containing magnet and ener- gizing coil. Two pole pieces extend slightly from the shell near the ends, and are ground carefully special grinding fixture conform the cylinder bore. indicating meter located top the cylinder, and selector switch just below the dial permits the operator take readings the thickness the cylinder wall either pole piece. second form the magnetic measuring instrument designed measure the wall thickness cast iron pipe contact with the outside. And third form the instrument will measure the thickness vitreous enamel steel panels such used electric refrigerators. Other forms the instrument may developed meet individual conditions. THE IRON AGE, June 16, 1938—33 " New Yale Towne Plant Stresses Daylight application daylight con- Struction multi-story indus- trated the new four-story building Philadelphia, where the Yale Towne Mfg. Co. now producing and assembling electric hoists, hand lift trucks, skid platforms industrial trucks and tractors. Designed and built the Austin Co. according modern functional principles design, the plant rein- 34—THE IRON AGE, June 16, 1938 forced concrete, with set back columns permit the installation practically continuous horizontal bands sash. are the flat slab type and extend beyond the columns the building line where they support wall masonry. Thus, the concrete floor band, together with cast stone sills, horizontal sweep contrast with sash and brick work. Columns are spaced 20-ft. centers and there F * Fe average ceiling height ft. throughout the first three floors. The fourth, where monitor has been in- stalled further increase the daylight, has center aisle giving 60-ft. clear span and clearance ft. the monitor section. The roof 2-in. gypsum plank, covered bonded waterproofing. The sash forms four bands around three sides the building intercepted only narrow vertical shafts ° ° ° HIS new four-story building recently completed the Austin Phila- delphia for the Yale Towne Mfg. Co. illustrates the appli- cation daylight construction ti-story industrial building. Continuous horizontal runs sash, ft. in. high, provide daylight three sides. The fourth side brick. 7. ° into plywood forms gives even reflecting surface when painted. This view shows section the second floor the Yale Towne building, with group driven screw ma- chines and lathes the right. ° ° introduced provide vertical contrast near the corners. The produc- tion and assembly lines have been laid out along these three daylighted walls, while storage tools, semi-finished parts and other materials concen- trated the center bays and along the fourth wall. Lighting fixtures have been installed 10-ft. centers and are two types, with glass-steel reflectors provide ft.-candles throughout the working areas, and with R.L.M. reflectors provide ft.-candles the storage The first floor the new building devoted production skid plat- forms several types. Steel de- livered the rear truck and un- loaded directly into stock racks ranged along the masonry wall, where special stacking facilities have been provided. Cutters, shears, punch presses, saws and shapers for fabricating skid legs and frames are arranged the aisles opposite these stock stacks. Beyond, the same aisle, paint booth with revolving rack for automatic dipping and early drying, from which parts are placed final drying racks, car- ried the assembly station lift Lumber for the skid platforms delivered truck the front the building, toward which the metal parts progress, and processed and as- sembled the metal bases adjacent the truck loading door, from which skids are shipped transferred for storage. This production line supplemented welding and other fabricating fa- cilities the other side this floor, which entirely devoted the manu- facture wide variety skid plat- forms and pallettes. The second floor used principally for the machining parts for hand lift trucks. complete battery modern machine located around the three outer walls, and the tool room located the center aisle. While some these machines are motor-driven, those operated belt are grouped fours from each mul- tiple drive shaft. Most the ma- chines are set 10-deg. angle, sim- plifying the stacking stock and feeding the machines. Rough castings and other parts are held stock bins mounted skid platforms which are stacked two-high the floor area be- tween the tool room and the rear the building adjoining the old ture. They are served electric lift trucks operating 10-ft. aisles. The third floor devoted the as- sembly electric hoists, motor drives and hoist units for electric lift trucks. Benches which the units are assem- bled have been set lines right angles the side walls and are served overhead chain hoists. Motor drives are transferred the principal assem- bly plant across the street for testing and assembly into finished trucks. Parts for use the assembly prod- ucts handled this floor are stored bins erected against the windowless rear wall. present, the fourth floor area being devoted storage finished parts and products. One outstanding feature the plant are the ceilings, which were poured plywood forms and have smooth and uniform reflecting surface, which was painted without any special pointing. 1939 Auto Production Started Slowly ILWAUKEE.—With the com- pletion the usual annual con- tracts between the Smith Corp., Milwaukee, and automobile manufac- turers for pressed steel frame require- ments for 1939 models, indicated approximate the same level for 1938 cars. also indicated that production new models will not started off the high levels which prevailed 1937. While hopeful higher produc- tion the fall and next spring than was experienced during the past sea- son, automobile make effort spread 1939 de- mands over several months rather than have the sharp peaks experienced the 1937-38 period. The frame awards also indicate that production cars will started off easily this fall test demand. First large de- liveries frames are scheduled for about Aug. Shipments frames for 1938 models will completed about the end July. THE IRON AGE, June 16, bey Facilitates Fabrication HIS article discusses briefly the application arc welding the design and construction the $600,000 flood control project across Turtle Creek just below the Westinghouse East Pittsburgh works. 1936 Pittsburgh flood still fresh the memories many who saw were any way affected its fury. The Westing- house Electric Mfg. Co., situated the Turtle Creek Valley about one mile upstream from the point where Turtle Creek empties into the Monon- gahela River, was this time flooded for the third time years. Many area that are vulnerable floods are situated that they cannot take any direct action protect themselves. The fortunate location the West- inghouse company, however, has made possible erect flood gates and prevent future flooding its East Pittsburgh works. point just downstream from the works and under the famous George Westinghouse bridge the Tur- tle Creek runs parallel road. The road and creek this point are bounded high natural bank and extensive railroad embankment. Also the high water the creek not caused the rainfall the Tur- tle Creek watershed, but water floods from the Monongahela River. This set conditions was ideal for developing suitable system flood control and Webster’s* dream many years was finally real- ized when sum $600,000 was ap- propriated the Westinghouse com- pany construct flood gates across the valley and 15,000-hp. pumping station. The general layout the flood gates and pumping station shown *J. Webster, Westinghouse general works engineer, supervised the design and construction the flood control project discussed this article. 36—THE IRON AGE, June 16, 1938 Fig. large gate ft. in. and ft. high spans the creek and smaller gate ft. long and ft. high spans the adjacent high- way. The ends the gates are sup- ported concrete piers and provided with anti-friction rollers facilitate raising and lowering. Normally the gates are held elevation ft. car above the street level accommo- date traffic. The gates are raised and lowered means cables operated auxiliary motors and are not put into use until the water reaches elevation 734 ft. above sea level, ft. in. above lock No. the Monongahela River. creek eleva- creen gate yard house IG. the Turtle Creek flood ect. tio cal ple ELEVATION LOOKING UPSTREAM ° ce Shutters | | 1 ; Fi 72/. = t PUMP ASSEMBLY N Flood Gates tion 738 ft. can obtained before causing damage the Westinghouse plant. Pumping Station Steel Also Are Welded Are welding was used fabricating the gates, the steel re- inforcements for the concrete founda- tions and piers, the structural steel for the pumping station and the dif- fuser chambers the outlet side the pumps. The three 5000-hp. syn- chronous motors used for driving the pumps are also are struction. The two gates consist essentially two horizontal trusses fabricated from heavy sections, series inter- lacing vertical trusses and solid face composed numerous 5/16 in. thick plate (see Fig. 2). The face plates are fillet welded lattice work channels and butt welded together their edges form leak- proof surface. The large gate weighs 180,000 Ib. and the small gate weighs 42,000 Ib. The three concrete piers supporting the ends the gates are reinforced four “I” beams and surmounted weld fabricated pylons facilitate the ABOVE RIGHT IG. 3—Welding plates the face flood gate. ° ° RIGHT 2—The large flood gate weighs 180,000 and the small one, 42,000 Ib. ° CHARLES JENNINGS Engineer Charge Welding Re- search, Westinghouse Electric Mfg. Co. lifting and lowering These piers were constructed first and the gates fabricated place. Order Erection and Welding The supporting framework for the face each gate was the first part the gate erected. Following this the trusses the back were erected and welded the face framework. Large jacks were used support the over- hanging weight the gate trusses until they were securely welded into place. The in. thick face plates were the last parts the gates assembled and welded into place. All material for the gates was cut size before being shipped the site. (CONTINUED PAGE 93) THE IRON AGE, June 16, - d Sma IRTUAL doubling output, to- with marked lowering foundry production costs has resulted from the modernization the Ontario, Cal., works the Gen- eral Electric Co. This foundry has been operated for more than years, latterly branch the G-E Bridgeport, works, which largely devoted the manufacture electric household appliances. Over the years its produc- G-E Foundry tion facilities have been gradually im- proved, but the present layout repre- sents improvement wholesale scale. The main product casting for electric flat irons. These vary cross- section from in. and castings, such for tailor irons, weighing much lb. There core work. 1933, when the present compre- Output hensive improvements about 2400 tons iron was being poured per year; 1937 more than 4200 tons was poured. Prior 1934 one hand-charged 42- in. cupola was employed, and castings were cleaned sand blast. Molds were made jolt-squeeze machines and poured the floor from hand ladles. There was operation, how- ever, unique molding machine for producing gang molds. The latter, Passage distributing belt sand bins Sand hopper Coke storage Scrap storage 38—THE IRON AGE, June 16, 1938 Casting storage storage Charging bucket loading prt Telpher crane for cupola charging Scrap storage loading pit floor curing Ladle for pouring ladles floor Tracks Sand storage plan present G-E Ontario, Cal., foundry. ventilated, type, the building 100 168 ft. with ft. minimum clearance from floor steel truss. All interior surfaces are coated with G-E Glyptal aluminum paint. 4 breaker t 7 un, ing 42- ngs nes for th, m All which permits pouring castings one time, has been retained the new set-up and its use extended, outlined below. Major items new equipment in- clude two twin, 42-in. cupolas, one stand-by; cupola charging airless steel abrasive machine for cleaning castings; new molding machines; and complete sand han- dling system, including magnetic separator, sand mixing mill, conveyor IG. 2—View cupolas and charg- er. The cab the charger the right, under the roof. The charging pit the right the central roadway. belts and storage bins. new all-steel, type foundry building has replaced the former structure and heavier monorail system has been pro- vided for handling molten metal and transporting castings from molding floor cleaning room. The handling bull ladles has been changed from two-man one-man job mount- ing one end the holding shank With New Equipment Since 1934 very good cupola prac- tice has been developed, with improve- ments the iron, particularly the direction denser structure that permits better plated finish applied. Cupola Charger Installed The layout the new foundry shown Fig. Among the first the present equip- ment installed were the twe cupolas, which, with the framework, monorail, cab, electric hoist, and charging buckets charger were transferred from the company’s dismantled Elizabeth, J., foundry. The cupolas and charging apparatus are pictured Fig. The cupolas are standard 42-in. units. The monorail system arranged take metal from either cupola. The mechanical charger runs ° MAURER General Electric Co., Ontario, Cal. ° ° monorail ft. above the ground, sup- ported steel framework extend- ing 100 ft. back from the cupolas. scrap breaker located the extreme end the monorail and cast iron scrap piled under and each side the monorail shown Fig. Between the scrap breaker and the cupolas the charging pit. Into this pit the charging buckets, loaded the scrap breakers with the approxi- mate charge purchased cast iron scrap, are lowered onto small cars designed pushed onto plat- form scale. Here the charge accu- rately made purchased scrap cast iron, shop returns, steel rail scrap and pig iron. Coke charges are also made the charging pit, and the proper amount limestone and dolo- mite are added. Materials are brought the pit small cars that run steel rails. THE IRON AGE, June 16, = | The loaded bucket elevated the hoisting mechanism the front end the mechanical charger the level the charging door, and then pushed forward into the cupola. Buckets are conical bottom drop type. 40—THE IRON AGE, June 1938 Metal charges are 1000 made only 22% per cent pig Monotrack and switching gear are used throughout the monorail pouring system. The Monotrack — and belt for handling sand. vibrating screen mounted top the muller and cated under the screen. Control switches are panel the front. “double bead” system which was too light for present operations. main track runs east and west the full length the building. From this, right angles, run pouring tracks for the molds grouped frames and 4—Shakeout grate. Note grate tilted dump cast- ings into tote box be- low trap door. The carriage for bringing frames molds and dumping them shown the right foreground. The tote box, after being filled raised air hoist and rolled roller conveyor, then the airless abrasive clean- ing machine background. ra — was the this, acks and youred knee height; and one track, the east end, for the bench made molds, poured floor level. The ladles are suspended from the mono- rail four wheel fixtures. very chain hoist used regulate their height for receiving and pour- ing metal. Sand Handling System Major Feature outstanding interest, perhaps, the new layout this foundry are the sand handling system and the opera- tion the group molding equipment. The sand handling system (Fig. operates the continuous principle. that is, there little storage, the sand being made into molds fast prepared the muller. system comprises mold shake- out grate with ventilating hood; short conveyor belt under the shake- grate which carries the sand over magnetic separator and into bucket elevator; rubber-mounted vibrating single screen; and storage bin hold the sand. Also, size sand muller; sand aerator; 40-ft. long sand elevating conveyor bearing rollers and 18-in. wide, 120-ft. long sand conveying (which also operates and four storage bins, into any which the sand may di- verted from the belt. water meter the muller regulates the amount water added each batch. The sand handling system further includes miniature track and carrier for transporting the castings from the pouring tracks the tion. carrier brought into position adjoining one the pouring tracks, and frame molds, its the carrier. The carrier then pushed the shakeout station and the frame molds overturned ro- tating the top table the carrier its mounting, whereupon the sand and castings spill out the grate (Fig. +). blow with sledge knocks the main sprue and gates from the cast- ings and the sand falls through the grate the belt below and over the magnetic separator. When three frames molds have been dumped, the sand elevated into the storage bin, and dropped into the muller. Water then added, and after being mixed for min., the sand elevated and distributed proper bin, cant piece equipment carried over the new set-up machine means which castings are poured one time. The molds are frame and held tightly together pressure applied end plates. The assembly resembles plate and frame filter press. Patent 1,717,245, issued Patterson, foundry foreman, taken out this equ pment, 4 — machines having 16-in. diameter air cylinder and 70-in. table. Air compressor. One the molding ma- chines, with its sand bin and pair molds, shown Fig. Molds are made two time, the rate 100 hour. Since each mold makes 5—Molding machine and sand bin. The pouring track with groups molds the foreground; molds with Calrod inserts place are shown the shelf the left. has been assigned the General Elec- tric Co. This process group molding has been used for several years produc- ing horseshoe shaped casting and for flat castings used “pressure plates.” With the installa- tion the sand handling system, how- ever, the process has been extended single-casting automatic Molds for the grouping frames are made four yoke-type jar squeezer two castings, four castings are pro- duced each cycle the molding machine. Each the four molding machines has four sets tracks front it. Three are used hold the groups finished molds, waiting poured, while one track used hold the empty frames, awaiting filling the flasks with sand. the dumping the previous day’s production takes place, the frame “empties” push- manually the track the mold- ing station. the molder fills THE IRON AGE, June and rating a 4 The olds tote lled the pan- frame, pushes away from him on- one the pouring tracks, where stays until poured. making the molds for automatic castings, one man operates the mold- ing machine while second man places the Calrod insert chill held 13. Lift molds off stripper plate, placing stand left. Operations the helper are: Raise two empty flasks from frame “empties” stand. Place Calrod inserts position, ends inserts into holes chill. 6—Close-up cleaning machine. this view, the loading mechanism discharging the contents tilted tote box into the machine. place the sand. Operations the machine operator are: Lower stripper plate over pattern. Place chills draw pins pattern. Place flasks position. Drop sand filler plate place. Place spring gate for runner (gate castings part pattern). Pull sand from bin tuck around chills and gate. Jolt twice more and smooth sand back level with filler plate. Squeeze 50-60 lb. per sq. in. pres- sure. Raise top filler plate, blow off mold around gates, pull spring gates. 10. Dust molds with Faceamol, openinz suction vent draw away excess dust. Pull draw pins chills will come free mold. 12. Tilt stripper plate forward, iifting molds off patterns. 42—THE IRON AGE, June 16, 1938 Blow off molds with air. Remove the two molds stand and place pouring track. Serew end plate frame when filled with molds. There are men the entire foundry crew, them day shift. Each week they regularly make molds, place heating elements and pour metal for 28,000 electric irons. Metal melted has averaged around 30,000 per day. Castings Cleaned Airless Abrasive Method New equipment has also been in- stalled for the cleaning castings. The system includes steel tote boxes into which the castings are tilted off the shakeout grate (Fig. 4); air hoist for lifting boxes castings from below the shakeout grate the cleaning floor level; and roller con- for transferring the full tote boxes airless abrasive cleaning machine (Fig. 6), and returning the empty tote boxes. Also, track and cars each end the roller conveyor for transferring full boxes from the air hoist the con- veyor and returning empty boxes the air hoist below the shakeout grate; and charging device which dumps tote box castings into the cleaning ma- chine. The latter uses chilled shot which projected rifle bullet speed from slots revolving wheel. Powerful suction removes all dust, allowing the working quarters. With the equipment above de- scribed have materially reduced our cleaning costs and have removed hazards from silica dust. operation, the castings top the shakeout grate are tilted off the grate into tote box below. When filled, the tote box rolled onto the roller conveyor, taken the cleaning section and then elevated electric hoist and dumped into the cleaner. Starting the main drive puts the wheel this cleaning machine into motion. Shot flows the center the wheel and flung radially high speed through vanes the wheel, hitting the surface the casting and knock- ing off all adhering sand. Loads castings that formerly required hr. for cleaning are now cleaned min. less. Close Technical Control The foundry well organized technical well personnel con- trol. The technical control function the engineering depart- ment, which responsible for the cor- rect materials being used, the correct iron being poured, and the proper sand being used under all conditions. All materials are inspected ceived. Chemical analysis made weekly the iron castings; screen and clay analyses the sand are also made weekly. Moisture, strength, and permeability tests are made every day. least once week load castings tagged special and followed clear through the plating room and sometimes through iron must such quality machine very freely, yet dense, with the graphite very small flakes assure smooth surface, free from porosity and “orange peel” effect, for plating. 4 i 7 q 7 | Belt Wrappers for Wider Mills and Heavier Strip ELT wrappers originally devel- oped the United Eng