The Iron Age 1944-10-19: Vol 154 Iss 16

BAUR 42nd New York 17, Market Vol. 154, No. October 19, 1944 Typography and Layout Editorial British and American Production Efficiency ° Regional Business Managers 42nd St. 100 East Electric Furnace Operators Debate Construction Methods Basic Furnaces Owned and Published Chromium Loss and Recovery CHILTON COMPANY New Equipment ® ° Features Executive Offices News Front : 49 Chestnut and Séth Sts. Assembly Line Philadelphia 39, Pa., VAN This Industrial Week BAUR Vice-President News Industry WILLIAM BARBER, Renting War Plants Suggested Power Crane Castings Price Rulings 134 Standard Forms for Contract Termination 138 Rocket and Munitions Program Expand 144 Steel Payrolls 146 Industry Made Vital Machine Tools 148 Machine Tool Market Developments 158 Non-Ferrous Metals News and Prices 160-161 Iron and Steel Scrap News and Prices 162-163 Comparison Prices Week and Year 164 Finished Iron and Steel, Steel Prices the Warehouse, Semi-Finished, Tool Steel Prices 168 Steel Pipe, Tubing, Wire Products, Prices 172-173 North America, South America Pri 174-175 Copy, Stainless Steel and Ferroalloy Prices 176-177 . | When specifications call for bar steel, phone Ryer- son. save time, trouble and get the bar exactly right for your job—because Ryerson stocks include practically every shape and size bar, practically every analysis steel now available. Whether its straight carbon alloy, hot rolled, cold finished heat treated, Ryerson has the right bar nearby stock and will ship once. Why elsewhere when the nation’s largest steel stocks are your surest source for just the bar you need. you have question steel selection application, experienced Ryerson metallurgists save time and use the RIGHT bar and engineers will glad work with you. There obligation. Inquiries well orders receive prompt attention. Ryerson Bar Stocks Include: Aircraft Alloys Forging Quality High Carbon Round Edge Allegheny Stainless Free Cutting Hot Rolled Screw Steel Alloy Gagger Bars Mild Steel Shafting Bevel Edge Galvanized Alloys Spring Steel Carbon Steel Hexagons Octagons Stainless Coal Screen Half Ovals Ovals Stressproof Cold Finished Half Rounds Pickled Steel Cold Twisted Heat Treated and Oiled Threaded Forged Hi-Steel Reinforcing Tool Steel Shapes, Plates, Sheets, Tubes and many other steel products are also stock for quick shipment. JOSEPH RYERSON SON, Plants: Chicago, Milwaukee, Detroit, St. Louis, Cincinnati, Cleveland, Pittsburgh, Philadelphia, Buffalo, New York, Boston. RYERSON STEEL-SERVICE money \ (RON ESTABLISHED 1855 ° ° Oct. 19, 1944 VAN DEVENTER President and Editorial Director BAUR Vice-President and General Manager ° ° ° DIX Manager, Reader Service ° Editorial Staff LIPPERT Technical Editor ........ OLIVER Commercial Editor, CAMPBELL ° ° Associate Editors WINTERS A'BIN JOHN ANTHONY BARMASEL Editorial Assistants SCHIEN WILLIAMS VAN CAMP MUNZER O'CONNOR MILLER Regional News and Technical Editors LLOYD Pittsburgh 428 Park POST Chicago 1134 Otis MOFFETT DONALD BROWNE EUGENE HARDY Washington National Press Bidg. BRAMS Detroit 7310 Woodward Ave. OSGOOD MURDOCK San Francisco 1355 Market St. Correspondents ROBERT Cincinnati DEAN Buffalo FRAZAR Boston HUGH SHARP Milwaukee SANDERSON Toronto, Ont. RAYMOND KAY Los Angeles JOHN McCUNE Birmingham ROY EDMONDS St. Louis JAMES DOUGLAS British and American Production Efficiency (Cabled from London) ISITING British industrial plants under the auspices the Min- istry Production both interesting and arduous. Our friends want make sure that one sees enough able sound con- clusions. result the pace set fast one, and the survivor such tour should good candidate for additional life insurance. But out all definite picture begins emerge, and one that might shake the complacency some home who like think that America has patent production efficiency. true that home can outproduce, and many instances undersell, other nations with respect mass production products but perhaps here are likely confuse cause and effect. Mass produc, tion efficiency may well the effect the large domestic market which permits the application mass production methods. America can produce motor cars, for example, much lower cost than can the British car but have market that will absorb say five million units year where the British market will run 500,000. Thus there are but three continuous strip mills the United Kingdom and, while one projected for the postwar era, none the existing mills are wide enough for one-piece top stamping. the other hand, machine tools, which not mass produc- tion proposition any country, the. British makers can produce ma- chines similar type and size considerably under our cost levels. The reason for this that labor the United Kingdom paid for work done and not merely for time put in. Incentive systems are the rule here and the principle accepted the unions. America the other way round. experienced observer can detect the presence absence labor efficiency walking through plant. There question whatever but that the degree application the task greater this side than back home America. good thing that have home market such size pro- tect for without the British incentive system might give trimming. 3 > — | Take firm hold piece Inland HI-BOND Reinforcing Bar and note its grip. This important you because when HI-BOND bars are placed con- crete they assure more effective me- chanical grip irrespective the position which they are cast the direction which they are pulled. The Inland Bar gives the first real improvement the bonding value reinforcing bars more than years. The scientific design this new Inland HI-BOND concrete reinforcing bar, with its reversed double helical ribs, provides vastly greater anchorage and bonding strength. provides more effi- cient transfer stress splices. The use HI-BOND Bars will materially reduce the width cracks thereby reduc- ing the possibility corrosion and pre- serving the appearance and safety reinforced concrete members. Inland HI-BOND Bars are made nine standard areas both new billet and rail steel qualities. Write for the new bulletin Inland HI-BOND Reinforcing Bars. INLAND STEEL COMPANY Dearborn St., Chicago Illinois 48—THE IRON AGE, October 1944 Ove | News October 17, 1944 Arrangements are now being attempted for tremendously large bulk sale war model jeeps Russia, perhaps under some sort arrangements. cations are that the Soviet Union has discussed this matter Washington, and soundings have been made the subject However, commitme yet been made, reported. Russia appears thinking terms need for half million jeep vehicles for internal use agriculture and general use applications. These jeeps will quite different from the Army variety. They will necessarily have power takeoff and will built larger scale. China also interested entering the postwar automobile market for about 450,000 trucks and passenger cars during the five years after Japan beaten. ever, because China's meager transportation, many second class vehicles will taken The likelihood that Germany will last through the winter leading the tation that the transition from war peace production will more gradual, than the completely abrupt shift that has figured prominently all plans. England, number war factories are beginning curtail activities, with resultant discharge workers. growing fear there that the production will not smooth expected, and desire for liquidity, has drop British industrial equities more severe than any since 1940. Russia, the Donetz Basin has just celebrated year liberation from Over 858 industrial units have been restored working order, among which are large mines, although many other mines this rich coal region still are But: The recovery the iron ore mines Krivoirog proceeding very slowly, and there has been little restoration the steel works. The government showing tendency move back many the plants from the Urals, for instance the tank and airplane plants (Voyenzavod), which are still Nizhny Tagil the Urals, the motor plants Stalino (which were originally built underground), and the pol works (armor plate), and many other combines. The many skilled workers evacuated from the Donbas with their plants the Siberia, and Central Asia have developed natural tendency rush back their erated homes. But: Pravda has emphatically cracked down with warning down for their new places habitation, their plants will remain where they are and units will built the recovered areas. The nickname "Father and Son" has been given Germany's composite airplane, which Messerschmitt 109 mounted above Junkers 88. Some distance frog target the 109 pilot releases the (which carries tons explosives) guides the objective means radio-controlled automatic pilot. The Allies have long been experimenting with similar remote controlling ventional aircraft, and also rocket aircraft and rocket bombs. And: Use the Allies this equipment against the Japanese V.1, the rocket bomb, was tested Northern Italy, Viconza, wit German pilots flying captured British Spitfires attempting destroy them The results led the Germans estimate that not more than per cent could knocked down aircraft. But: Meanwhile the British had introduced the very fast Hawker Tempest fighte their fighter, which accounted for far higher percentages flying bombs casualties. underground German radio has stated that during the recent attempt life Messerschmitt 264 airplane was warmed Lechfeld take Hitler Japan the rebel generals gained the upper hand. The 264, which has never been mentioned before, described having mile range. similar airplane was said have flown from Germany Japan last year. — 7 | | i Electrostatic Spraying And Detearing Even complex metal parts now are painted automatically, economically, and with superior finish electro- static field. Similar desirable results attend the de- tearing parts dipped paint. TRIKING success has followed the use electrostatic processes the finishing metals. The ordinary methods both spraying and dipping have obvious drawbacks. the usual spraying procedure, much the material has been wasted. has been necessary turn the part for the paint reach all sides, and uneven distribution the paint film frequently results. The process spraying electrostatic field has not only eliminated the above difficul- ties, but has also effected vastly 50—THE IRON AGE, October 19, 1944 22 q improved finish uniformity and smoothness. all dipping operations, the forma- tion tears and fatty edges en- countered. the use electrostatic detearing dipped parts, conveyer line carries the articles from the dip tank over electrically charged grid which draws off the surplus paint and leaves the lower edges with smooth even finish. Both processes have found wide range application, are automatic the nature their operation, and ° ° ° HARRY FORSBERG President, Japan Co., Cleveland ° ° ° result superior finish. Electrostatic spraying has certain similarity electroplating, that paint deposited upon the work passes through charged field. both processes, the placement and deposition material electrically controlled. Higher potentials are used spraying than plating. voltage 100,000 more has been found necessary give the minute spray particles small charge. Consequent- they are attracted the work, which has been given opposite the detearing process. The high-voltage grill quite visibly drawing excess en- amel from the sam- ple part held within the electrostatic field. | hic bly hin ° ° ° Fragmen- tation bomb parts passing through de- tearing booths ac- tual production. These parts have number tension springs and are dif- ficult finish with- out clogging the springs and creating heavy tears the work. Now pos- sible dip and de- tear them, obtaining much shorter time with notable sav- ing both man- power and money. The control panel for the electrostatic field shown the left and the power pack the right the booth exit. polarity. The attraction unlike charges results the spray particles being deposited the work with gratifying degree uniformity and smoothness. Wasteful overspray virtually eliminated. This method makes possible satisfactory spray application even odd-shaped parts. Electrostatic spraying spectacu- lar process. The part sprayed electrostatic field which created 3—The paint being sprayed directly gun onto the part, and covers only one side most the paint by-passing the part and being lost. vertical electrodes, charged with 100,- 000 volts electricity and located within range fixed spray gun. Acquiring charge they enter this field, the paint particles are instantly attracted the part sprayed, this being grounded through its own conveyer hook. The paint drawn all sides the part simultaneously, creating the appearance light fog the atomized paint enveloping the piece coated. Somewhat better results may obtained revolving the part the field, although this not strictly necessary. This process obviously results increased speed operation. For instance, consider the following ex- ample the difference between ordi- spraying and the new electro- static process with respect improved production speed. the Japan Company’s plant, recent job was the application two TRE IRON AGE, October 19, , coats paint mine housings. With ordinary spraying, these mines could given one coat paint the rate 200 Using the electrostatic paint from 300 400 per hr. with both coats. Also, the ordinary spraying process required three booths with operator and three helpers each booth. The electrostatic spraying quires only two booths with one oper- ator and one assistant. other words, two men using this improved process are now doing the work 12. The old spray process has always been extremely wasteful one, with much per cent the paint wasted some jobs. When paint sprayed object, only small part the paint intercepted and ad- heres; much passes the object and wasted the walls and floors the spray booth. Even with the most efficient use the ordinary spraying method, probably cor- rect say that not more than per cent the spray material utilized. Because the electrostatic field causes the paint particles drawn toward given point, this waste prevented. This method painting object highly efficient and causes the paint spread more smoothly than was ever possible the past, resulting greatly reduced amount paint re- quired for any given operation. Thus, paint conserved two ways: (1) practically all the paint sprayed deposited the part, and 5—A laboratory study the effects detearing. the left part which has been dipped heavy enamel and allowed dry without detearing. the right the same part after electrostatic detearing and baking. Fig. only cur- rent has been ap- plied and the atom- ized paint seized the field, converted into fine fog around the part, and de- posited evenly and smoothly upon the metal surface, using far less material and resulting control film thick- ness. static field ated the four fine wires which are hanging down. The heavy insulators with turnbuckles are the suspension hooks for the detearing (2) much less paint required each action the spray gun. Electrostatic finishing also results great improvement finishing quality. general, thinner, more flexible paint film applied, reducing the risk chipping. But the most important point that absolute con- trol and uniformity film thickness. are made possible. The spacing electrodes, fluid and atomizing pressure, conveyer speed and coating process—all factors the efficient operation this method —must properly correlated ob- tain the best results. With these fac- tors carefully determined, the paint- ing process fully automatic. with electroplating, the uniform- ity the coating some extent dependent the contours the arti- cle painted. The same tendency deposit more material protrud- ing surfaces and less those which are recessed noted. The degree this variation depends largely the extent which certain sections are shielded from the electrostatic field, there certain measure con- trol over even this factor. The degree economy that can attained electrostatic spraying large extent depends upon the shape and size the articles finished. With small parts, ordinary spraying methods, previously noted, fre- quently waste from per cent the material sprayed. Less saving effected large, flat parts, and possible that the spraying metal sheets hand spray- ing would more efficient. the 7 x 4 52—THE IRON AGE, October 19, 1944 the: finishing all smaller parts, how- ever, the electrostatic process will re- sult important economies, greatly increased speed, and distinctly im- proved quality finish. Typical savings high produc- tion finishing recent job involving about 200,000 small stamped parts, which previously cost $55 thousand paint. Sprayed electrostatically, the total cost finishing has been cut $23. Electrostatic Detearing applying paint any part product, dipping has always been the speediest and most economical meth- od, since assures complete coverage and minimum wasted material. Its limitations are well known, and these have made impossible its use for certain jobs. Its most serious disad- vantage, probably, has been the ac- cumulation excess paint tears the drain-off points. These tears and fatty edges have seriously compli- cated the finishing process. example, has been neces- sary bake the part tempera- ture suitable for hardening the thick- est sections the coat. Unless this done, the excessively heavy coat the edges will soft, tacky, and per- haps wrinkled. Frequently, tears have removed manually before the baking process started, resulting high percentage rejects and al- ways requiring additional labor. Electrostatic detearing auto- matic method getting rid excess material between the dipping and bak- ing processes, and results smoothly finished, clean-edged part after leaving the bake oven. The work carried the conveyer over the drain board, and allowed drain the point where the flow has ceased and tears have formed the drain-off points. next passed over grid which electric cur- rent low amperage and very high voltage (approximately 85,000 volts for most jobs) has been applied. This creates strongly attractive electro- static field between the part and the grid. This force stronger the lower points where draining natu- rally occurs. the work passes through this field, the excess paint drawn off thin streams attracted the grid, and smooth, uniform coating results. The work can then conveyed through the baking oven baking schedule suited the en- tire coating. Detearing electrostatically has made possible dip many parts that necessary formerly spray much higher cost. many jobs, this has resulted 6—Mines German design (manufactured for practice use American forces) being loaded conveyer for electrostatic spraying. the difference between profit loss, and, also, the difference between ob- taining job losing it. example the latter occurred within the past days. manufacturer component am- munition parts asked for quotation the job supplying bomb part that was finished ready for as- sembly. The quoted price was $98 per 1000 pieces, and the Army Ordnance De- partment rejected the bid the grounds that the price was prohibitive. analysis the price revealed the fact that large part was rep- resented the cost finishing the parts according Government speci- fications. The cost estimate had been figured the basis spraying the parts, since dipping would not have provided the smoothness finish re- quired. When the job was re-figured the basis dipping and electrostatic de- tearing, was found that was pos- sible supply the finished part the required specifications price $35 per 1000, cost saving more than per cent. The Ordnance De- 7—Here the mines are shown just they leave the electrostatic field with their final coat paint. THE IRON AGE, October 19, 1g re m- SS. nt- icy excellent example cost reduction electrostatic spraying. this job, paint consumption was reduced one-fifth that hand spraying, and naturally the automatic set-up has eliminated much labor. partment accepted the bid this fig- ure and the contract was let. Many similar cases where equally large cost reductions have been made possible the electrostatic detearing process might cited. Some the special equipment re- quired this process shown the illustrations accompanying this article. Its effective use requires con- siderable industrial finishing experience and skill, since, for optimum results, certain factors must carefuly trolled. For instance, the interval be- tween the dipping operation and the application the electric field must exactly determined. The resulting variations depend the size and shape the parts, the flow character- istics the coating material being used, and the evaporation rate the solvents. electrostatic detearing, there are two limitations that well note. The first obviously found when the coating material thermostatic cause harmful during the bake, after the detearing has been effected. The second would restrict its use the case of-objects formed that the drain-off radius was comparatively large one. The process does not remove excess paint from such surfaces. But this can, some cases, corrected hanging the part such way drain off the excess paint from relatively small radius. Electrostatic detearing and spray- ing are done the same production line—in the same booths matter fact—and the changeover from one minutes. The same equip- ment used for spraying and detear- ing, with only minor changes neces- sary. The function the production line follows: Parts are loaded hand upon the large hooks the 450-ft. overhead conveyer, sometimes five hook, shown Fig. the dipping proc- ess they are carried through dip tank which placed tandem booth containing the detearing grill, and after passing over drain board they through the electrostatic field and have all excess paint drawn off. Then they travel through infra-red oven fer their first bake, and after they have been air cooled sufficiently are carried through another dip tank, an- other detearing booth, and another infra-red oven, thus repeating the and returning point near the loading tables, where they are un- loaded, packed and sent directly freight cars. the spraying process, the dip tanks are removed from beneath the conveyer and the parts pass directly into the booths and into the range automatic spray guns which spray the parts they enter the electrostatic field. other words, the same finish- ing cycle repeated under slightly different circumstances. The entire process is, course, continuous, with conveyer speeds adjusted suit the type work being done. Diaphrams Fabricated Seam Welding IAPHRAMS for sensitive pres- sure gages are now produced instead the old method crimping and soldering the edges, according the Resistance Welder Manufacturers’ Association, Philadelphia. Formerly made beryllium-copper phosphor-bronze, they are now manufactured stain- less steel and Monel, ranging from 0.006 0.008 in. thickness. 54—THE IRON AGE, October 19, 1944 many cases where resistance welding has been introduced, reduc- tion manufacturing operations was effected. Where, before, two separate stampings had made allowing extra flange one stamping for crimping; now, two sections the same stamping are seam welded to- gether. This has produced better diaphram less cost than was here- tofore possible. > LINE Your Incentive Will Work last five years have seen growing recognition the value incentive programs increasing factory performance. Start- ing out originally means in- ducing factory employees engaged di- rectly actual production increase their output, modern incentives have been developed cover virtually all industrial personnel and ing the general factory manager. While certainly true that in- systems and programs have come long way from the earliest simple plans which were based upon the offer flat reward the em- ployees who turned the top per- formances, also lamentably true that large number incentive pro- grams currently use are admitted- unsuccessful. There doubt that properly thought out, well-planned and exe- euted system incentive payments for production above carefully set standards can one industry’s most potent means achieving sig- nificant increases labor and over- all plant productivity. Actually, there plant too small and certainly plant too large benefit greatly from the application sound incen- per cent per cent productivity minimum goal any effective incentive program, and there have been innumerable instances plants which productivity has increased much per cent above the level ordinary day work produc- tion. But such increases produc- tion are not cheaply bought. They require careful thinking and sound planning. There are three basic requirements that every sound incentive plan must meet. All three are completely in- terrelated, and incentive system can expected successful for any length time unless meets all three. These are: productivity labor. (2) must result reduction Properly Planned employees and employers. order for such program truly successful, must insure high quality work, increased pro- ductivity and decreased unit cost while guaranteeing the employee increased earnings not subject arbitrary reductions. How achieve incentive system that solidly based careful and accurate work standardization herein described. This article the last group three the subject time study. The pre- ceding appeared THE IRON AGE Aug. 17, pp. and Sept. 28, pp. 45. the unit cost manufacture. (3) must result increased level earn- ings for the participating group em- ployees. incentive system essentially system profit sharing. Unless there mutual advantage em- ployee and employer, incentive pro- gram cannot work effectively. analysis were made programs which have failed, there ques- tion but that would found that all them failed meet one more the above requirements. The statement these objectives far simpler matter than their achievement. Unfortunately, there has not been enough understanding the close planning and careful cal- culation that required achieve workable incentive program. too many factories the tendency has been base standards upon existing levels performance, rather than upon any objective measurement. characteristic standards set this manner complete lack uni- formity the skill and effort re- quirements the many jobs under standard, and the usual result the creation serious personnel prob- lems. This method generally punishes the conscientious and efficient oper- ator setting high standard his task and rewards the less efficient operator setting low standard for his work. Even where this has DAVID ANDERSON not Industrial Engineer and study has ARTHUR HANSEN Head Standards Department Bulova Watch Co., Woodside, been done, and where time been used basis for setting stand- ards, too often in- sufficient atten- tion has been given careful plan- ning the flow work and distri- bution personnel, that the proper possibilities can exist for in- centive performance. has been the experience many plants that although the productivity groups employees may often increase under incentive, the unit cost manufacture may rise. This often occurs when not enough consideration has been given planned flow materials that periods intense activity incentive levels per- formance are frequently followed periods idleness which must paid for base rates. Unless proper attention has been paid work stand- ardization and quality control, in- creased productivity may accom- panied general, and often subtle, deterioration quality which may not detected until long afterwards when finished material taken from stock for final assembly disposition. Motion Analyses Essential Another serious pitfall which has been the nemesis many incen- tive program has been the absence sound methods work preceding the setting standards, for unless there has been thorough motion analysis, THE IRON AGE, October 19, 1944—55 | é , : ) 1 1 1 1 ‘ 7 e e | { JOB ANALYSIS METHOD ANALYSIS TOOLS AND EQUIPMENT JOB STANDARDIZATION APPLICATION PRINCIPLES MOTION ECONOMY WORK PLACE LAYOUT ELIMINATION MOTIONS AND IDLE TIME BEST METHOD ISSUED DEPARTMENTAL FOREMAN STANDARD METHD CONTROL SHEET INSTRUCTIO SHEET FOR SUPERVISOR SELECTING THE OPERATOR DISCUSS PURPOSE STUDY WITH OPERATOR TAKING THE STUDY SEPARATION ELEMENTS RECORDING THE READINGS RATING THE PERFORMANCE CALCULATIONS SELECT ELEMENT TIMES APPLY RATING PERSONAL FACTOR DETERMINE FATIGUE ALLOWANCES DELAYS CONSTANTS VARIABLES MACHINE TIME HANDLING TIME SET THE STANDARD 56—THE IRON AGE, October 1944 examination the work place layout, and the tools being used and their condition, there can assurance that the standard being based the most economical and efficient performance the task. this event, even though careful time study the job, performed, made, there still every likelihood the establishment large num- ber unsatisfactory standards. soon the standards have been put into effect, seemingly small but often very important changes may made the job layout and tooling. These will quickly result numerous runaway rates with all the conse- quent personnel and production prob- lems they bring. Operators working normal standards resent the high earnings those low standards. The same variations the required work may take place many jobs the opposite direction, resulting tight high standards. this oc- curs even per cent the standards, complete chaos the re- sult. The standards cease have any real relation the actual skill and effort applied employees their tasks. The employee resentment and poor morale which can sweep the fac- tory may the incentive program completely worthless. the manage- ment tries correct high rates reductions, employee reaction often likely extremely undesirable. Standards Affect Morale Incentive systems are two-edged swords. poor incentive program can easily result much more harm factory morale, and ultimately, production, than any temporary good that may accomplish. has been the experience the authors that incentive almost always better than poor incentive. The first requisite met the creation sound incentive the establishment production standards with which measure the perform- ance each employee group employees terms normal produc- tivity. Before this can done, how- ever, there are several preliminary steps which must taken. The first requirement standardi- zation work. Before any particular job can measured, the work performed must clearly identified. addition, there must some as- surance task will remain un- changed long the standard effect. soon the job changes any respect, re-evaluation the standard must take place. order achieve work standardization where absent, and assure its con- tinued maintenance where pres- ent, PROGRAM FOR INCENTIVE PLANNING tim bre: con tior | divi | of SIMPLIFICATION sibl | tha ANALYSIS CHART per req TIME STUDY bec req the the sta fic: tio tiv MAINTENANCE tir ent, operation breakdown and analysis should part every time study. Often the mere process job down into its separate constant and variable elements will result considerable work simplifica- tion. For example, operation such “inspect and repair” may often divided into the two simple operations “inspect and separate” and “re- pair.” This serves not only the purpose providing two operations which can more easily measured, but will often result better utilization the employee’s skill, since may pos- sible assign the less skilled part the work such “inspect” less skilled operator and thus allow the more skilled operator working “re- pair” specialize and concentrate that part the work requiring his full ability. addition, may now possible set stable time value the operation “inspect and sepa- rate” and the operation “repair”. standard had been set the combined operation, any change the percentage units that required re- pair would tend invalidate the standard. the percentage units requiring repair were increase, the standard would become too low; were decrease, the standard would become too high. Job Analysis Work standardization and simplifi- requirement good time study prac- tice. The ability see operation both terms the whole and the sum any component parts one the things which distinguishes time study engineer from merely “rate setter”. The gains very often derived from the job analysis should take place integral part all time study, especially time study for incentives, are very often great enough more than pay for the cost the entire incentive in- stallation. Work standardization fication include many things. All them are basic smoothly func- tioning organization whether with without incentives. The presence incentive system, however, serves highlight and emphasize the need for and the value thorough job analysis. matter fact many organizations use their incen- tive standards significant guide determining the relative efficiency their processing departments. As- suming that careful and competent time study has been used set the production standards, the extent which department meets exceeds the standards set, and therefore the FORM Fa 110 DESCRIPTION Loea arbor, cut teeth, gauge and DEPT. JOB CLASS LEFT METHOD CONTROL inspect OPER. WO. RIGHT HAND” Load Arbor while is_in Opers tion ldle Insert arbor in chuck and tighten chuck idle Push wheel ail the way up the arbor. Continue picking up wheels with arbor until Hold arbor chuck Idle Unlock arbor palm, pick up new arbor from pre-position tray Place loaded arbor in machine Lock arbor Turn knob up loosely Upload cut R. P. id. of Hob-400 Feed -008" per rev. of work Gear Ratio 30:60 gage eye loop Load and Unloed Mechine Unlock kmob, pull carriage back shen necessary. Unlock bayonet Remove finished arbor from machine, hold in Hold bayonet Pick up arbor chuck Hold arbor chuck Pick up wheel on arbor by stabbing with erbor. All wheels must face in same direction. Hold arbor chuck wheels are on arbor. Open arber chuck Lock bayonet Idle Push up clutch handle—very slowly arbor, and inspect Hold arbor ' Pick up locking pin, open arbor Place arbor in a small potence Idle Hold arbor _| Pull dow handle to push arbor out of sheels Pick up cut wheels end hold Separate end wheel with heavy burr and discard Hold cut sheels Separate wheel from other end and put aside in small box Drop balance of wheels in small metal box Idle Gauge one wheel out of each arbor. Equipment: - Mikron Gear Hobber 2—This type motion analysis valuable both for purposes job standard- ization and for employee instruction the job. THE IRON AGE, October 19, I is in ie m ‘ds di- lar ed. as- the ere extent which its employees earn incentive wages, often barometer the degree overall efficiency. Many organizations have found their incentive system ef- fective and very valuable means making comparisons between their several departments. Quality Maintenance The problems involved program work standardization and its cor- rollary, work simplification, are two- fold: Every job must examined from both qualitative and quantita- tive point view. The task must set that the nature the work remains qualitatively the same. That is, the work done each lot must nearly the same pos- sible. polishing operation, for example, the work done each lot must nearly identical possible the other from the point view the amount material removed, where this has signifi- cant effect the time required for the operation, and from the point view the handling, pre-positioning, and inspection required. Sometimes order achieve standardization, examination all the work done the part the operation under consideration may called for. Variations Short Cycle Work Standardization is, course, important consideration practical- all types work, but should remembered that particular importance short cycle work. job which the cycle time for exam- ple 0.10 min., variation the re- quired time little 0.02 min. will result increase the over- all time per cent and will, there- fore, accompanied decrease the hourly output 16.67 per cent. Conversely, reduction only 0.02 min, the time required complete the job will result decrease the overall time per cent and, therefore, increase hourly pro- duction per cent. This im- portant fact bear mind. short cycle work, small changes the job setup, resulting what may often seem the foreman insignificantly small changes the time required for operation, will often create extremely important changes the total rate production. precision work such done Bulova, examination the “on the job” gaging and inspection re- quirements will often result some very surprising increases produc- tion. group short cycle coun- terboring operations, for example, 58—THE IRON AGE, October 19, 1944 was found that the operators were gaging and inspecting the rate about one piece out every pieces co-bored. Since the working time per piece was 0.08 min. and the time required for gaging and inspect- ing was 0.25 min., the gaging and in- spection added least 0.01 min. per piece the cycle time the opera- tion. examination the opera- tion revealed that actually size ad- justment the machines was very seldom required more frequently than every 150 pieces. The job re- quirements were, therefore, changed for gaging and inspecting only one out every 100 pieces. The gaging time 0.25 min., prorated over 100 pieces was only 0.0025 min. per piece instead 0.01 min. per piece. The co-bored pieces were dropped into small box instead into the large tote box. After every 100 pieces completed, the operator gaged and inspected one piece, and that piece was satisfactory, the 100 pieces were dropped into the large tote box. Thus the quality control was maintained just closely before, and the overall output the opera- tion increased about per cent. Uniform Earning Potential another instance, the earnings incentive group milling op- erations were very erratic. exam- ination these operations revealed the fact that the diameter hole the piece, which was used locate the piece under the milling cutter was not sufficiently uniform from lot lot permit all times easy po- sitioning, and removal the piece from the pilot pin. change the positioning fixture that the piece now located means pins which the piece its outside con- tour instead the hole, not only increased the output this opera- tion but resulted incentive rate with much more uniform earning potential. The second phase job standardi- zation, that is, quantitative standard- ization, generally easier attain, but just important. the incentive are always reflect the skill and effort put into the job the employee, the amount work done, well the nature the work, must carefully controlled. For example, study opera- tion calling for the staking flat spring into slot, was found that many the springs freouently had burr them which prevented their being positioned the slot. order stake these springs, the oper- ator had put down his tweezer and deburr the spring taking several strokes carborundum stone. study revealed that when the oper- ator was working lot where there were very few springs with burrs, his output was about 500 pieces hr. When working lot where there was substantial percentage springs deburred, output dropped about per cent, 300 pieces hr. Obviously successful incentive rate could placed the work while was this condition. examination revealed these springs were all inspected for flatness and size before the staking. was simple matter expand this inspec- tion include the separation springs that Stable incentive rates could now set the staking operation, and the deburring operation. addition, was found actual check, that the total output the same operator now working both operations was greater than his output the single staking operation, which included de- burring when necessary. Every time study should include consideration all the fac- tors which might affect the time re- quired for the operation, and every effort should made separate those factors which are constant for the operation from those which are variable. course, while complete standardization the goal towards which the time study engineer strives, probable that for the most part, can completely achieved only fully automatic work. The time study engineer must, therefore, make every effort sure that the perform- ance which studying being made under representative conditions. For example, studying deburring operation, must sure that the lot being studied average with re- gard the amount burr. drill- ing and hand milling, for example, the drill cutting tool should neither too dull through excessive use nor freshly sharpened. Overcoming Foreman Resistance The second task which must accomplished the time study engineer before can proceed with the actual establishment standard for any given job the com- pletion method and motion sis the manner which the work being done. here that the time study engineer likely encounter the greatest resistance the part departmental foremen and direct su- pervision. For the time study engineer now concerned with the manner which the work being performed. The general feeling the part fore dire the ods eng mal the eno niq The ing bee sta ext sta sta for foremem direct supervi- sion that through their years direct contact with the work, they are far better position determine the best manner performing the work. Many foremen feel that meth- ods work the part the time study engineer reflection the fore- man. Unfortunately, many time study men are themselves responsible for the prevailing attitude. Often, not enough time spent with the fore- men explaining the purpose and tech- niques motion and method analysis. The experience the authors, work- ing with all lines supervision, has been that once the foremen under- stand the approach the time study engineer the job setup, they will generally cooperate with him. The method and motion analysis extremely important insuring the stability incentive rates. Before standard can definitely established for any work, paramount im- portance that every effort should made determine whether the work being studied being economically and efficiently performed. This calls for: (1) examination the work place layout: The work per- formed should located within the normal working area. The normal working area that area defined two arcs made both hands sweep- ing across the work table when the elbows are kept loosely the side the body. The maximum working area the area defined the two hands sweeping across the table when the arms are extended shoulder. The area the most effec- tive performance for both hands directly front the operator the area where the arcs the normal working area overlap. All tools and parts picked should as- signed definite locations within the normal maximum work place area. (2) examination the tools and fixtures being used for the job: All tools required for the operation should examined determine whether they are designed for the most effec- tive use. Sometimes larger smaller handles may required for the most efficient utilization. Often may Possible suggest changes the tool itself for more economical perform- ance its task. Particular attention should paid the design fix- tures. From motion economy point view, often possible effect considerable improvement the job under study. For example, wherever Possible, drop through delivery fin- ished work should used. Very often, air ejection finished work may installed with minimum difficulty, particularly drilling, co-boring and press Frequently, spring ejec- tion from chucks and fixtures easily achieved. Wherever the hands ean relieved for useful work, examination should made deter- mine the feasibility the use foot pedals. Through these and many other simple changes, which will often sug- gest themselves the observant time study engineer, the job performance under study will frequently show amazing improvement. one depart- ment the Bulova plant, simple survey determine whether foot pedals were being utilized sufficiently, disclosed surprising number in- stances where, through the installation foot pedals, production cent. (3) thorough motion analysis in- cluding left and right hand motion analysis chart: The final aspect job and job method analysis the construction motion analysis chart similar that shown Fig. Through examination the work performed each hand the accom- plishment given task, often possible achieve better distribu- tion the work between the two hands. Frequently the motion analysis will show that the operation being performed includes many needless and many incorrect movements. Many the details the job performance 3—Pivot pol- ishing high speed carboloy wheel limits 0.0002 in. which might otherwise escape the at- tention the time study engineer often become apparent through the use left- and right-hand motion analysis chart. cannot empha- sized too much. that very frequently, the smallest change the operator method can exert tremendous influ- ence the rate production. Through left- and right-hand mo- tion analysis may become apparent that the major portion the work being performed with only one hand while the other hand idle en- gaged merely “holding” when might productively employed. Often both hands cannot actively participate the actual performance task, may possible for the idle hand assist the working hand through the selection preposition- ing material. Sometimes better hands may make possible attain much higher degree rhythm the job. Through small improvements the layout the work, possible reduce eliminate many sharp changes the direction the hands, which tend increase the visual at- tention required the work and in- terfere with the acquisition rhythm and automaticity. should stated here that, more often than not, these changes not mean harder work upon the part the operator. the contrary, through better rhythm, bal- ere rith ere ped ork less ing. on ion, hat itor was de- fac- Te- ery for are lete ves, art, udy ery r , 3 anced movements and better sym- metry, possible both increase the output and lessen the fatigue and strain the part operator. almost always easier the oper- ator both hands are used wherever possible rather than having all the work done with one hand. The purpose motion study not make the operator work harder, but make the work easier. Advantages Written Reports The written motion study also lends itself another very important pur- pose for which can great value. The motion study the written record how the job should per- formed. the basis for operator in- structions and training and source reference for work standardization. Bulova, the motion study used much more than record for the time study files. Every departmental foreman gets copy the motion study, and every new operator placed tion sheet. course, the motion study also valuable record, providing the time study engineer with com- plete record exactly what has gone into every standard. When the motion study has been IRON AGE, October 19, 1944 completed, and copy has been pre- pared for the processing department, the actual time study upon which the standard will based may made with complete confidence that every precaution has been taken for the creation standard that will extremely stable. There can question, once the methods work has been completed, that the standard will based upon performance that economical and efficient prac- tical. When standards are set through careful methods work, there need hesitation upon the part man- agement guarantee the incentive rate against arbitrary reduction, for the extent which the standards are exceeded the employees becomes the measure the employees’ skill and effort. Guaranteed standards are one greatest incentives that may offered employees stimulate them maximum productivity. One the most formidable obstacles that incen- tive systems have had overcome industry whole has been the fear employee groups that the stand- ards were exceeded any substan- tial margin, the incentive rate would reduced and the standard increased. this fear removed from the minds Diamond polishing jewel bearings the size pin. employees, important barrier maximum production removed. Incentives Predetermined Level The primary purpose incentives, from management point view, increase overall productivity. attain this end, the incentive must offer opportunities for additional earn- ings large portion the par- ticipating group possible. Each employee must understand that the amount his incentive pay, com- pared that any other employee, will determined the level skill and effort which brought bear the job. This means that the stand- ards must based upon the require- ments the individual operator who happens the job. The stand- ards cannot based upon the output either the slowest the fastest operator. They must rather based upon some predetermined level per- formance which expected from each employee before can earn in- centive pay. The amount incentive pay must naturally proportion the amount which the predeter- mined level performance ceeded. The process determining this “normal” level performance has been the subject much discussion and theorizing. There are today q 7 Batteries leave cutting machines holding tolerances 0.0005 in. eral schools thought, and several different methods are widely used normal level performance. course, the ideal answer would able select normal operator for each study, certain his complete cooperation, certain that was neither increasing his normal rate output nor holding back his performance effort “get better rate” possibly through nervousness. Once had determined the most efficient and economical job method, the time study engineer could then make time study the per- formance such operator and simply base the standard upon his per- formance. For the most part, however, such solution not possible. The time study engineer must able set satisfactory standard with the performance that available. the operator being studied particularly skillful conscientious, the time study engineer must able deter- mine the exact amount which his performance yielding higher rate production than normal. Conv