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398 Forging- Stamping - Heat Treating
Up to this time, forgings were credited to the forge
department as production. They had to be straightened
after heat treatment. This was done by hand.
holding the forging upon an anvil and striking with
a hammer. Five men were required for a normal
production of 1.000 dozen carbon steel forgings per
day. Where stainless steel forgings were run the five
men produced 500 dozen. One of the men received
50 cents per hour, and the others 45 cents, making
a daily payroll for this operation of 20.70. The costs
on this operation are as follows:
TABLE I
Carbon Steel Stainless Steel
Forgings Forgings
Production per day 1000 dozen 500 dozen
Xumber of employees 5 5
Daily payroll..., $20.70 $20.70
Production per man 200 dozen 100 dozen
Cost per 100 dozen.... .... $2.08 $4.16
Various efforts to increase production with less
than five men failed. Difficulty to keep help was experienced,
and many complaints had to be taken from
the foreman. The fact that an experienced man could
sit down for nine hours, and double the production of
any of the operations carried no weight with the foreman.
It could not be done every day. However,
sufficient data was gathered showing in detail the
amount of loafing actually- done by the operators.
The production of the experienced man was used as
a basis to set this operation on a piece work basis
under the new foreman, and today this operation
requires but two men for a normal production of 1,200
dozen carbon steel forgings. or 600 dozen carbon
steel forgings and 375 dozen stainless steel forgings.
The daily payroll now is $12.00 per day for 1,200
dozen carbon steel forgings compared with $20.70 for
1,000 dozen. For 600 dozen carbon and 375 dozen
stainless steel, the daily payroll is $11.63 against
$20.70 for 500 dozen stainless steel forgings.
TABLE II
Carbon Steel Stainless Steel
Forgings Forgings
Production per day 1200 dozen 375 dozen
Number of employees 2 1
Rate per 100 dozen $1.00 $1.50
Operator's daily earning.. $6.00 $5.63
It has been customary- to pack forgings from the
forging operators into boxes for the next operation.
To do this required four men. Three to do the packing
and one for trucking. The weekly payroll for this
was $80.00 to pack and truck on an average of 10.500
dozen forgings. Under the new foreman the packing
was placed on piece work at 28 cents per 100 dozen.
All the packing is now done by one man, whose
weekly earnings are $30.00 per week compared with
$20.00 per week previously. The two other packers and
the trucker were discharged. The trucking is now
done by the department time clerk, who previously"
had spent his spare time loafing around the production
operators disturbing them. The total weeklyexpense
for this work now is $30.00 compared with
$80.00.
The data compiled on daily production of drop
hammers and rolls are too massive to incorporate in
this article and would be of no direct benefit. Only
the final results will be mentioned. Previous to changing
the foreman, it required to maintain a weekly
production of 5,000 dozen forgings, five drop hammers
and six rolls. To maintain this same production, at
November, 1925
present only four drop hammers and five rolls are used.
Since nine men now produce what eleven men did
formerly, each man is earning more money as the
piece rates remained the same. The company's saving
is reflected in a lower overhead on the department.
Formerly a breakdown meant decreased production,
which had to be made up by working overtime, but
with one hammer and one roll idle no delays are
experienced.
The hardening unit was next taken in order to try
out a long advocated economy. It had required four
men to run this department, two men to harden, one
to draw, and one to tumble and pack. This job was
placed upon a group piece rate system, and the Tables
III and IV present an interesting study. The wages
of the three men now handling this work are $39.00,
$30.00 and $25.00, respectively as compared to $35.00
$27.50 and $21.50.
TABLE III
FORGE HARDENING RECORD—DAY WORK SYSTEM
No. of Total
Total Production
Total Pay
Employes Man Hrs.
Production Man Hrs
$103.30
4 202
7509-0* 37-0*
102.50 7624-0 38-0
4 200
119.50 9189-0 37-0
6 24854 96.25 6775-0 35-6
4 190
79.40 3004-0 19-0
4 158
49.50 3904-0 43-0
4 90
76.05 5162-0 37-6
105.00
4 138
6417-0 32-0
105.00
4 200
5997-0 30-0
•Production is given in dozens. 105.00 5625-0 28-0
1 200
94.50
TABLE 4663-0 26-0
4
IV 200
FORGE
4
HARDENING 180 RECORD—GROUP RATE
PIECE SYSTEM
No. of Total Total Stainless Steel Total Prod.
Employes Man Hrs Pay Prod. Prod. Prod. Man Hr.
3 135 $85.50 1290-0 3847-0 5139-0 38-0
3 150 95.62 594-0 5963-0 6557-0 43-0
3 150 95.87 573-0 5957-0 6530-0 43-6
92.27 1097-0 4760-0 5857-0 39-0
3 150
66.31 633-0 1977-0 2610-0 24-0
3 109 84.52 944-0 2672-0 3616-0 27-6
3 132 95.30 1209-0 4846-0 6055-0 40-6
3 150 75.09 1568-0 2731-0 4299-0 36-6
3 118 70.53 1053-0 2939-0 3992-0 36-3
3 110 96.67 3045-0 1668-0 4713-0 33-6
This concludes the major portion
3 141 93.55 1909-0 3502-0 5411-0
of the
37-6
more
important economies initiated. All had been attempted
3 under 144 the old foreman but utterly failed.
The reason was always evident at the time of failure
from the attitude taken by the foreman, and was naturally
reflected by the operators. Under the new foreman,
these improvements, claimed as impossible,
have been successfully accomplished.
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COMING MEETINGS
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The American Society for Steel Treating, Winter
Sectional Meeting at the Hotel Statler, Buffalo, N.
V.. January 21 and 22, 1926. W. H. Eisenman, secretary.
4600 Prospect Ave., Cleveland, Ohio.
* * *
Annual meeting of the American Society of Mechanical
Engineers at the Engineering Societies
Bldg., 29 W. 39th St., New York City, November
30 to December 4. Calvin W. Rice, secretary.