Machine shop

“ Machine shops doing principally lathe work as a matter of course use a larger percentage of their contracted power than shops doing lathe and bench work with the same hands. In no case will the service of the motor exceed 65 or 70 per cent. of its contract use, for machine shops, like sewing machine shops, will never average over 75 per cent. of the shop capacity for operators the year round. The average, especially in the case of a shop doing much bench work, will fall as low as 40 per cent. ”

“ A machine shop consisting of lathes of different kinds and sizes, planers and drills would be able to turn out machinery for making guns, engines, agricultural implements, clocks, etc. In a large country like China, I told them, they would need many primary or fundamental machine shops, but that after they had one (and a first-class one at that) they could make it the mother shop for reproducing others — perhaps better and more improved. ”

“ The writer, however, while still a young man, had all lingering doubt as to the value of a drafting room dispelled by seeing the chief engineer, the foreman of the machine shop, the foreman of the foundry, and one or two workmen, in one of our large and successful engineering establishments of the old school, stand over the cylinder of an engine which was being built, with chalk and dividers, and discuss for more than an hour the proper size and location of the studs for fastening on the cylinder head. ”

“ The cleanliness of a man's machine also—although cleaning a machine is no part of his duty—is usually an indication of his intelligence.
Here are some of the suggestions: A proposal that castings be taken from the foundry to the machine shop on an overhead conveyor saved seventy men in the transport division. There used to be seventeen men—and this was when production was smaller—taking the burrs off gears, and it was a hard, nasty job. ”

“ The machine selected by him fairly represented the work of the shop. It had been run for ten or twelve years past by a first-class mechanic who was more than equal in his ability to the average workmen in the establishment. In a shop of this sort, in which similar machines are made over and over again, the work is necessarily greatly subdivided, so that no one man works upon more than a comparatively small number of parts during the year. ”

“ Beyond the stock-room, and occupying about half the building on the same floor, lie a machine shop, engine-room, and boiler-room. This machine shop is well equipped, and in it is constantly employed a large force of mechanics whose time is occupied in constructing the heavier class of models and mechanical devices called for by the varied experiments and inventions always going on. ”

“ This is chiefly accomplished by anticipating our machine shop requirements or demands far enough in advance so that the majority of work passing through the toolroom can be manufactured in quantities great enough to be produced economically, and also bringing the toolroom work nearer to an actual manufacturing basis. ”

“ Here are employed approximately 1,000 expert tool makers, machinists and die sinkers. These men are engaged in making new machinery (designed in the company shops) , tools, jigs, fixtures and other machine shop accessories, and repairing those in use.
Overhead are traveling cranes which have a capacity of forty tons each. ”

“ In a milling machine the cut is carried continuously from its commencement to its end, whereas in a shaping or planing machine the tool does not usually cut during the back or return stroke. In either of these machines, therefore, the operator’s skill is required as much in measuring the work, setting the tools feeds, &c., as in shaping the tools, whereas in the milling machine all the skill required lies in the chucking and adjustment of the work to the cutter, rather than in operating the machine, which may therefore be operated by comparatively unskilled labor. ”

“ Hence, when a machine was assembled the unyielding metal parts had to be filed and trimmed and hammered to fit them together. If any accident occurred to a machine, the damaged part could not be replaced by another taken from stock. The entire machine had to go back to the shop where an experienced mechanic would make a new part to replace the damaged one. In those days a machine was not manufactured but was built as an individual mechanism, just as a house or a boat is built to-day. ”

“ The practical experience in the various departments of machine construction, its sale and its use, is undoubtedly almost absolutely necessary for the average man in this work.
Its value is primarily to give an opportunity to see things in actual operation. The shop affords an opportunity to see how a machine stands up to its work, where it is weak, and a thousand and one points that can best be seen in actual operation. But there is still another phase that is comprehended more readily by the practical experience, and this applies to the various departments of business as well as to the works. ”

“ Accurate watches and clocks, bicycles and motor cars, innumerable devices to save labor in the home, the office, the shop, or on the farm, are within the reach of all, because the machine tool, tended by labor comparatively unskilled, does the greater part of the work of production. In the crisis of the World War, American manufacturers, turning from the arts of peace, promptly adapted their plants to the manufacture of the most complicated engines of destruction, which were produced in Europe only by skilled machinists of the highest class. ”

“ There is no economy in making men work with poor light, bad air and in a cold place.
Buying Machine Tools.—Having secured by lease or by purchase a shop, or factory suitably located your next effort will be directed toward equipping it with the proper tools and machinery.
Besides the usual machinists’ hand tools you should buy (1) a gas furnace; (2) a grinder; (3) a plain lathe; (4) a screw cutting lathe; (5) a drill press; (6) a planer; (7) a shaper; (8) perhaps a milling machine, and (9) a buffer. Several of each of these kinds of machines may be needed.
Fig. ”

“ The positions occupied among machine tools at the present time by shaping and planing machines are not as important as was the case a few years ago, because of the advent of the milling machine, which requires less skill to operate, and produces superior work. ”

“ Hardly a week passes without some improvement being made somewhere in machine or process, and sometimes this is made in defiance of what is called "the best shop practice." I recall that a machine manufacturer was once called into conference on the building of a special machine. The specifications called for an output of two hundred per hour. ”

“ The whole machinery is propelled by the same engine as that below. In this shop there is one large planing machine, nine shaping machines, six drilling machines, three slotting machines, one double-headed slot drill for cutting key-ways in axles, one twelve-inch lathe, four ten-inch lathes, four eight-inch lathes, two six-inch lathes, one ten-inch break lathe, six small planing machines of different sizes, four screwing machines, one nut-cutting machine, two grindstones, one hoist, twenty pairs of vices, etc., etc. ”

“ The work stands without a rival. It is a complete practical treatise on the art of American Tool Making and system of interchangeable manufacturing as carried on to-day in the United States. In it are described and illustrated all of the different types and classes of small tools, fixtures, devices, and special appliances which are in general use in all machine manufacturing and metal working establishments where economy, capacity, and interchangeability in the production of machined metal parts are imperative. ”

“ All who were able to procure machines [Pg 176] did so as fast as the inventors could supply the demand. This became so enormous and pressing that new manufactories were speedily established, and rival machines came into use by scores. Clothing-shops and other establishments went into operation with a hundred machines in each, throwing multitudes of sewing-women out of employment. Steam was called in to take the place of female fingers. The human, machine was suddenly discarded,—turned off, without notice or compunction, to seek other occupation, or to suffer for want of it. ”

“ The men might have been parcels shifting one by one up to the packers’ tables and away from them, or those pieces of metal in a factory which trickle up leisurely to a whirling lathe, are seized by it, turned, poked, spun about with feverish haste for a minute by the machine, pushed out clear to resume their leisured progress while the machine jumps on the next piece and works its ordered will upon it. ”

“ The principals of continental manufacturing establishments were accustomed to make frequent visits to England for the purpose of purchasing various machine tools required for the production of the ponderous as well as the lighter parts of their machinery. We gave our foreign visitors every facility and opportunity for seeing our own tools at work, and they were often so much pleased that, when they came to order one special tool, they ended by ordering many,—the machine tools in full activity thus acting as their most effective advertisements. ”

“ The most exquisite and the most expensive machinery is brought into play where operations on the most common materials are to be performed, because these are executed on the widest scale. This is the meaning of the vast and astonishing prevalence of machine work in this country: that the machine, with its million fingers, works for millions of purchasers, while in remote countries, where magnificence and savagery stand side by side, tens of thousands work for one. ”

“ The industries that use machines were forced out of the homes and into the factories. There was no alternative. The steam driven machines produced goods so cheaply that the hand power, or home machine could not earn its owner a livelihood. Thus the factory system developed, partly because of the mechanical necessity of concentration where the power from one engine could by the use of shafts and belts be made to run a great number of machines, and partly because of the natural tendency of the man with the most money to acquire possession of the factory and have others work for him. ”

“ Today they are standing outside the shops, factories, mills and mines, the same as the fifty, where the first machine factory whistle blew. And as machinery began to become dominant in society, those owning this machinery began to form organizations also, till today we have the employers' organizations—the trusts and the merchants' and manufacturers' associations. Since the time when the first machines made the workers get together they have kept on getting together—and they are still at it. ”

“ Most of the operatives in a watch factory would find machines very similar to those with which they were familiar if they strayed into a gun-making factory or sewing-machine factory, or a factory for making textile machinery. A watch factory, with those who worked in it, could be converted without any overwhelming loss into a sewing-machine factory. ”

“ Our present splendid machine shops, gun shops, locomotive works, typewriter and bicycle factories, are examples of the wonderful extensions of this art. In later years the field has been filled so full of improvements and special machines for special work, that only a brief citation of a few representative types is possible, and even then selection becomes a very [387] difficult task. Many special tools, particularly those designed for bicycle work, have been devised, as exhibited by patent to Hillman, August 11, 1891, No. ”

“ This principle is the very foundation today of all American large-scale production. The manufacturer produces separately thousands of copies of every part of a complicated machine, confident that an equal number of the complete machine will be assembled and set in motion. The owner of a motor car, a reaper, a tractor, or a sewing machine, orders, perhaps by telegraph or telephone, a broken or lost part, taking it for granted that the new part can be fitted easily and precisely into the place of the old. ”

“ The irregularity and carelessness of the workmen naturally proved very annoying to the employers. But it gave an increased stimulus to the demand for self-acting machine tools by which the untrustworthy efforts of hand labour might be avoided. The machines never got drunk; their hands never shook from excess; they were never absent from work; they did not strike for wages; they were unfailing in their accuracy and regularity, while producing the most delicate or ponderous portions of mechanical structures. ”

“ Every day saw more and more of the work of the world taken up by machinery. Did a labor union demand increased wages, then a machine was devised to do the work with less assistance. In a return issued by the U.S. Government, it was estimated that 4,500,000 factory machine workers of that country were turning out products in quantities equal to the hand labor of 45,000,000 men. That meant that 90 per cent. of the work in factories was being done by machinery; that one man, with the help of machines could produce ten times more than he needs. ”

“ But by the employment of such a machine as I describe, even when placed under the superintendence of well-selected intelligent lads, in whom the faculty of good sight and nicety of handling is naturally in a high state of perfection, any deficiency in their physical strength is amply compensated by these self-acting machines. The factory engine supplies the labour or the element of Force, while the machines perform their work with practical perfection. The details of machinery are thus turned out with geometrical accuracy, and are in the highest sense fitted to perform their intended purposes. ”