coat dipping o p eratio n s. S om e fo rm of inspection should be s e t up.
Control should check w o rk by v is
ual inspection o r p r e fe ra b ly b y a dipping test. W hile th is la tte r te s t has not been used in p ro d u ctio n , it is the only sure m ean s of d isc o v erin g slightly dented w a re w hich w ould not otherwise be d etected u n til dipped in ground coat. T h is in sp e c
tion would involve a pre-dip ta n k containing som e aq u e o u s so lu tio n to be used for w are w hich w ill h a v e a cover coat ap plication a n d w h e re setup involves m ass p ro d u c tio n w ith great possibility of w a re b ein g d a m aged between press o p e ra tio n s a n d ground dip operation. S uch a check would also locate w a re n o t pickled properly.
Any of the g re a se o r o th e r con
tamination still re ta in e d on th e s u r face will prevent th e g ro u n d co a t enamel from d rain in g p ro p e rly . A large saving can easily r e s u lt fro m this installation.
Performance of o rd in a ry v isu a l in spection can be acco m p lish ed a t pi ess departm ent, pickle ro o m o r a t the ground-coat dip. T h e dip te s t should be done only a f te r th e pickle operation for best re su lts. C ost of ordinary inspection involves a b o u t -00 man-hours p e r 1000 fee t. C ost 0 a Pre-dip se tu p w ould r e q u ir e
£ut 1-50 m an-hours p e r 1000 fee t.
To estimate sav in g s on th is item involves certain assu m p tio n s. F irs t, assume that about 13 p e r c e n t of nmshed ware is u su a lly w ash e d off ecause of dented o r d ir ty sto c k —an efficiency of about 87 p e r cent. I f it requires 12 m an-hours p e r 1000 fe e t or ground coat operatio n , m u ltip ly - ing by 13 percent show s 1.56 m a n nouis lost per 1000 feet. T h e n to
“ ttlis g ro u rid co a t enam el
‘om defective w are r e q u ir e s 0.30 man-hours per 1000 fee t. I f th e ground coat enam el is w ash e d dow n
C le a n e r: C o n tro l sh o u ld te s t fo r to ta l a lk a lin ity , t it r a te ac tiv e a n d in a c tiv e alk a li, check so a p fac to r, ch eck s u r fa c e te n sio n , check c lea n in g a b ility , p re v e n t excess c a r ry over, k ee p low co n c en tra tio n s, p ro p e r im m ersio n . T h e se te s ts sh o u ld be m a d e ev e ry 3 o r 4 h o u rs o f o p e ra tion.
T h e s tr e n g th of so lu tio n s should be recorded. C osts h e re involve 0 20 m a n -h o u rs p e r 1000 fe e t o f w a re fo r te s tin g so lu tio n s ev e ry 3 h o u rs an d
C<
ta n t sa v in g is m a d e p ossible b y in c re a sin g th e life o f th e solution.
Also, it is possible to in c re a se th e s q u a re f e e t th ro u g h th e acid b a th by p re v e n tin g a n o v erp ic k le on p a r t o f th e w are. A n o th e r fo rm o f w a ste is th e u se o f live s te a m to h e a t th e acid b ath . E lim in a tin g live s te a m sh o w s a sa v in g o f a b o u t 9 ce n ts p e r 1000 fee t. A n o th e r 6 c e n ts p e r 1000 f e e t can be sa v ed by in c re a sin g th e life o f th e so lu tio n .
N ick e l: C o n tro l involves te s tin g
• O N T R O L a n d c o s t i n f o r m a t i o n s h o u l d be t i e d i n t o s h o p p r o c e d u r e b y a n e n g i n e e r w h o s e j o b i t is to f i n d o u t - a n d w h o h a s a u t h o r i t y to d e c id e - w h e t h e r a s o l u t i o n is s p e n t o r s t i l l u s e f u l, h o w e n a m e l ca n b e s t b e r e c la im e d ,
w h e t h e r t h e j o b can be d o n e b e t t e r s o m e o t h e r w a y
allo w in g tim e f o r m a k in g ad d itio n s a n d p erio d ic e x a m in a tio n o f th e pickled w are.
E s tim a te d sa v in g s f o r a clea n er ta n k w ith n o t en o u g h fre e b o a rd and no a u to m a tic w a te r v alv es f o r k e e p in g th e so lu tio n a t th e p ro p e r level m ig h t be exp ected to ru n 20 cents p e r 1000 f e e t a s r e s u lt o f e lim in a tin g w a ste d c le a n e r fro m boiling o v er o r overflow ing. W h e re no d istin c t con
tro l h a s h e re to fo re been exercised, i t w ould in o rd in a ry circ u m sta n ce s be e a sy to double th e life o f a c lea n e r so lu tio n a n d to sh o w a sa v in g of 20 c e n ts p e r 1000 f e e t fro m th is item .
A cid: C o n tro l o f acid involves te s t
in g p e r c e n t acid ity , te s tin g iro n o r fe rro u s s u lf a te c o n ten t, w a tc h in g fo r g re a s e film s, p re v e n tin g excess c a r
ry o v e r, m a in ta in in g p ro p e r im m e r
sion. T h e se te s ts sh o u ld be p e r fo rm e d ev e ry 3 o r 4 h o u rs, rec o rd s
D AT A p r e s e n t e d h e r e s h o w 6 t o 7 p e r c e n t t o t a l p a y -
°U m an-hours s h o u l d b e a l l o w e d f o r c o n tr o l w o rk , a n d 5 per c e n t m o r e f o r c le r k in g a n d s u p e r v is io n o f r(>l work. T h is t o t a l o f 10 to 12 p e r c e n t w ill s h o w Uerage savings e q u i v a l e n t to 7.5 m a n - h o u r s f o r e a c h
m a n - h o u r u s e d f o r c o n tr o l
of 56 c e n tthere is an a d d >ti°nal loss
Pi b f P£!r 1 0 0 0
feet-control 'o p m 'f inneStS’ Uke a11 o th e r Iv foolnrnnf Î a r e n o t a b s o lu te - '.vays of
J ° r there are so
m a n y®fferem t, *n g te s ts a n d s o m a n y industry I I I t V * te s ts u se d in th * dividual p ï n t trr,e m h nS f ° r th e in '
stan d ard s Tt Çhoose its ow n
trv to cover „ b.e ho Pcless to a ll th e d iffe ren t te s ts . December 2, 1940
a n d c o sts k e p t a s m e n tio n e d u n d e r clean er.
E s tim a te d S a v in g : W ith p re se n t d ay p ick le ro o m p ra c tic e im p ro v in g , it is believed m o st p la n ts could w o rk th e ir acid so lu tio n s m u c h lo n g e r th a n th e y do. Acid b a th s h av e been u sed u n til th e iro n co n te n t te ste d 20 p e r c e n t fe r ro u s s u lf a te w ith still no sig n s o f tro u b le , no c o p p e r h e a d in g o r fish scale. T h u s a n im p o r
pH, te s tin g n ickel c o n c e n tra tio n , p r e v e n tin g excess c a rry o v e r, m a in ta in in g p ro p e r im m ersio n . P e r fo rm a n c e a n d co sts a r e m e n tio n e d u n d e r clea n er.
E s tim a te d S av in g : T h e only m e th od h e re o f sh o w in g a n y siz ab le s a v in g is to in c re a se th e so lu tio n life, w hich can ea sily be done by in s ta ll
in g a filte r to e lim in a te p re c ip ita te s a n d scum . A sa v in g of 8 c e n ts p e r 1000 fe e t can be expected fro m th is item .
N e u tra liz e r: C o n tro l involves te s t
in g fo r a lk a lin ity an d ch e ck in g p ic k u p a t th e g ro u n d c o a t dip. P e r fo r m a n c e an d cost a r e s a m e a s fo r clea n s
er, m e n tio n e d above.
E s tim a te d S av in g : A s in p rev io u s in stan c es, th e o n ly s a v in g ac co m plished is b y in c re a s in g so lu tio n life.
H ere a s u ita b le filter s y ste m w ill e lim in a te p re c ip ita te s in th e so lu tio n and sh o w a sa v in g o f a b o u t 1.6 c e n ts p e r 1000 feet.
W a te r: W hen no co n tin u o u s o v e r
flow o f w a te r is used, th e rin s e sh o u ld be checked a t th e h alfw a y period o f th e s h if t f o r a lk a lin ity or acidity, d e p e n d in g on th e ty p e o f rin se. A m e te r sh o u ld be av a ila b le to check w a te r co n su m p tio n p e rio d i
cally. P e rfo rm a n c e a n d co st a r e sa m e a s m e n tio n e d u n d e r clean er.
E s tim a te d S a v in g : I f r u n n in g w a te r is red u c ed to a m in im u m a n d a ll w a s te checked, a sa v in g of a b o u t 1.6 ce n ts p e r 1000 fe e t o f w a re can be show n.
Mill R oom : C o n tro l h e re involves re c o rd in g o f m ill f o rm u la a n d th e m a k in g o f a fired s a m p le of each m ill ch a rg e , a s w ell a s c h e ck in g s p e cific g ra v ity , fineness, a g in g o f en am els, s c re e n s of th e ro to s p ra y , ball c h a rg e s, m ill lin in g a n d w o rk a b ility of b isq u e co v e r co a t. F ir s t f o u r te s ts sh o u ld be m a d e on each m ill c h a rg e . A d efin ite ro u tin e o f how m a n y tim e s o r w h en to m a k e
63
T A B L E X— C o s t A n a ly s is
Saving Man-Hours Per 1000 sq. it.
Cost Man-Hrs. Column 3 Total of
Per 1000 sq. tt. Saving ot converted Saving Column 4 Cover Material to Man Hrs. of Man- and 5 for Ground Coat in S per by dividing Hrs. as Cover Coat Ground
Coat Ware 1000 sq. ft by $.80 result Ware Coat
Ware (Ground as result hourly of con (Ground Ware
only incl. ) of control wage rate trol inclj only
Draw ing Compound. 0.20
Perform ance ... 0.13 0.40 10.00 10.00
Time S tu d y ... 0.13 0.40
1.40 7^50 7^50
Ceramic E ngineer. .. . o!l3 0.40
Total ... 0.9G 6.71 17.20 21.37 28.92 50.29 10.02
co n tro l te s ts on th e la s t five ite m s is