because the machine was purchased from him. Moreover, does the foundryman replace free of charge castings that are defective through no fault of the foundry? In other words, are machine scrap castings replaced free of charge? Of course not.

Manufacturers with machine shops frequently install highly specialized automatic machines to save seconds when finishing large quantities of pieces. There is an automatic molding machine that is faster than any other machine on the market, yet few foundrymen will use it because they will not give the machine and the equipment the care that the machine shop would give an automatic as a matter of course.

Equipment Changed with Superintendent

The change in foundry methods caused by the introduction of machinery is calling for mechanical training that was not necessary with the old floor methods. Too many foundrymen depend on their hunches that the equipment is all right or not. Often when foundry superintendents and foremen are changed, the entire equipment is changed. This is an economic waste which reacts seriously on the industry. Equipment is often condemned when it only needs a little intelligent care.

One example is typical. During a call at a foundry, a well known power rock over molding machine was condemned because it would not rock over. The handle for the 3-way operating valve had come off and had been replaced improperly so that the valve seemed to be leaking all the time through the exhaust opening on the valve. Somebody had screwed a pipe plug in the exhaust opening and there was no way to let the air out of the cylinder to complete the rockover. It was repaired in five minutes, but the machine had been discarded for months because there was no upkeep man with sufficient intelligence in the foundry to fix it. The average foundry depends on the handy man flask carpenter to oil and repair the machinery. It is absurd to think that the flask carpenter can take care of the electric crane, air compressor, sand cutter and molding

machines. In the first place he does not have time, and in the second place he seldom has had the proper training.

Idle Machinery Should be Protected

Many foundries buy equipment for certain work and when that is completed, the equipment is taken out into the back yard and allowed to rust. When it is needed again it is found to be ruined. A little care in covering it up and slushing with grease would save thousands of dollars every year.

Others, when their molding machines are out of service, allow bottom boards, old shoes, shirts and all sorts of trash and dirt to accumulate on them. When a job comes that could be run on the machine, it is too much bother to dig it

out.

The logical and cheapest way to reduce the foundryman's worry is to hire a competent master mechanic or upkeep man to look after the mechanical details of the equipment in the foundry, as is done in rolling mills, machine shops, paper mills, etc.

The combination of foundry sand, dust and oil is real dirt. The man who works in it and who takes care of the machinery properly is entitled to a fair wage. The man who knows the condition of all equipment and can head off trouble in the foundry is a valuable asset to a foundry.

With the installation of sand handling machinery, conveyors, etc., where the breakdown of one conveyor shuts down the whole foundry, managers are beginning to realize that upkeep is as important in the foundry as in the machine shop. However, the large majority of foundries have not yet reached this point.

Overruled Mechanic; Plant was Shut Down

A man who has given his whole thought and training to this class of work can tell how and when to look for trouble. For example, a master mechanic of a foundry. equipped with conveyors, and other mechanical equipment, asked to have the foundry shut down on a Saturday, about the fifteenth of May, as he did not think the conveyor

would run longer without certain repairs. The production manager decided that the plant could not shut down then, but agreed that the work could be done during the Decoration day lay off. The conveyors broke down on the Wednesday following May 15, causing a loss of production of two days instead of the half day, as suggested by the master mechanic. Needless to say, after this experience when this master mechanic thinks repairs should be made, they are made.

Fully 95 per cent of the trouble with foundry equipment is due to improper lubrication. Where it is possible heavy grease should be used on revolving shafts as it will form a collar of grease outside the bearing, making the finest dust protector possible. On some sliding surfaces on handrammed molding machines, ordinary plumbago or facing makes an excellent lubricant as the sand does not stick to it. One superintendent experimented with different oils on his molding machines and found that the fuel oil used in melting furnaces washed the sand out of the sliding surfaces and had enough body to properly lubricate the surfaces.

Uses Novel Method to Insure Oiling

The complaint is heard that the men do not seem to take the interest in their work they formerly did. In order to have some check on the man in care of machines, one foundry has installed a watchman patrol system with a key at every important bearing, machine and motor. The oiler carries the clock, which he must ring at every station. By this clock record, the superintendent at least knows that the oiler has visited each place.

When a molding machine is out of service in this plant, it is cleaned up and boxed to protect it from dirt. The boxes are arranged to be easily taken apart and stored when not in use.

An automobile foundry realizes that the operators do not take care of the machines or patterns properly, so when the day's work is finished, one man blows off, cleans and oils the molding machines. A second man cleans the patterns and puts a tarpaulin over the machine so the dust will

not get into the machines. These measures insure that the machines will be ready next morning for the scheduled production.

Foundrymen often operate equipment carelessly and then call for the maker to send an expert.

The expert oils the machine, or renews a hose and the equipment is in service again. A competent master mechanic or upkeep man may reduce the number of useless trips of the manufacturers' experts. Often the foundrymen expect the equipment manufacturers to stand the expense of these trips.

When an automobile is stalled outside of town, the owner does not expect the garage man to tow it in without charge. The service expense of the foundry equipment manufacturers is one of the large items of the cost of equipment.

Equipment Men Eager to Help

The equipment manufacturers have experts traveling through the country, and for their own information, as well as to be of service to foundrymen, they would like very much to inspect from time to time the machines in service. They would do this gladly free of charge if they were allowed in the plants. Many purchasing agents do not allow the manufacturers' experts to examine equipment, even though in many cases thousands of dollars would be saved for equipment manufacturers and foundrymen if the experts were allowed to give needed assistance and advice.

With proper care, equipment lasts longer and the replacement costs are less. When equipment is not properly cared for, it may run a long time before it breaks down, but with a lowered output. The saving in labor costs effected by the increased production of all kinds of foundry equipment when operating properly more than pays for an expert maintenance department.

Promises can be kept; the product will be improved; labor costs will be reduced; the first cost of equipment will be reduced; and the life of all foundry equipment will be increased.

The Economical Control and Handling of Patterns in a Large Foundry

By WALTER D. JONES. Canton, O.

Every foundryman knows the problem presented in attempting to deliver the pattern and the core boxes to the foundry on time, correct according to the blueprint, and in relation to the promise date of shipment; to return them to the pattern storage the instant the foundry releases them; and to properly place them in the pattern storage section and shelf, where they will be found when wanted. The familiar sight of hundreds of patterns littering and cluttering up the passageways in and around the foundry and the oft-repeated abili as to why a pattern is there or is not there, as the case may be, is sufficient to recall to the mind of all the confusion which has existed and exists in most of our foundries today.

A complete description of the methods adopted at the plant of the Canton Steel Foundry Co. together with cuts and illustrations of forms, etc., appeared in the May 15 issue of The Foundry. Anyone whose interest is aroused in this brief outline of our pattern control system, is referred to the article mentioned. The photographs of the various forms used will help to make clear the explanation of our system here offered.

Offices Are Concentrated

The development of the plan made it necessary to bring together the various offices so as to co-ordinate the work. Therefore, a very important link in the chain is the arrangement of the offices of the superintendent, order, production, dispatcher and checker which are located in the main pattern storage building. The pattern shop is adjacent to the pattern storage building. The arrangement of these offices permits of easy access to one another with a minimum loss of time. Immediately outside of the checker's room is the active floor.