[Trade Journal]
Publication: Ceramic Industry
Chicago, IL, United States
vol. 4, no. 6, p. 462-463, col. 1-3
A Foolproof Routing System Which Produces Results
How a Plant Keeps Track of Its Product During Every Processing Stage
MANY DIFFICULTIES are encountered by concerns which do not have a routing system. They appear in the nature of unfilled promises, delayed shipments and imperfect ware. Often the regular processing has to be changed in order to make room for delayed orders. Costly production, stagnation and inconvenience at once begin to dissipate profits.
A Different Routing System
During a conversation with L. L. Beecken, general manager of the Ke-nova, W. Va., plant of the Jeffry-Dewitt Insulator Co., the plan which that company uses to control the routing of its various orders was discussed. Mr. Beecken explained how each defect which appears during the processing of the ware is noted for future reference. In this manner failures which occur, even while a high tension insulator is in use, can be traced.
As an example of how the system operates, suppose that a defective insulator on a line should be discovered. In looking thru, let us say, slip No. 3, the production order and lot number, which are stamped on the insulator, at once make it possible for the factory to place its hands on a clue which may solve the problem. On this sheet the casting, drying, and forming departments register each lot of ware which passes thru their hands. If the particular lot in question had an excessive loss due ,to casting cracks, drying cracks, groove cracks, or air holes, and if the defective insulator gave visible signs of failure due to one of these causes, the company could, if it desired, remove every one of this particular lot number from the line, thus preventing the recurrence of failure. The defects caused by the casting department may be due to one or more reasons, such as high viscosity, high slip temperature, or variations in grinding, the notations for which are all jotted down on slip No. 1.
Slips Made in Triplicate
Each one of these slips is made in triplicate, one of which goes to the laboratory, one to Mr. Beecken and the third to the accounting office. There is a Berated line between the main sheet of each form and That appears to be the tag on which the number is found. As soon as each lot leaves a department the tags are removed from the main sheet and taken to a clerk's office where Mr. Beecken has installed a cupboard having a number of pockets. It is made of sheet iron and the pockets are just large enough to permit the tags to fit, while in a horizontal position.
The value of this cupboard, which in reality is a production inventory, may be illustrated as follows: Should an order, or a letter asking when a certain lot can be shipped, come to his attention, Mr. Beecken can at once go to this production inventory cabinet, cast his eye over the production lot numbers which are placed at the end of each row of pockets, and quickly locate the cards he desires. By this means it is possible to immediately tell how many of this lot are in the various departments, and knowing the production schedules he can advise the office when he can ship the order. Mr. Beecken has this system worked out to such a state of perfection that it might justly be called foolproof.
A clerk is maintained to handle all of these charts and slips in the general office. It requires about one hour of her time each day to complete her filing. If the accompanying illustrations are closely studied it may be seen how every process and step can be checked back to the original blunging of the batch for any particular lot number. This absolute check precludes the possibility of guess work at any step of the processing. With a few minor changes, it is possible that this system can be put to excellent use in many of the plants in the ceramic industry.
Chances for Enough Labor Are Slim
Recent federal statistics of births and deaths show that for some time the population of the United States has annually increased at a rate of about ten persons per 1,000 population, which has proved insufficient to meet the increasing demands of national economy or of the requirements of an adequate world trade, in the opinion of industrial leaders consulted by the National Industrial Conference Board. It is pointed out that, on the basis of an excess of ten births over deaths annually per 1,000, and with an estimated population of 110,000,000 persons in 1920, the increase in the resident population for that year amounted to about 1,100,000. These newly born, not available for immediate productive requirements, constitute the maximum potential supply about 16 years later when they shall have attained working age. According to vital statistics, not more than 75 per cent. of these will survive the 16th year, and many will not be gainfully employed, existing populations statistics showing that not more than two-fifths of the entire population of the United States are engaged in gainful occupations. With this same proportion prevailing in 1936, it would mean that less than 400,000 survivors of these born in 1920 would be available for productive work upon reaching a working age.
Since the business and industries of the United States have been absorbing an average of 627,000 persons each year since 1900, of which manufacturing, the mechanical trades, agriculture, mining and transportation activities alone took nearly 500,000 yearly on an average. the 400,000 that may be counted on from the birth rate excess over deaths in 1920 would obviously be an inadequate supply, according to population studies made by the National Industrial Conference Board in connection with the subject of immigration.
