Postby dognose » Sat Dec 20, 2014 10:52 am
CONVERTING A FACTORY FOR MUNITIONS MANUFACTURE
BY JOHN S. HOLBROOK, PROVIDENCE, R. I.
The Gorham Manufacturing Company, probably the largest silversmiths in the country, if not in the world, has been identified particularly with the sterling-silver trade. It has also made a considerable amount of silver-plated ware and of late years has produced a large quantity of bronze statuary, structural and ornamental bronze, besides various ecclesiastical wares such as pulpits, altar rails, chalices, etc., at its Elmwood plant in Providence, R. I. The step from this sort of work to the manufacture of metal goods for war munitions is consequently not as great as at first it might appear when we speak of silversmiths as munitions makers, for our men are trained in the handling of metals and in the use of machinery adapted to their manufacture–whether drafting, spinning, stamping, or casting, and we therefore were not handicapped as a strange concern might have been in the knowledge of metal handling.
Very shortly after the war broke out the Allied governments came to this country for munitions and we began to receive inquiries. Our superintendent at that time was Capt. O.V. Kean, a graduate of West Point and thoroughly familiar with ordnance work and the ordnance schools, and he naturally became interested in these inquiries.
The first negotiations entered into were with the British Government for 50,000,000 brass cups for small arms and the same number of cupro-nickel cups for Serbia, these being made in knuckle-joint presses which we already had on hand in our machine shop. The cupro-nickel cups were contracted for on April 14, 1915, and were delivered on time.
On May 11, 1915, we contracted for 50,000,000 brass cups to go with the cupro-nickel, but found our presses were too light to handle the heavier gage, which necessitated the purchase of new presses.
At the same time the French Government appeared in the market for cartridge cases for the 75-mm. gun, considered by many the most efficient weapon of the war. This was an entirely new proposition and involved a large expenditure both for new buildings and equipment, but after careful consideration the directors of the company felt that the contract was profitable and that as a matter of patriotic assistance to the Allied governments, with whom our sympathies even then were very strong, we should take the contract. They therefore authorized the building and equipment of a new one-story brick, brass-case shop, 360 ft. 6 in. by 122 ft. 8 in., which has cost approximately $500,000.
The first contract with the French Government was for 500,000 of these 75-mm. cartridge cases, which upon completion was followed immediately by an order for 975,000 more. These orders were filled so satisfactorily that when we entered the war the French Government went out of their way to compliment our work to the United States Government.
The French Government contracts were followed by one from the Russian Government for 1,000,000 brass cases for 75-mm. high-explosive ammunition, and another from the Swiss Government for 200,000 75-mm. brass cartridge cases of a still different type. Later the Netherlands appeared in the market and gave us a contract for 1,000,000 lb. of brass disks for their small-arms cartridges, as well as for 340,000 lb. of cupro-nickel cups. Also the Danish and British Governments each placed orders for about 225,000 lb. of the latter, and smaller orders were filled for the Norwegian and Portuguese Governments. It should be stated that each of these contracts required a different cup, slightly different in gage, height, thickness of bottom, etc., and that special metal had to he carried for each contract.
These various contracts had fitted us with a broader experience and we had built up a reputation and were ready to begin serious work for the United States Government when we entered the war. At the same time we have been able to do some work for the Allied governments in addition to our United States Government work.
The first U.S. Army contract came March 30, 1917, even before war was declared, and was for small cups, 6,600,000 each of the brass and of the gilding metal, the latter being for the U.S. Army bullet jackets. In May, 1917, a contract was closed with the Maxims Munitions Corporation for 275,000,000 each of brass and cupro-nickel cups for Italy. The first order for cases was placed. May 1, 1917, for the U. S. Navy 3-in. landing gun–again a different case from anything we had made before and requiring an entirely new outfit of tools but not machinery.
Immediately on the outbreak of the war our plant was placed at the command of the Government both as to its special war machinery and as to the silver plant. The Navy contract was followed by one in August for a large number of 3-in. cases for the U. S. Army–again a different case from that for the Navy landing gun, and French 75-mm. cases, the Army having decided to adopt that gun.
The Government then began to inquire what we could do on grenades, and after some negotiations we took no less than four separate orders for grenades, and at the request of the Government built an assembling and loading plant at a cost of considerably over $250,000, at East Providence. This plant is designed for an output of 100,000 loaded grenades per day. Ground was broken in December, 1917, and work started in the plant six weeks later.
Our contract for the Navy landing-gun case was so successfully filled that the Government asked us to make a large number of the large 4-in. 50-caliber cases. Another plant was required for this work, as it is done almost entirely by hydraulic presses, and after some negotiations the old Plant of the Providence Machine Company on Eddy Street and Allen’s Avenue was purchased, new buildings erected, the old buildings repaired, and the machinery installed, and they are just beginning production. The plant’s ultimate capacity will be 2500 per day.
In December, 1917, the Army placed an additional order for the 75-mm. cases with the proviso that if we finished them by August 1, 1918, we should continue and make an additional million. More than one million have been delivered and we expect to complete the balance well in advance of the date specified.
Early in 1918 the Government took up with us the question of our assembling and machining the Stokes trench bomb. This involved a further outlay for machinery, but there was space enough in the Allen’s Avenue plant and we accepted an order for these, deliveries of which have already begun. We anticipate turning out 1500 per day on our automatic machines and may considerably exceed this.
The machinery directly engaged on our munitions work and bought for that purpose has a capacity of between 25 and 30 millions of dollars’ worth of output per year on the basis of which we now work, which is that the Government furnishes the raw material and we the labor and assembling. Contracts actually in hand total something over a third of this amount– between 8 and 10 millions of dollars. This, however, does not take into consideration any machinery in the silver plant, and finding that we had capacity over and above our usual business, we have taken a considerable number of orders for miscellaneous equipment of various kinds. The disposition of the directors of the company is to place the plant as largely as possible on work which is directly useful to the Government and assist in every way in the successful prosecution of the war.
SPECIAL EQUIPMENT
With regard to the tools which the Gorham Manufacturing Company has found necessary in order to arrive at the stage of production which it has reached in this work, the following particulars may be of interest: The machinery and tools of the silver plant have in the main been totally inadequate and impractical for the munitions work. Certain knuckle-joint presses which we had been using in the machine shop of the silver plant were used for bullet cups, as mentioned in an earlier paragraph, but the brass small-arms cartridge cups came from stock so heavy that it broke down our presses and we had to order special presses from the E. W. Bliss Company.
The equipment for the brass-case shop consists approximately of 4 cupping presses, 2 indenting presses, 15 rack-and-pinion presses, 4 heading presses, 4 tapering presses and 33 Ballard lathes. There are also marking presses for stamping the heads of the cases with their identifying marks and lot numbers. The cupping presses (E. W. Bliss Co., No. 77½) are large presses for making the first cupping from the disk and are very powerful. The indenting presses were originally put in for work on the Russian and Swiss cases. As these are no longer made the presses are now used for cupping. The rack-and-pinion presses (E. W. Bliss Co., No. 66½) are presses which make the second, third and fourth draws of the French cases.
The annealing ovens consist of three large annealing furnaces and a number of mouth and body annealers. Most of the latter have been built by us and are so arranged that the case is turned around in a frame and at the end of a certain number of minutes is presented at the opening, where it is withdrawn by a man with a pair of pincers.
For the grenade plant we purchased 14 acres of land in East Providence from the Rumford Chemical Company and erected one-story frame buildings covered with asbestos Shingles, all of a temporary character. These buildings consist of two assembly rooms connected with the loading plant by a covered passage, power house, loading plant, detonator assembly room, shipping and storage sheds, office building, and of course the usual accessory buildings such as toilets, rest room, etc., together with two magazines. We have also arranged with the New Haven road for a spur track into the property.
The plant at Eddy Street and Allen’s Avenue is built on land having an area of about 100,000 sq. ft. Here it was found necessary to erect one new building as there was none with sufficient height to take the huge hydraulic presses, some of which require 40 ft. of headroom. These presses were obtained in various places and are of the following capacities:
2–250-ton, 1st draw 3– 150-ton, 5th draw
2–250~ton, 2d draw 4– 210-ton, 6th draw
2–250-ton, 3d draw 1– 90-ton, taper
3–200-ton, 4th draw 2– 100–ton, header
There are also such small presses for stamping, etc., as may be necessary, and ten lathes. All the presses mentioned above, with the exception of one, which was used in the Russian indenting and which was moved from the Elmwood plant. are hydraulic.
To manufacture the trench bombs we were also forced to buy new equipment, consisting mainly of automatic machinery. This included three large automatic lathes for the machining of the head of the bomb, and automatic machinery for making the boosters and other parts.
THE QUESTION OF EMPLOYEES
In connection with the East Providence plant it may be stated that we have large storage magazines buried in the woods two or three miles away from the plants, where a large part of the nitrated starch is carried. This material is transferred as required to smaller magazines at the plants and only a few hours’ supply is carried on the premises. From the smaller magazines it is brought underground by a pneumatic conveyor.
As to employees, we have 25 to 30 trades represented in the silver shop and some of these employees are at work on war materials, a few having been transferred as the opportunity presented itself through the slowing down of the silver shop.
Most of them, however, are at work in the silver shop in their regular rooms, working on such war materials as bomb sights, powder cans, ramrods, etc. Our highly skilled men, such as die sinkers, designers, etc., we have not been able to transfer to this war work. The chasers have been kept busy on their regular silver work as have also the designers. The die sinkers have been of help in making tools, but most of the tools are made in the machine shop.
At the present time there are over 3200 employees on the payroll, which means about $60,000 per week. The employees as a rule have stayed with the company and those transferred to the munitions work have been successfully trained under expert foremen acquainted with that kind of work. We found it necessary to add to the organization a number of expert men who had had previous experience in munitions manufacture and they are responsible for the training and up-building of the force.
The force of women employed has considerably more than doubled and it will be more than trebled by the time this paper is presented. The women employed in the Elmwood and Eddy Street plants are largely inspectors on brass cases and on parts of trench bombs and do not aggregate 100 altogether, whereas the number of women in the silver plant normally is in excess of 150. In the East Providence plant, or grenade plant, the women are in the majority, there being over 300 at present, which number will be increased to 500 to 600 when the plant is running at its full capacity. These girls are taken from the surrounding towns and are entirely untrained in the sort of work they are required to do. They assemble and load hand grenades, except as to certain processes which are entrusted to men. They are carefully selected and each one entering our employ has to be vouched for by at least two reputable citizens. We cannot afford to take any chances in a plant of this kind. The help is carefully picked and the inefficient ones rejected, this being shown by the large labor turnover–100 to 150 per week at the present time.
From the foregoing statements it will be seen that the problem of the Gorham Manufacturing Company has not been so much the transferring of present plant capacity and man power as it has been the building up of the new organization to handle this work. The organization has been efficiently built up and its importance may be gaged by the fact that while the number of employees before the war was normally 1600 to 1800 at the Providence plant, it is at present about double that number, and all these new people have had to be brought in and trained. We have secured the help of able men, most of them acquainted with the production in their particular lines–some of them merely good machinists and mechanics. Of course this applies to the munitions only. We have found in the silver plant and bronze shop that our own foundrymen are able to handle any casting job which comes to us, and the munitions jobs which we have taken are far less complicated than the elaborate statuary moldings with which our molders are acquainted. The bronze-shop force, under the supervision of their foreman, has proved capable of handling such work as has come to them–ramrods, powder cans, thumb nuts, etc. An interesting part of this work is the work that is being done for the Government by means of our special process for depositing–on range finders and the like. We have had one or two contracts where very fine graduations were required and where the Government has found this process of great value for the reason that it might be depended upon to reproduce important parts absolutely without shrinkage.
Source: Mechanical Engineering - American Society of Mechanical Engineers - 1918
Trev.