The saving of a cent per piece may be distinctly worth while. A saving of one cent on a part at our present rate of production represents twelve thousand dollars a year. One cent saved on each part would amount to millions a year. Therefore, in comparing savings, the calculations are carried out to the thousandth part of a cent. If the new way suggested shows a saving and the cost of making the change will pay for itself within a reasonable time—say within three months—the change is made practically as of course. These changes are by no means limited to improvements which will increase production or decrease cost. A great many—perhaps most of them—are in the line of making the work easier. We do not want any hard, man-killing work about the place, and there is now very little of it. And usually it so works out that adopting the way which is easier on the men also decreases the cost. There is most intimate connection between decency and good business. We also investigate down to the last decimal whether it is cheaper to make or to buy a part.
The suggestions come from everywhere. The Polish workmen seem to be the cleverest of all of the foreigners in making them. One, who could not speak English, indicated that if the tool in his machine were set at a different angle it might wear longer. As it was it lasted only four or five cuts. He was right, and a lot of money was saved in grinding. Another Pole, running a drill press, rigged up a little fixture to save handling the part after drilling. That was adopted generally and a considerable saving resulted. The men often try out little attachments of their own because, concentrating on one thing, they can, if they have a mind that way, usually devise some improvement. 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. A man roughly sketched a special machine. His idea was worked out and the machine built. Now four men have several times the output of the seventeen men—and have no hard work at all to do. Changing from a solid to a welded rod in one part of the chassis effected an immediate saving of about one half million a year on a smaller than the present-day production. Making certain tubes out of flat sheets instead of drawing them in the usual way effected another enormous saving.
The old method of making a certain gear comprised four operations and 12 per cent. of the steel went into scrap. We use most of our scrap and eventually we will use it all, but that is no reason for not cutting down on scrap—the mere fact that all waste is not a dead loss is no excuse for permitting waste. One of the workmen devised a very simple new method for making this gear in which the scrap was only one per cent. Again, the camshaft has to have heat treatment in order to make the surface hard; the cam shafts always came out of the heat-treat oven somewhat warped, and even back in 1918, we employed 37 men just to straighten the shafts. Several of our men experimented for about a year and finally worked out a new form of oven in which the shafts could not warp. In 1921, with the production much larger than in 1918, we employed only eight men in the whole operation.
And then there is the pressing to take away the necessity for skill in any job done by any one. The old-time tool hardener was an expert. He had to judge the heating temperatures. It was a hit-or-miss operation. The wonder is that he hit so often. The heat treatment in the hardening of steel is highly important—providing one knows exactly the right heat to apply. That cannot be known by rule-of-thumb. It has to be measured. We introduced a system by which the man at the furnace has nothing at all to do with the heat. He does not see the pyrometer—the instrument which registers the temperature. Coloured electric lights give him his signals.
None of our machines is ever built haphazardly. The idea is investigated in detail before a move is made. Sometimes wooden models are constructed or again the parts are drawn to full size on a blackboard. We are not bound by precedent but we leave nothing to luck, and we have yet to build a machine that will not do the work for which it was designed. About ninety per cent. of all experiments have been successful.
Whatever expertness in fabrication that has developed has been due to men. I think that if men are unhampered and they know that they are serving, they will always put all of mind and will into even the most trivial of tasks.
CHAPTER VII
THE TERROR OF THE MACHINE
Repetitive labour—the doing of one thing over and over again and always in the same way—is a terrifying prospect to a certain kind of mind. It is terrifying to me. I could not possibly do the same thing day in and day out, but to other minds, perhaps I might say to the majority of minds, repetitive operations hold no terrors. In fact, to some types of mind thought is absolutely appalling. To them the ideal job is one where the creative instinct need not be expressed. The jobs where it is necessary to put in mind as well as muscle have very few takers—we always need men who like a job because it is difficult. The average worker, I am sorry to say, wants a job in which he does not have to put forth much physical exertion—above all, he wants a job in which he does not have to think. Those who have what might be called the creative type of mind and who thoroughly abhor monotony are apt to imagine that all other minds are similarly restless and therefore to extend quite unwanted sympathy to the labouring man who day in and day out performs almost exactly the same operation.