While all this was happening—indeed long before the later happenings above mentioned—workers in iron had found that the pig iron coming from the furnaces contained so much carbon that it could not be successfully worked. So they managed to get rid of the carbon, by melting the iron in an open hearth and passing flames over it, and as the carbon is combustible it was gradually burned out. This made soft malleable iron, but not of the consistency to have the required strength or serve the purposes that are now served by steel. To bring it to the proper condition it was necessary to reintroduce a very small quantity of carbon so evenly that both the quantity and the distribution could be determined. This was done for many years by placing the bars of iron in a crucible or other
closed receptacle surrounded by charcoal, and subjecting them to intense heat for several hours or days. So the making of steel was a slow and expensive process until about the middle of the nineteenth century. Then Sir Henry Bessemer, an Englishman, discovered that by forcing air into the bottom of a great retort containing molten iron the oxygen of the air would combine with the carbon of the iron and in a few minutes the objectionable carbon would be all burned out, and that by then reintroducing in this molten mass of pure iron the required amount of carbon in the form of spiegel iron or ferro manganese, steel could be made much more cheaply and quickly than before. William Kelly, an American, also devised a similar process about the same time. Thus began the process of modern steel making, which has in a single half century increased tenfold the world’s consumption of steel and thus of iron, for a very large proportion of the iron now utilized in the world is transformed into steel before being applied to the service which it is to perform for men.
In all the processes by which iron and steel making have been transformed from the simple methods of a century or two centuries ago to the present system by which a single establishment may now make in a week or month or year as much iron or steel as the whole world then made in an equal length of time, machinery and capital have been the great causes of the development—machinery for digging iron and coal, for transporting them to the place of manufacture, for handling the material in the natural state, for handling it in the furnace, for handling it in the molten state, for rolling and shaping it after it passes from the molten state to that in which it begins to take the form of the finished product, and capital to purchase this machinery and the great quantities of material required. “The very richness of our resources,” says J. Russell Smith in The Story of Iron and Steel, “has made such a wealth of opportunity for occupation in the United States
that labor is and has been scarce. As a consequence the American iron industry has been driven over to a machine basis, and its very success has arisen from the fact that a scarcity of labor has compelled the introduction of machinery which has surpassed the dreams of its inventors. In the iron and steel industry of America man does little more than touch levers, while the balance is done by steam and electricity. Four large Bessemer converters, holding 15 or 20 tons of molten iron do their work by an air blast driven through the molten material by the force of an engine. The electric cranes swing the 20-ton charges and the heavy converters as easily as a schoolboy swings his dinner pail, and pours the new made steel into a metal mold which stands on a tram ready to take it to the hydraulic machine which draws the mold off the red-hot ingot. The manless way in which this great steel ingot is turned into a useful piece of steel never ceases to be a marvel. The great machines are seen but the plant seems to be deserted. Then there arises a rumble and roaring noise and the great piece of red-hot metal is seen to travel with all the independence of a serpent across a lot of black rollers and dive into the jaws of the rollers which squeeze it into flatter shape. Then it stops, turns over and dives again through the same rollers, which flatten it still more. After this has been repeated a few times you discover, standing on a high platform, a man or two pulling the levers which start the machinery of the six or seven thousand horsepower engines that drive the knowing rollers which are crushing and rolling the ingot into the shapes which man can use.”
“Perhaps the greatest difference between English and American steel works,” said an English writer on this subject, “is the absence of laborers in the American mills. The large and growing employment of propelling and directing machinery is responsible for this. In a mill rolling three thousand tons of rails in a day not a dozen men
are to be seen on the mill floor. To witness in such a mill the conversion in a half hour of a red-hot steel ingot weighing several tons into finished stamped steel rails ninety feet long, and all this perfectly, by the agency of unseen hands, is to gain new ideas of the possibilities of mechanism, of the subservience of matter to mind.”
These are some of the steps by which the systems of the manufacturing world have been, in the past 150 years, transformed from household work, or that of the small shop, into that of the factory—and the factory developed into enormous establishments through the investment of great sums of money in the purchase and installation of ever-improving machinery, more ingenious, more productive, more costly, but turning out more and better of the finished product with each new device and new investment of capital.
III. DEVELOPMENT OF THE FACTORY SYSTEM.
The inventions by which the manufacturing of the world was transformed from the household and the workshop to the great factory were the result of years, generations indeed, of study of conditions one by one as they arose. “No one of the inventions which were greatest in their effect,” says Hobson, “was in the main attributable to the effort or ability of a single man: each represented in its successful shape the addition of many successive increments of discovery; in most cases the successful invention was the slightly superior survivor of many similar attempts. This is the history of most inventions. The pressure of industrial circumstances directs the intelligence of many minds toward the comprehension of some single point of difficulty, the common knowledge of the age induces many to reach similar solutions, that solution which is slightly better adapted to the facts comes out victorious, and the inventor, purveyor or in some cases the robber is crowned as a great inventive genius.”
England was the earliest scene of the development of the factory system, the bringing together of great buildings and centers of great masses of machinery operated by water or steam power and manned by great numbers of people—for however ingenious the machine a certain amount of human intelligence is necessary for its management and the conduct of the work which it is to perform. The reasons for the earlier development in England are not difficult to find. It had its colonies in all parts of the world, from which to draw the raw material and in which to market the manufactures, for it for many years discouraged or prohibited manufacture in the colonies; it had great shipping facilities for transporting its products to all parts of the world, and to bring raw material and food supplies to its workers at home; the ownership of its lands in great estates had a tendency to send to the cities and manufacturing centers that part of the population which under other circumstances would have employed itself in agriculture; the laboring population yielded more readily to the methods of the manufacturing interests than in other countries where trade guilds determined more definitely the occupations and methods of occupation of the working classes; and the comparative freedom from wars permitted a more rapid growth than that of other countries in which disturbances of this character were more frequent and more liable to frequency than in an insular country, England. “When Crompton’s mule, Cartwright’s power loom and Watt’s engines were transforming the industry of England,” says Hobson, “her continental rivals had all their energies absorbed in wars and political revolutions.”